Hermetically Sealed Sensor Monolithic Body Design
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Solution Overview
Problem
Existing sensors, such as load cells and pressure/torque sensors, face challenges in surviving harsh environmental conditions like high temperatures and pressure extremes associated with autoclaving or sterilization processes, as they often require hermetic sealing which is difficult to achieve in smaller devices.
Innovation Solution
A hermetically sealed load cell with a monolithic annular body design, where header elements pass through the same body part housing the flexure element and circuitry, using glass or ceramic seals to secure the pins and maintain a hermetic seal, allowing the sensor to withstand extreme temperatures and pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate header and flexure components are welded together to create hermetic seal, then hermetic sealing is achieved, but device size must be larger and manufacturing complexity increases
Solution Approach 1:
The patent combines the header and flexure elements into a single monolithic body structure. The header pins are directly integrated into the flexure element, eliminating the need for separate components and welding operations. This integration maintains hermetic sealing while reducing manufacturing complexity and device size.
Solution Approach 2:
The monolithic body serves multiple functions simultaneously: it provides structural support, houses the flexure element, and integrates the header for electrical connections. This multi-functionality eliminates the need for separate header and flexure components, resolving the contradiction between hermetic sealing and manufacturing complexity.
2Reliability
If separate header and flexure components are used, then hermetic sealing can be achieved, but overall device size increases
Solution Approach 1:
The patent merges the header and flexure into a single monolithic body, eliminating the space required for separate components and their joining structures. This integration achieves hermetic sealing while minimizing device size.
3Reliability
If traditional hermetic sealing methods are used, then environmental protection is achieved, but the sensor cannot survive autoclave conditions
Solution Approach 1:
The patent employs a monolithic construction where the entire sensor body is made from a single piece of material that inherently withstands autoclave conditions. This eliminates the need for separate sealing materials that may fail under high temperature and pressure, achieving both environmental protection and temperature tolerance.
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 enables the load cell to survive conditions that prior designs cannot tolerate, ensuring reliable operation in harsh environments while maintaining a compact, small-scale form factor.
Implementation Method 1
A seal of glass or ceramic is formed in each of the holes to hold the respective pin in the one piece shell body and to hermetically seal the holes. In the case of a load cell, a flexure member is secured to the interior surface of the one piece shell body such as by spanning the interior walls.
Data Source
AI summary
A sensor such as a load cell includes a metal body containing the sensor electronics and flexure elements. Power is brought into the electronics and signals are taken out via header pins arranged in any of various groupings so as to extend through holes in the body. The pins are fixed by means of fused glass or ceramic material and the body is sealed to tolerate harsh environmental conditions.