Piezoelectric Acceleration Sensor Manufacturing with Flexible PCB
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Solution Overview
Problem
The manufacturing process of piezoelectric acceleration sensors, such as the 'Type 8763B' sensor, is costly and error-prone due to the complex assembly of multiple components within a small housing.
Innovation Solution
A method of manufacturing a piezoelectric acceleration sensor that involves using a housing element with an inner space, a flexible printed circuit board element hosting IEPE, and a connector element, where the flexible printed circuit board is mechanically fixed to the body element, and electrical connections are simplified by reducing the number of connections required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple components (piezoelectric measurement elements, IEPE, TEDS, printed circuit board) are assembled within a small housing, then the sensor achieves high functionality and integration, but the manufacturing process becomes costly and error-prone
Solution Approach 1:
The patent divides the complex assembly into modular components: a housing element containing the piezoelectric measurement elements, a separate flexible printed circuit board element with IEPE and TEDS, and a connector element. This segmentation allows each module to be manufactured and tested independently, reducing overall manufacturing complexity and error rates while maintaining high functionality.
Solution Approach 2:
The patent implements a nested structure where the flexible printed circuit board element with IEPE and TEDS is integrated within the housing element, and the connector element provides external access. This nesting approach achieves high integration density without proportionally increasing manufacturing difficulty, as each nested component can be assembled in a standardized sequence.
2Ease of manufacture
If the number of electrical connections is reduced, then the manufacturing process becomes simpler and less error-prone, but the functionality of connecting multiple measuring elements and electronics may be compromised
Solution Approach 1:
The patent merges multiple electrical connection functions into the flexible printed circuit board element, which simultaneously provides mechanical support, electrical connectivity, and signal routing for multiple measuring elements, IEPE, and TEDS. This consolidation reduces the total number of discrete electrical connections required while maintaining full functionality through integrated circuit traces and contacts on the flexible board.
Solution Approach 2:
The flexible printed circuit board element acts as an intermediary between the piezoelectric measurement elements and the external connector. It provides a standardized interface that simplifies electrical connections by consolidating multiple signals into a single flexible board connection point, reducing the number of direct wire connections needed between components.
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 method significantly reduces the number of electrical connections needed, making the manufacturing process more cost-effective and less prone to errors, while also resulting in a less expensive piezoelectric acceleration sensor.
Implementation Method 1
A piezoelectric acceleration sensor comprises piezoelectric material which creates electric charge when subjected to a force. The electric charge is proportional to the applied force and can be measured directly by means of electrodes.
Data Source
AI summary
A method of manufacturing a piezoelectric acceleration sensor that includes a housing element containing a plurality of measuring elements, a flexible printed circuit board element and a connector element. Each measuring element measures an acceleration along a respective sensitive axis and generates electric charges proportionate for the measured acceleration. The flexible printed circuit board element hosts a plurality of IEPE, which amplify and convert electric charge from the measuring elements into an output voltage. The flexible printed circuit board element is introduced into the housing element and mechanically fixed to a body element inside the housing. The measuring elements are fixed to the body element. The measuring elements are electrically connected to the flexible printed circuit board element. The connector element is electrically connected with a connector section of the flexible printed circuit board and mounted on the housing element.