Porous Gel Chamber Sensor for Pressure-Balanced Bonding
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Solution Overview
Problem
Conventional sensors with cavity structures are prone to damage or detachment due to improper adhesive application, leading to sealing issues or joint failures.
Innovation Solution
Integration of a porous gel material with a porosity greater than 80% into the sensor, allowing gas communication between the inner space and the outside, which balances air pressure and reduces the need for adhesive glue spots, thereby enhancing structural integrity and reducing heat loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is used to fix the cavity structure on the carrier baseplate, then the cavity structure can be fixed, but the cavity structure is likely to be sealed due to too many glue spots, which will easily cause the sensor to be damaged during operation
Solution Approach 1:
The patent introduces a porous plug with porosity of not less than 80% that is disposed in the cavity. This porous structure allows gas to pass through while maintaining structural support, eliminating the need for excessive adhesive spots and preventing sensor damage from sealed cavities.
Solution Approach 2:
The porous plug acts as an intermediary component between the cavity structure and the external environment. It mediates the conflicting requirements by providing both mechanical support (reducing adhesive needs) and gas permeability (preventing damage), thus resolving the contradiction between bonding strength and reliability.
2Reliability
If too few glue spots are formed by the adhesive, then the sensor damage risk is reduced, but it will easily cause the joint surfaces to fall off
Solution Approach 1:
The porous plug provides mechanical support and structural stability to the cavity assembly, compensating for the reduced adhesive coverage. This allows fewer glue spots to be used while maintaining joint strength, as the porous plug bears part of the mechanical load.
Solution Approach 2:
The porous plug serves multiple functions simultaneously: it provides structural support, maintains cavity integrity, and enables gas permeability. This self-service capability reduces dependence on adhesive for structural purposes, allowing fewer glue spots while maintaining joint strength.
3Strength
If the cavity structure is sealed with adhesive, then the joint surfaces are well bonded, but the sensor is easily damaged during operation
Solution Approach 1:
The porous plug with high porosity (≥80%) allows gas to permeate through the cavity structure, preventing pressure buildup that would occur with complete sealing. This eliminates the harmful effect of pressure imbalance while maintaining adequate bonding strength with reduced adhesive.
Solution Approach 2:
The invention extracts the sealing function from the adhesive and transfers it to the porous plug structure. The adhesive is no longer required to provide complete sealing, as the porous plug inherently controls gas flow, thereby reducing the harmful sealing effect while maintaining bonding strength.
4Strength
If the cavity structure is supported by adhesive, then the structural integrity is maintained, but heat loss in the inner space increases
Solution Approach 1:
The porous plug provides structural support to the cavity while its porous structure allows for better thermal management. The reduced adhesive coverage and porous structure minimize thermal conduction paths, thereby reducing heat loss in the inner space while maintaining structural integrity.
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 porous gel material ensures the sensor's structural support and maintains sensing functionality while minimizing damage and adhesive-related issues, while also reducing heat loss.
Implementation Method 1
the porous gel material includes a first surface covered by the cavity wall without exposing to an outside and a second surface exposed to the outside without covering by the cavity wall, wherein a porosity of the porous gel material is not less than 80%, so that gas is capable of communicating between the inner space of the cavity body and the outside through the second surface
Data Source
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AI summary
A sensor with a chamber comprises a base (10), a cavity body (20), a sensing element (30), and a porous gel material (40). The cavity body (20) is disposed on the base (10) and has a cavity wall (21) and an inner space (22) formed inside the cavity wall (21), the sensing element (30) is disposed on the cavity wall (21), and the porous gel material (40) is disposed between the base (10) and the cavity body (20), the porous gel material (40) has a porosity of not less than 80%, so that gas is capable of communicating between the inner space (22) of the cavity body (20) and an outside (60), thereby forming a passage for gas to enter and exit to balance a pressure in the sensor with the chamber, increase a support of the sensor with the chamber, and reduce the risk of conventional bonding between the sensing element (30) and the base (10) using die-bonding adhesive.