Metal-Base Sensor Insulation Against Etching-Residue Short Circuits
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Solution Overview
Problem
Conventional sensors using a metal base with a conductive layer pattern face issues in securing insulation properties between the conductive layer pattern and the metal base surface, particularly when the metal base surface is formed with streaks, leading to potential short circuits due to etching residues.
Innovation Solution
The sensor design includes a metal base with streaks on the surface, where an insulation film covers a specific area and exposes additional areas differently, preventing direct contact of etching residues with the conductive layer pattern, thereby maintaining insulation and allowing for efficient production without mirror polishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the metal base surface is formed with streaks to improve productivity and reduce polishing costs, then manufacturing efficiency is improved, but insulation between the conductive layer pattern and metal base deteriorates due to etching residues
Solution Approach 1:
The surface of the metal base is segmented into distinct functional areas: a first area covered by insulation film for electrical insulation, and a second exposed area for welding contacts. This spatial segmentation prevents etching residues from causing short circuits while maintaining productivity benefits from streaked surface formation.
Solution Approach 2:
Different regions of the metal base surface are given different properties: the first area receives insulation film coverage for electrical isolation, while the second area remains exposed for mechanical welding. This local differentiation resolves the contradiction between maintaining insulation and preserving manufacturing efficiency.
2Ease of manufacture
If an exposed area is formed to expose the metal base for electrode contact in conventional sensors, then welding contact is secured, but insulation between conductive layer and metal base is compromised
Solution Approach 1:
The metal base surface is divided into functionally distinct zones: an exposed second area providing welding contact areas, and a first area covered by insulation film that prevents electrical shorting. This segmentation allows both welding accessibility and electrical insulation to coexist.
Solution Approach 2:
The insulation film acts as an intermediary element that selectively covers certain areas while leaving others exposed. It mediates between the conflicting requirements of electrical insulation and welding contact, allowing the conductive layer to be electrically isolated from the metal base in critical areas while permitting contact in designated welding zones.
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 design effectively secures insulation between the conductive layer pattern and the metal base, reduces production costs, and enhances detection sensitivity while avoiding short circuits, thus improving productivity and reliability.
Implementation Method 1
those which uses a pressure resistance effect (also known as a piezoresistive effect) to detect strain of the base (it may also be referred to as a membrane or diaphragm) based on a resistance change
Data Source
AI summary
A sensor, including: a metal base having a surface formed with streaks along a first direction in plan view, and a conductive layer pattern provided on an insulation film formed on the surface; wherein, on the surface, the insulation film covers a first area which exists towards a first direction in plan view with respect to a conductive layer pattern forming area formed with the conductive layer pattern, and the surface comprises an exposed area exposed from the insulation film at a position different from the first area in plan view.