Pressure Sensor Assembly Modular Design
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Solution Overview
Problem
Existing sensor assemblies lack improvements in design and manufacturing methods, leading to inefficiencies in pressure sensing and signal transmission, which affects accuracy and durability.
Innovation Solution
A pressure sensor assembly design featuring a sensor unit with a carrier forming a fluid path, a pressure sensor, and printed circuit boards, along with an electrical connector and outer housing, which includes a cover to maintain mechanical spacing and protect internal components, enhancing signal transmission and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensor assemblies use traditional design and manufacturing methods, then manufacturing simplicity is maintained, but pressure sensing accuracy and signal transmission efficiency deteriorate
Solution Approach 1:
The sensor assembly is divided into distinct functional modules: a sensor unit with a pressure sensor and carrier, a separate cover with electrical terminals, and a housing. This segmentation allows each component to be optimized independently for its specific function while maintaining overall accuracy and reducing manufacturing complexity through modular assembly.
Solution Approach 2:
The cover acts as an intermediary component between the sensor unit and the housing, providing mechanical spacing, electrical connection pathways, and protection. This intermediary structure enables precise positioning of internal components and facilitates signal transmission without requiring complex direct integration between other parts.
2Measurement precision
If mechanical spacing is not maintained between printed circuit boards, then device complexity is reduced, but signal transmission accuracy deteriorates
Solution Approach 1:
The cover serves as a mechanical intermediary that maintains precise spacing between the first and second printed circuit boards. Electrical terminals extending through the cover provide controlled signal pathways while the cover's rigid structure ensures consistent mechanical positioning, preventing signal interference and maintaining transmission accuracy.
3Reliability
If internal components are not protected, then device complexity is reduced, but reliability deteriorates
Solution Approach 1:
The sensor unit, cover, and housing are nested within each other in a hierarchical protective structure. The carrier protects the pressure sensor, the cover protects the printed circuit boards and electrical terminals, and the housing provides outer protection. This nested arrangement ensures component protection while minimizing overall structural complexity through efficient space utilization.
Data Source
AI summary
The present disclosure relates to sensors including pressure sensors, humidity sensors, flow sensors, etc. In some cases, a sensor assembly may include a pressure port connected to a sensor unit, an electrical connector connected to the sensor unit and an outer housing encompassing at least portions of the pressure port, sensor unit and electrical connector. In some instances, the sensor unit may include pressure signal output terminals electrically connected to electrical terminals of the electrical connector.