Measuring System Carrier Element Sensor Fluid Channel Connection
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Solution Overview
Problem
Conventional soldered connections between carrier elements and micromechanical sensors in fluidic arrangements result in uneven dead volumes, leading to inconsistencies in fluid transfer during mass production.
Innovation Solution
A measuring arrangement with a connection element integrally connected to the carrier element, using an adhesive or solder connection, and a metallic connection layer for improved pressure stability and reproducibility, featuring a galvanic coating or solder connection with gold and tin for chemical resistance, and a conductive lacquer for enhanced deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional soldered connections are used between carrier element and sensor, then mechanical connection is achieved, but dead volume becomes uneven and fluid transfer consistency deteriorates
Solution Approach 1:
A connection element is introduced as an intermediary component between the carrier element and the sensor. This connection element features a defined internal geometry that creates a controlled, reproducible dead volume. The connection element mediates the fluid transfer while its precise internal dimensions ensure consistent dead volume across all assembled units, resolving the inconsistency caused by direct soldered connections.
Solution Approach 2:
The invention changes the geometric parameters of the connection pathway by introducing a connection element with specifically designed internal dimensions. This parameter change transforms the undefined, variable dead volume of direct soldered connections into a controlled, reproducible dead volume determined by the connection element's internal geometry, thereby improving manufacturing precision and fluid transfer consistency.
2Manufacturing precision
If connection element protrudes into sensor fluid channel, then fluid transfer path is defined, but shear force stability deteriorates due to pressure instability
Solution Approach 1:
The connection element incorporates a metallic connection layer (such as gold or tin) that provides both mechanical strength and chemical resistance. This composite structure combines the geometric definition capability of the connection element's protruding shape with the strength and stability of the metallic layer, resolving the shear force instability while maintaining the defined fluid transfer path.
Solution Approach 2:
The invention changes the material parameters of the connection interface by applying a metallic connection layer to the connection element. This material parameter change enhances the mechanical strength and pressure stability of the connection, thereby improving shear force stability while the geometric parameters of the protruding connection element continue to define the fluid transfer path precisely.
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 achieves a more defined dead volume, improved pressure stability, and reproducibility in fluid transfer, reducing leaks and shear force instability, while maintaining chemical resistance and stability across varying pressures.
Implementation Method 1
the sensor is connected to the carrier element by an adhesive system or a solder connection
Implementation Method 2
the sensor is connected to the carrier element by an adhesive system or a solder connection
Implementation Method 3
the connection element can have a metallic connection layer at an outlet opening of the fluid channel for mechanical connection of the connection element to the carrier element
Implementation Method 4
The metallic connection layer either only between the sensor and connection element or between the sensor, connection element and carrier element can advantageously be designed as a solder connection. For a reliable solder connection and good reproducibility, it is advisable to melt a solder wire or, particularly preferably, a prepunched solder foil or an electrochemically deposited solder coating to produce the solder connection
Implementation Method 5
an electrochemically deposited solder coating to produce the solder connection
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A measuring system comprising a) a carrier element (14, 21, 32, 41) having a longitudinal axis (A), on which carrier element a sensor (1, 22, 33) for determining a process variable of a gaseous or liquid fluid is arranged, and b) the sensor (1, 22, 33) wherein the sensor (1, 22, 33) has a fluid channel (34) and the carrier element (14, 21, 32, 41 ) has a fluid channel, characterized in that the carrier element (14, 21, 32, 41 ) has at least one connecting element (6, 7, 23, 35, 42) for connecting the fluid channel of the carrier element (14, 21, 32, 41) to the fluid channel (34) of the sensor (1, 22, 33), which connecting element projects from the carrier element (14, 21, 32, 41) perpendicular to the longitudinal axis (A) and protrudes into the fluid channel (34) of the sensor (1, 22, 33).