Eccentric Sensing Column Layout for Compact Pressure Sensors
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Solution Overview
Problem
Existing pressure and force sensors with vertical sensing columns have large footprints, leading to larger device sizes and inefficiencies.
Innovation Solution
The use of eccentric and inclined sensing columns with a gel material, a printed circuit board, and a protective cap, which allows for a compact design by utilizing an elliptical profile and angled orientation to accommodate more components on the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a vertical sensing column is used, then the sensor structure is simple, but the device footprint is large
Solution Approach 1:
The sensing column is designed with an inclined and eccentric geometry rather than a vertical symmetric structure. The column is inclined at an angle (e.g., 45 degrees) relative to the substrate and positioned eccentrically, allowing the pressure-sensitive diaphragm to extend closer to the substrate and reduce the overall device footprint while maintaining structural integrity and sensing functionality
Solution Approach 2:
The sensing column transitions from a vertical orientation to an inclined orientation in three-dimensional space. This dimensional change allows the column to utilize diagonal space more efficiently, projecting the pressure-sensitive diaphragm closer to the substrate plane and reducing the horizontal footprint of the sensor device
2Area of stationary object
If an inclined and eccentric sensing column is used, then the device footprint is reduced, but the manufacturing complexity increases
Solution Approach 1:
The sensor device is divided into distinct functional segments: the substrate with electronics, the housing that defines the sensing column cavity, the gel material filling, and the pressure-sensitive diaphragm. This segmentation allows each component to be manufactured and assembled separately, with the inclined column geometry being defined by the housing cavity rather than complex machining of the column itself
Solution Approach 2:
The housing acts as an intermediary structure that defines the inclined and eccentric sensing column cavity. Rather than directly manufacturing complex inclined column geometries, the housing cavity provides the geometric framework, and the gel material and diaphragm are contained within this predefined space, simplifying the manufacturing process
3Area of stationary object
If a compact sensor design is used, then device size is reduced, but component accommodation becomes difficult
Solution Approach 1:
The inclined sensing column utilizes three-dimensional space more effectively by extending diagonally from the substrate. This allows the pressure-sensitive diaphragm to reach closer to the substrate plane, creating additional space for accommodating electronics and other components on the substrate while maintaining a compact overall device footprint
Solution Approach 2:
The asymmetric inclined and eccentric column configuration creates uneven distribution of internal space within the housing. This asymmetric space distribution allows for optimized placement of different components in available spaces, enabling better component accommodation in a compact form factor compared to symmetric vertical column designs
Data Source
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Figure 3A~3B
AI summary
Example embodiments described herein may include a housing for at least one sensing element defining an inclined and/or eccentric sensing column cavity. The sensing column cavity may be filled with a gel material for imparting force and/or pressure to a sensing element. In some embodiments, the sensing column cavity may have a first width at the end of the sensing column cavity proximate to a PCB. The sensing column cavity may have a second width at the end of the sensing column cavity proximate to a protective cap. The first width may be smaller than the second width, wherein the first width defines a diameter of a substantially circular profile of the sensing column cavity and the second width defines a major axis of a substantially elliptical profile of the sensing column cavity. The sensing column cavity may comprise one or more additional widths defining one or more additional profiles.