Piezoelectric Sensor Insulating Layer to Prevent Film Crack Shorts
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Solution Overview
Problem
Existing piezoelectric sensors face issues with short circuits due to cracks in the piezoelectric film layer, leading to reduced product yield and performance.
Innovation Solution
Incorporating an insulating layer that contacts at least part of the piezoelectric thin film layer, filling cracks and ensuring the capacitance and resistance ratios meet specific conditions to prevent short circuits, thereby improving product yield and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a piezoelectric element is directly mounted on a printed circuit board, then assembly is simple, but the element is vulnerable to damage from board bending and external forces
Solution Approach 1:
The piezoelectric element is nested within a protective housing structure that encloses it completely. The housing acts as a container within the larger sensor assembly, protecting the fragile element from external forces and board bending while allowing the element to function internally.
Solution Approach 2:
The piezoelectric element is pre-mounted onto a support board before the final assembly is completed. This preliminary mounting allows the element to be positioned and secured in a protected state before being integrated into the complete sensor unit, preventing damage during subsequent assembly steps.
2Reliability
If the piezoelectric element is enclosed in a housing, then protection is improved, but manufacturing complexity increases
Solution Approach 1:
The housing is designed as a thin-walled structure that provides adequate protection for the piezoelectric element while minimizing material usage and structural complexity. The thin-walled design reduces the overall complexity of the housing while maintaining sufficient protective functionality.
Solution Approach 2:
The housing structure is divided into multiple components including a first wall portion, second wall portion, and bottom wall portion that can be manufactured separately and then assembled. This segmentation allows each part to be optimized independently and simplifies the manufacturing process while providing complete enclosure and protection.
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 insulating layer effectively prevents short circuits, enhancing the structural stability and vibration properties of the piezoelectric sensor, ensuring reliable operation and higher yield.
Implementation Method 1
a piezoelectric element (330) mounted on the second side of the support board (302), wherein the piezoelectric element (330) is configured to detect a force applied to the diaphragm (304)
Data Source
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AI summary
A piezoelectric sensor, comprising: a base substrate (1), and a first electrode layer (2), a piezoelectric thin film layer (3), an insulating layer (4) and a second electrode layer (5) which are arranged in sequence away from the base substrate (1), the insulating layer (4) making contact with at least part of the piezoelectric thin film layer (3). The present invention is used to prevent short circuits in a piezoelectric sensor and improve product yield. Also provided are a fabrication method for a piezoelectric sensor and a haptic feedback device.