Differential Pressure Sensor Resin Coating for Corrosive Gas Protection
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Solution Overview
Problem
Conventional differential pressure measuring devices face challenges when measuring corrosive gases, particularly in exhaust gases from motor vehicles, due to the need for protecting electronic components and using inert ceramic substrates, which are expensive and pose sealing issues.
Innovation Solution
A differential pressure measuring device that uses a resin to protect the substrate and electronic components from corrosive gases, eliminating the need for ceramic substrates and simplifying the manufacturing process by integrating all components in a single cavity, thus avoiding complex sealing challenges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electronic components are isolated in a separate chamber to protect them from corrosive gases, then reliability is improved, but device complexity and sealing difficulty increase
Solution Approach 1:
The patent merges the protection function with the existing housing structure by applying a resin coating directly to the electronic components and substrate within the single cavity, eliminating the need for a separate protective chamber. This integration maintains reliability while reducing structural complexity.
Solution Approach 2:
The resin coating acts as an intermediary protective layer between the corrosive gases and the electronic components. This mediator provides corrosion protection without requiring a separate chamber, thus improving reliability while avoiding the complexity of additional sealing structures.
2Reliability
If ceramic substrates are used to protect against corrosive gases, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive ceramic substrates with a standard printed circuit board substrate combined with a protective resin coating. This substitution uses cheaper materials while achieving the same corrosion resistance function, thereby improving ease of manufacture without sacrificing reliability.
Solution Approach 2:
The invention uses a composite protection system consisting of a standard substrate material (such as FR4) combined with a resin coating. This composite approach provides corrosion resistance comparable to ceramic substrates but at lower cost and with better manufacturing ease.
3Ease of manufacture
If all components are integrated in a single cavity, then ease of manufacture is improved, but sealing requirements become more critical
Solution Approach 1:
The resin coating serves as an intermediary protective barrier that eliminates the need for complex internal sealing between chambers. By coating the electronic components and substrate directly, the invention achieves protection against corrosive gases while maintaining the simplicity of a single-cavity structure.
Solution Approach 2:
The patent merges the protection function into the housing and component structure itself through resin coating, rather than relying on separate sealed chambers. This integration simplifies the overall structure while maintaining effectiveness against corrosive gases.
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
The solution allows for a cost-effective and straightforward manufacturing of pressure measuring devices capable of accurately measuring corrosive gases without the need for expensive ceramic substrates, enhancing operational efficiency and reducing sealing complications.
Implementation Method 1
the substrate is protected from corrosive gases by the resin
Implementation Method 2
the resin coats the electronic components of the pressure sensor
Implementation Method 3
The pressure difference deforms the diaphragm, and the measuring device sends back a signal, most often electrical, based on this deformation
Data Source
Figure 1~2
AI summary
The invention relates to a differential pressure device including: a pressure sensor comprising a substrate (14) supporting a pressure measurement member (10) provided with a membrane (16) having opposite first and second surfaces, the pressure sensor being configured to emit an electrical signal on the basis of a difference between the first and second pressures exerted on said first and second surfaces, respectively; and a housing (5) defining a cavity (12) in which said pressure sensor is arranged. Said cavity is partially filled with a resin (50) such that said resin covers said substrate without being in contact with said membrane.