Low Profile Pressure Sensor Using Segmented PCB and Nested Diaphragm
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pressure sensors for fluid pressure measurement are complex, costly, and physically large, making them difficult to integrate into space-limited areas.
Innovation Solution
A low-profile pressure sensor design comprising a nylon socket, upper and lower PCBs, and a hex housing with a diaphragm that deforms in response to fluid pressure, using strain gauges to measure pressure changes, and featuring a simplified construction with cost-effective materials and a compact form factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional pressure sensor designs are used, then measurement precision can be maintained, but device complexity and physical size increase
Solution Approach 1:
The pressure sensor is divided into distinct functional segments: a diaphragm for pressure sensing, strain gauges for measurement, and separate PCB assemblies for signal processing. This segmentation allows each component to be optimized independently while maintaining overall measurement precision, thereby reducing construction complexity
Solution Approach 2:
The patent implements a nested structure where the diaphragm is positioned within a housing, strain gauges are mounted on the diaphragm surface, and PCB assemblies are integrated into the housing structure. This nesting approach consolidates multiple components into a compact arrangement, reducing device complexity while preserving measurement capabilities
2Measurement precision
If traditional pressure sensor designs are used, then measurement precision can be maintained, but physical size increases
Solution Approach 1:
The patent transitions from a conventional three-dimensional bulky design to a flattened, two-dimensional profile by mounting strain gauges directly on the diaphragm surface and arranging PCB assemblies in a planar configuration. This dimensional change maintains measurement precision while significantly reducing the sensor's physical volume
Solution Approach 2:
Components are nested within each other to minimize external dimensions: the diaphragm is housed within a compact housing, strain gauges are positioned on the diaphragm surface rather than extending outward, and PCB assemblies are integrated into the housing structure. This nesting reduces the sensor's overall volume while maintaining measurement precision
3Reliability
If traditional pressure sensor designs are used, then reliability can be maintained, but manufacturing cost increases
Solution Approach 1:
The patent employs cost-effective materials and components such as standard strain gauge elements, conventional PCB assemblies, and readily available diaphragm materials. These components are selected to provide sufficient reliability for the application while significantly reducing manufacturing costs compared to traditional expensive sensor materials and assemblies
Solution Approach 2:
The patent combines multiple functions into integrated assemblies: the diaphragm serves both as a pressure sensing element and a mounting surface for strain gauges, while the PCB assemblies integrate signal conditioning and output functions. This merging reduces the number of separate components and assembly steps, lowering manufacturing costs while maintaining reliability
4Measurement precision
If traditional pressure sensor designs are used, then measurement precision can be maintained, but ease of installation decreases
Solution Approach 1:
The sensor is segmented into modular components that can be independently positioned and connected: the diaphragm assembly with strain gauges, the PCB assemblies, and the housing. This segmentation allows for simplified installation where components can be assembled in a standardized sequence, maintaining measurement precision while improving ease of installation
Solution Approach 2:
The PCB assemblies are designed with universal mounting interfaces and standardized electrical connections that can be adapted to various installation configurations. The diaphragm assembly incorporates standardized pressure port connections, enabling the sensor to be easily installed in different locations while maintaining measurement precision
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 provides a cost-effective, compact, and efficient pressure sensor that can be easily integrated into space-limited areas, offering reliable fluid pressure measurement with a simplified manufacturing process.
Implementation Method 1
exposing a first side of the diaphragm to the fluid within the axial port. The diaphragm deforms in response to the fluid contacting it
Implementation Method 2
thereby changing a resistance of the strain gauges coupled to the diaphragm
Data Source
AI summary
A pressure sensor may comprise a socket, an upper CB, a lower CB, and a hex housing. The socket may include a plurality of co-molded electrical pin conductors extending axially from electrical connectors defined within a top end of the socket for receiving an external electrical cable to a bottom end of the socket. A top side of the upper CB may have electrical contacts configured to contact the electrical pin conductors. The lower CB may be connected to the upper CB by at least one structural member, and electrically coupled to the upper CB and to strain gauges coupled to a diaphragm. The hex housing may have an interior axial port extending from a bottom of said hex housing to a counterbore for holding the diaphragm, thereby exposing a first side of said diaphragm to the fluid within the axial port.