Inductive Glass Bonding for Pressure Sensor Manufacturing
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Solution Overview
Problem
Conventional methods for manufacturing pressure sensors to determine fluid medium pressure are inefficient for large-scale production due to long tempering operations and require precise geometry for a strong bond, making them uneconomical and difficult to reproduce.
Innovation Solution
A method involving a pressure connection with a deformation element made of induction material, where a glass element is positioned and melted using pyrometric temperature measurement and inductive heating to form a glass layer, allowing for a sensor element to bond integrally, and the setup is cooled to stabilize temperature distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional thermal contact conduction heating is used for seal glass bonding, then the glass element can be joined to the pressure sensor, but the tempering operation becomes long and uneconomical for large-scale production
Solution Approach 1:
The patent replaces conventional thermal contact conduction heating with induction heating technology. The induction heating device generates an oscillating magnetic field that directly induces eddy currents in the pressure sensor body, converting electromagnetic energy directly into heat within the workpiece. This eliminates the need for thermal contact conduction through intermediaries, significantly reducing heating time and enabling efficient large-scale production while maintaining bonding quality
Solution Approach 2:
The induction heating process employs periodic oscillating magnetic fields at high frequencies to rapidly heat the pressure sensor body. This periodic action allows for precise control of the heating process, achieving the required tempering effect in much shorter time compared to conventional continuous thermal conduction methods, thereby improving production efficiency
2Manufacturing precision
If conventional heating methods are used, then heating can be achieved, but precise temperature control and reproducible sensor characteristics are difficult to obtain
Solution Approach 1:
The patent incorporates a pyrometer that continuously measures the temperature of the pressure sensor body during induction heating. This temperature information is fed back to the control unit, which adjusts the heating power in real-time to maintain the optimal temperature range. This closed-loop feedback control ensures precise temperature management, producing reproducible glass layer geometry and consistent sensor characteristics across production batches
Solution Approach 2:
The patent utilizes the ability to dynamically adjust induction heating parameters (frequency, power, duration) based on real-time temperature measurements. By changing these parameters adaptively during the process, the system maintains optimal heating conditions throughout, ensuring precise glass layer formation and reproducible sensor characteristics that cannot be achieved with fixed conventional heating methods
3Area of moving object
If larger measuring regions are implemented in pressure sensors, then measurement capability is improved, but the complexity of achieving strong bonds with precise geometry increases
Solution Approach 1:
The patent applies induction heating selectively to specific regions of the pressure sensor body where bonding is required, rather than heating the entire component uniformly. This localized heating approach simplifies the bonding process by concentrating energy only where needed, making it easier to achieve strong bonds with precise geometry even on sensors with larger measuring regions
Solution Approach 2:
The induction heating device is configured to generate magnetic fields that concentrate heat in specific local regions of the pressure sensor body corresponding to the bonding areas. This local quality approach allows different parts of the sensor to have different thermal histories, with bonding regions receiving precise controlled heating while other regions remain unaffected, simplifying the overall bonding 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 method enables efficient and cost-effective mass production of pressure sensors with improved temperature control and precise geometry, reducing cycle time and power demand while maintaining high accuracy across a wide pressure range (0-5000 bar) with minimal deviation.
Implementation Method 1
measuring at least one temperature of the pressure deformation element with the aid of at least one pyrometer
Implementation Method 2
inducing a voltage in the pressure deformation element with the aid of at least one inductor
Implementation Method 3
inducing a voltage in the pressure deformation element with the aid of at least one inductor in such a manner, that the glass element melts
Implementation Method 4
cooling the pressure connection with the aid of the holding fixture capable of being cooled
Data Source
AI summary
A method of manufacturing a sensor set-up for determining at least one pressure of a fluid medium. The method includes: a) providing a blank of a sensor set-up including at least one pressure connection, the pressure connection including at least one pressure deformation element made up of at least one material suitable for induction; b) positioning at least one glass element onto a surface of the pressure deformation element; c) measuring at least one temperature of the pressure deformation element using at least one pyrometer; d) inducing a voltage in the pressure deformation element using at least one inductor in such a manner, that the glass element melts and a glass layer forms on the pressure deformation element; e) positioning a sensor element onto the glass layer in such a manner, that an integral bond forms between the sensor element and the glass layer.