Flat-Port Pressure Sensor with Sealed Auxiliary Connections
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Solution Overview
Problem
Pressure sensors used in frictionless braking systems face challenges with media isolation and connectivity issues, particularly when dealing with hazardous fluids and corrosive chemicals, which affect their performance and reliability.
Innovation Solution
A pressure sensor design featuring a base port, sensing portion, and connector portion with multiple connector pins, including internal and external pins, a diaphragm, and a printed circuit board, allowing for secure fluid connection and signal transmission to external devices, while incorporating a sealant to protect against fluid leakage and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pressure sensor is used in frictionless braking systems to measure exhaust gas/oil pressure, then the braking control function is achieved, but media isolation and connectivity issues arise due to hazardous fluids and corrosive chemicals
Solution Approach 1:
The pressure sensor is divided into distinct segments: a process connection portion for fluid intake, a sealing portion with multiple sealing elements, and a connector portion with auxiliary connections. This segmentation isolates the hazardous media to specific zones, preventing contact with sensitive electronic components while maintaining measurement functionality.
Solution Approach 2:
A pressure transfer fluid is introduced as an intermediary between the hazardous exhaust gas/oil and the sensor's internal components. The fluid transmits pressure from the diaphragm to the sensing elements without requiring direct contact between hazardous media and sensitive electronics, thus maintaining reliability while isolating harmful factors.
2Adaptability or versatility
If a pressure sensor with auxiliary connections is designed to enable direct connection between external devices, then connectivity and control capability are improved, but device complexity increases
Solution Approach 1:
The connector portion integrates multiple functions into a single structure: electrical connector pins for signal transmission, auxiliary connection terminals for external device attachment, and structural support for the entire sensor assembly. This merging reduces the need for separate components and simplifies installation while maintaining high adaptability.
Solution Approach 2:
The connector portion is designed with universal multi-functionality, incorporating both primary sensing connections and auxiliary connections that can serve multiple purposes (power supply, control signals, data transmission). This allows a single connector structure to handle various connectivity requirements without increasing overall device complexity.
3Adaptability or versatility
If multiple connector pins are integrated into the connector portion, then signal transmission and control capability are enhanced, but manufacturing complexity increases
Solution Approach 1:
The connector pins are nested within the connector portion housing, with electrical contacts embedded in a structured arrangement. The auxiliary connection terminals are integrated into the same housing structure, creating a compact nested assembly that simplifies manufacturing by reducing the number of separate assembly steps while maintaining enhanced signal transmission capability.
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
Enhances the reliability and connectivity of pressure sensors in harsh environments by ensuring secure fluid connection and effective signal transmission, enabling precise control of frictionless braking systems.
Implementation Method 1
a pressure transfer fluid to translate movement of the diaphragm to the sense die
Data Source
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AI summary
A pressure sensor is provided. For example, a pressure sensor comprises a base port connected to fluid source whose pressure is to be sensed, a sensing portion to receive the fluid via the base port, and a connector portion comprising a main body and first and second pluralities of connector pins. The sensing portion comprises a diaphragm, a sense die, a pressure transfer fluid, and a printed circuit board (PCB). Each of the first plurality of connector pins has a first end electrically connected to the PCB and a second end exposed via an open end of the main body. Each of the second plurality of connector pins has a first end exposed through a side wall of the main body and a second end exposed via the open end of the main body.