Ceramic Pressure Sensor Membrane via 3D Screen Printing
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Solution Overview
Problem
The production of ceramic pressure sensors is labor-intensive and requires complex post-processing steps due to limitations in geometric shapes and dimensions, particularly in achieving the desired membrane thickness and accuracy.
Innovation Solution
A shaped body for a pressure sensor is produced using additive manufacturing, specifically 3D screen printing, with a ceramic membrane and support section, allowing for precise control of thickness and geometry, reducing the need for mechanical post-processing and enhancing manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pressing processes are used to manufacture ceramic sensor bodies, then production can be performed using conventional methods, but the membrane layers become thick and uneven requiring complex post-processing steps
Solution Approach 1:
The patent changes the manufacturing method from conventional pressing to additive manufacturing (3D screen printing), which fundamentally alters how the membrane is formed. This parameter change enables precise control of membrane thickness (e.g., 20 µm) and eliminates the need for post-processing steps like grinding or lapping, directly resolving the contradiction between ease of manufacture and manufacturing precision
Solution Approach 2:
The patent replaces the mechanical pressing process with an additive manufacturing process (3D screen printing). This substitution allows for digital control of membrane geometry and thickness without mechanical contact, eliminating the inherent limitations of pressing methods and the associated post-processing requirements
2Ease of manufacture
If pressing processes are used to manufacture ceramic sensor bodies, then conventional production methods can be maintained, but geometric shapes and dimensions are restricted
Solution Approach 1:
The patent changes the manufacturing approach from conventional pressing to additive manufacturing, enabling arbitrary geometric shapes and dimensions to be produced directly from digital models. This allows the membrane and sensor body to have customized geometries without tooling changes, resolving the contradiction between maintaining conventional production and achieving geometric flexibility
Solution Approach 2:
The patent transitions from two-dimensional pressing (requiring molds and tooling) to three-dimensional additive manufacturing. This dimensional change enables complex 3D geometries, internal structures, and variable thickness profiles to be created directly, vastly expanding geometric versatility while simplifying the manufacturing process
3Measurement precision
If mechanical post-processing is performed to achieve desired membrane thickness and accuracy, then measurement precision can be improved, but manufacturing effort and time increase
Solution Approach 1:
The patent performs the membrane thickness and geometry formation during the additive manufacturing process itself, before sintering. By creating the precise final geometry in the green state (before firing), the membrane requires no post-processing to achieve the desired thickness or measurement accuracy, thus improving productivity without compromising precision
Solution Approach 2:
The patent replaces mechanical post-processing operations (grinding, lapping) with precise digital control during additive manufacturing. The membrane geometry is defined by digital models and deposited layer-by-layer with micrometer precision, achieving measurement-grade accuracy directly from the manufacturing process without subsequent mechanical intervention
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of pressure sensors with improved measurement accuracy and flexibility, reduced manufacturing effort, and increased resistance to aggressive media, while maintaining high operational safety and quality.
Implementation Method 1
the membrane is produced at least in sections from a ceramic material by additive manufacturing, in particular 3D screen printing
Data Source
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AI summary
Molded body, in particular for a pressure sensor, with a membrane and with a support section carrying the membrane, wherein the membrane is produced at least partially from a ceramic material by means of additive manufacturing, in particular 3D screen printing, and has an outer circumferential shape with at least one corner.