Pressure Sensor Insulating Adjusting Member Center Alignment
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Solution Overview
Problem
In pressure sensors, misalignment between the base member and housing can lead to insufficient welding, causing liquid leakage when the housing is filled with an insulating liquid, as the centers of these components must be coincident for secure joining.
Innovation Solution
A pressure sensor design that includes a metallic base member with a holding section and flange, an insulating adjusting member positioned between the base member and housing flanges, and a metallic housing with a diaphragm, where the adjusting member ensures center alignment and secure welding, preventing liquid leakage by using projection welding or seam welding techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the base member and housing are joined by welding, then the structural strength is improved, but if the centers are not coincident, insufficient welding occurs and liquid leakage happens
Solution Approach 1:
An insulating adjusting member is introduced as an intermediary component between the base member and housing. This adjusting member serves multiple functions: it acts as a mechanical stop to prevent excessive welding penetration, provides insulation to prevent short circuits, and most importantly, serves as a positioning reference to ensure the centers of the base member and housing are coincident, thereby preventing insufficient welding and liquid leakage
2Reliability
If the center alignment is strictly controlled to prevent liquid leakage, then the reliability is improved, but the manufacturing complexity and difficulty increase
Solution Approach 1:
The insulating adjusting member is designed to automatically perform the centering function during assembly. By incorporating positioning protrusions or tapered structures on the adjusting member that mate with corresponding features on the base member and housing, the component self-aligns the centers of all three parts without requiring external alignment tools or complex positioning procedures, thereby maintaining reliability while simplifying manufacturing
3Reliability
If the adjusting member is added to ensure center alignment, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The insulating adjusting member is designed as a multi-functional component that simultaneously performs five functions: (1) electrical insulation between the base member and housing, (2) mechanical stopping to control welding depth, (3) center positioning to ensure alignment, (4) structural support for the sensor chip, and (5) sealing assistance. By consolidating multiple functions into a single component, the overall device complexity is minimized while achieving high welding reliability
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 enhances the reliability of the welding process, prevents liquid leakage, and allows for a thinner diaphragm, thereby increasing the sensitivity of the pressure sensor.
Implementation Method 1
an insulating adjusting member configured to provide on the holding section, and a circumference of the adjusting member being positioned between the circumference of the holding section and a circumference of the first flange
Implementation Method 2
the base member and housing are generally joined to each other by welding
Implementation Method 3
a diaphragm configured to provide on the housing and to cover the opening section
Data Source
AI summary
A metallic base member includes a holding section and a first flange. A sensor chip on which sensor element is arranged is provided on the holding section. An insulating adjusting member is provided on the holding section around the sensor chip and a circumference thereof is positioned between a circumference of the holding section and a circumference of the first flange. A metallic housing includes an opening section and a second flange, an inner surface of the opening section is brought into contact with the circumference of the adjusting member, and the second flange is joined to the first flange.