Compact Sensor for Filter Elements Using Wireless Data Transmission
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Solution Overview
Problem
Existing filter elements with sensors are large, expensive, and difficult to install, making it challenging to detect small pressure differentials and requiring extensive installation space and wire connections, which are laborious and costly.
Innovation Solution
A compact sensor design using electronic and sensor chips arranged within a small functional space (≤5 mm x 3 mm x 0.8 mm) with wireless energy and data transmission, enabling precise pressure differential measurement without the need for extensive wiring or additional installation, utilizing 180 nm technology and CMOS processes for efficient integration into filter elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If large sensors are used to detect small pressure differentials, then measurement precision is improved, but device size and installation complexity increase
Solution Approach 1:
The sensor system is divided into separate functional modules: a sensor chip for pressure detection, an electronic chip for signal processing, and a housing structure. This segmentation allows each component to be optimized independently, enabling precise pressure differential measurement while maintaining a compact overall size of at most 5mm x 3mm x 0.8mm.
Solution Approach 2:
The patent transitions from traditional planar sensor layouts to a three-dimensional stacked architecture where the sensor chip and electronic chip are vertically arranged within a compact housing. This dimensional reorganization enables precise measurement functionality to be achieved in a significantly reduced volume, resolving the contradiction between measurement precision and device size.
2Measurement precision
If large sensors are used for pressure detection, then measurement capability is improved, but manufacturing cost and installation difficulty increase
Solution Approach 1:
The sensor chip and electronic chip are merged into a single integrated module housed within a unified housing structure. This combination eliminates the need for separate mounting and wiring operations, significantly simplifying manufacturing and installation processes while maintaining the precision measurement capability through the integrated design.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it protects the sensitive pressure sensing elements, provides mechanical support, and facilitates integration into the filter element. This multi-functionality reduces the number of separate components needed, simplifying both manufacturing and installation while preserving measurement precision.
3Reliability
If wired sensors are used for data transmission, then reliability is improved, but ease of operation and installation simplicity deteriorate
Solution Approach 1:
The wiring requirement is extracted and eliminated from the sensor system by implementing wireless data transmission. The sensor module communicates pressure differential data and operational status wirelessly to external systems, removing all physical connection requirements. This extraction maintains reliable data transmission while dramatically improving ease of installation and operation.
Data Source
AI summary
A sensor has an electronic chip and a sensor chip which are arranged within a functional volume which is at the most 4-5 mm long, a maximum 2-3 mm wide, and with a maximum height of 0.5-0.8 mm, thereby provide a potentially economical filter element having a compact sensor.