Polygonal Diaphragm Self-Alignment in Pressure Transducers
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Solution Overview
Problem
The production cost of pressure transducers is higher for devices using circular diaphragms due to the complexity of accurately orienting and attaching them to substrates, whereas polygonal diaphragms, such as square or rectangular shapes, are less costly to produce and assemble.
Innovation Solution
A pressure transducer design utilizing a polygonal diaphragm, specifically a ceramic material, with an electronic module assembly and electrodes, is proposed, where the diaphragm is easily attached to a substrate with a protrusion and depression configuration allowing for efficient stacking and bonding in a heated environment using sealing glass, reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If circular diaphragms are used in pressure transducers, then the sensing accuracy and performance are improved, but the production cost and manufacturing complexity increase due to the need for accurate orientation and attachment
Solution Approach 1:
The patent applies asymmetry by using a polygonal (non-circular) diaphragm shape with flat sides instead of a circular shape. This asymmetric geometric feature eliminates the need for precise angular orientation during assembly, as the flat sides provide natural alignment references. The substrate includes corresponding alignment features such as protrusions that fit into depressions on the diaphragm, further reducing orientation requirements. This resolves the contradiction by maintaining sensing accuracy while dramatically simplifying manufacturing and reducing production costs.
2Measurement precision
If circular diaphragms are used in pressure transducers, then the sensing accuracy is maintained, but the assembly complexity and time increase due to orientation requirements
Solution Approach 1:
The polygonal diaphragm shape with flat sides creates inherent asymmetry that provides natural alignment references during assembly. The substrate includes corresponding alignment features such as protrusions that fit into depressions on the diaphragm, eliminating the need for complex orientation procedures. This asymmetric design resolves the contradiction by maintaining sensing accuracy while dramatically simplifying the assembly process and reducing assembly time.
3Ease of manufacture
If polygonal diaphragms are used instead of circular diaphragms, then the production cost and ease of manufacture are improved, but the attachment alignment precision may be compromised
Solution Approach 1:
The polygonal diaphragm shape with flat sides creates inherent asymmetry that provides natural alignment references during assembly. The substrate includes corresponding alignment features such as protrusions that fit into depressions on the diaphragm, eliminating the need for complex orientation procedures. This asymmetric design resolves the contradiction by maintaining sensing accuracy while dramatically simplifying the assembly process and reducing assembly time.
Solution Approach 2:
The alignment features (protrusions and depressions) are integrated directly into the diaphragm and substrate structures, allowing the components to self-align during assembly without requiring external alignment tools or complex procedures. The flat sides of the polygonal diaphragm naturally guide the alignment process, enabling workers to achieve proper orientation through simple placement rather than complex adjustment procedures.
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 reduces production costs by simplifying the attachment process and enabling cost-effective manufacturing of pressure transducers with polygonal diaphragms, while maintaining the sensitivity and accuracy required for pressure sensing applications.
Implementation Method 1
bonding the diaphragm to the substrate in a heated environment using sealing glass
Data Source
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AI summary
A method of generating a plurality of diaphragm assemblies, the method comprising: providing a first substrate including a first side with a first protrusion and a second side with a first depression; positioning a first diaphragm on the first protrusion to form a first assembly; providing a second substrate including a first side with a second protrusion and a second side with a second depression; positioning the second substrate on the first assembly such that at least a portion of the first diaphragm and at least a portion of the first protrusion fit within the second depression; positioning a second diaphragm on the first side of the second substrate to form a second assembly; and applying a force to the stacked first and second assemblies to assist in bonding the first and second diaphragms to the first and second substrates, respectively.