Laser-Welded Sensor Enclosure With Hermetic Sealing and Fluid Channels
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Solution Overview
Problem
Existing enclosures fail to effectively interact with, measure, or influence properties of fluids in harsh or aggressive environments, particularly in medical and bio-processing applications, where hermetic sealing and fluid exchange are required.
Innovation Solution
A hermetically sealed enclosure comprising two transparent substrates laser-welded together, with a common laser weld zone providing a permanent bond and hermetic sealing, and a fluid channel for interaction with the environment, allowing for measurement or modification of fluid properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If substrates are hermetically sealed to protect components, then reliability is improved, but adaptability to fluid environments deteriorates
Solution Approach 1:
The enclosure is segmented into hermetically sealed regions (protecting electronics and sensors) and non-sealed fluid-exposed regions (allowing fluid interaction). The laser weld creates distinct sealed zones while leaving other areas open for fluid access, enabling simultaneous protection and environmental interaction.
Solution Approach 2:
Different regions of the enclosure have different sealing properties. The laser weld zone provides hermetic sealing where needed, while other regions maintain openness for fluid interaction. This local differentiation of sealing quality allows the enclosure to simultaneously protect components and interact with fluid environments.
2Strength
If substrates are joined to form enclosed structure, then strength is improved, but ease of manufacture deteriorates
Solution Approach 1:
Traditional mechanical joining methods (screws, clips, adhesives) are replaced with laser welding. This substitution creates stronger bonds while simplifying the manufacturing process by eliminating complex assembly steps and reducing the number of components needed for joining.
Solution Approach 2:
The laser welding process utilizes controlled changes in laser parameters (power, speed, focus) to optimize the welding process. This allows for strong joints to be created efficiently through parameter optimization rather than complex mechanical design, improving both strength and manufacturability.
3Reliability
If enclosure is made robust for harsh environments, then reliability is improved, but device complexity increases
Solution Approach 1:
The enclosure utilizes composite construction with at least two different substrates (e.g., sapphire, glass, metal, or polymer combinations). This composite approach provides enhanced environmental resistance through material properties while maintaining relatively simple overall structure, avoiding the need for complex multi-component assemblies.
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 enclosure enables robust interaction with fluid environments, facilitating measurement and modification of fluid properties while maintaining hermeticity, suitable for harsh conditions and medical applications.
Implementation Method 1
at least one common laser weld zone wherein material of the first and second substrates is mixed, wherein the laser weld zone is designed such to permanently join the first substrate to the second substrate
Implementation Method 2
The first substrate may be having an outer surface and the second substrate may also be having an outer surface... The first substrate is transparent at least in part and/or at least for a wavelength bandwidth
Data Source
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AI summary
An enclosure is shown, comprising at least a first substrate and a second substrate, wherein the first substrate is transparent at least in part and/or at least for a wavelength bandwidth, at least one common laser weld zone wherein material of the first and second substrates is mixed, wherein the laser weld zone is designed such to permanently join the first substrate to the second substrate and/or to provide for a hermetic sealing between the first substrate and the second substrate, at least one function zone, for example comprising a cavity, enclosed inside the enclosure, and at least one fluid channel allowing for a fluid flow between said function zone and an outside.