Integrated Flame Arrestor Packaging for Gas Sensor Arrays
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Solution Overview
Problem
Conventional gas sensor device packages require separate manufacturing and assembly of a flame arrestor, leading to a large gap between the sensor and the arrestor, which can become separated during use, rendering the sensor unsafe due to potential ignition and explosion risks.
Innovation Solution
The integration of a flame arrestor with the lead frame and thermoplastic material in the gas sensor device package, forming a unified structure that prevents flame propagation while allowing gas diffusion, and the use of protective materials like filters and films to shield the sensors during assembly and singulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flame arrestor is used in a gas sensor device package, then safety is improved by preventing flame propagation, but the device complexity increases due to separate manufacturing and assembly requirements
Solution Approach 1:
The flame arrestor is integrated directly into the gas sensor device package structure, combining the flame arrestor and gas sensor into a single unified component. This eliminates the need for separate manufacturing and assembly of the flame arrestor, reducing device complexity while maintaining the safety function of preventing flame propagation from the sensor cavity to the external environment.
2Reliability
If a flame arrestor is located proximate the sensing material, then flame propagation is prevented, but manufacturing complexity increases due to separate assembly requirements
Solution Approach 1:
The flame arrestor is formed as an integral part of the gas sensor device package during the same manufacturing process, eliminating separate assembly steps. The flame arrestor remains positioned proximate to the sensing material to prevent flame propagation, while the integrated manufacturing approach simplifies production by forming both components in a single process.
3Adaptability or versatility
If a flame arrestor and gas sensor are separately assembled, then manufacturing flexibility is maintained, but the gap between components increases leading to potential separation during operation
Solution Approach 1:
The flame arrestor and gas sensor are formed as a single integrated component, eliminating the gap between them that exists in separately assembled designs. This integration ensures stable relative positioning and prevents separation during operation, while the unified structure is manufactured as a single piece, maintaining manufacturing efficiency.
4Manufacturing precision
If separate manufacturing of flame arrestor and gas sensor is used, then component optimization is possible, but assembly time and potential for separation increase
Solution Approach 1:
The flame arrestor and gas sensor are manufactured as a single integrated component in one manufacturing process, eliminating the assembly step entirely. This integration removes the time required for separate assembly while maintaining optimal design of both components within the unified structure, as both can be optimized during the single manufacturing process.
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 integrated design ensures the gas sensor device packages remain safe and contamination-free during assembly and operation, reducing the risk of ignition and maintaining sensor integrity.
Implementation Method 1
The flame arrestor is formulated and configured to absorb the heat required for ignition and, therefore, may prevent an explosion
Implementation Method 2
a protective covering over the plurality of gas sensor device packages
Data Source
AI summary
An array of gas sensor device packages comprises a plurality of gas sensor device packages, each gas sensor device package comprising a lead frame including bond pads and at least one gas sensor die in electrical communication with the bond pads. The array further comprises a protective covering over the plurality of gas sensor device packages. Related gas sensor device packages and arrays and methods of forming the arrays are also disclosed.