Pressure Sensor Header With Asymmetric Glass Seals for ESD Protection
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Solution Overview
Problem
Industrial pressure sensors face challenges in providing effective Electrostatic Discharge (ESD) protection without compromising the size and integrity of the glass seals, which are crucial for maintaining electrical isolation and withstanding high-pressure differentials.
Innovation Solution
The pressure sensor header is designed with asymmetrically configured openings and glass insulation, directing ESD pulses through a specific ground pin by reducing the diameter of its associated opening and glass insulation, ensuring a path of least resistance to ground, thereby protecting sensitive electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the size of the glass header seal is increased to provide sufficient ESD resistance, then ESD protection is improved, but the seal becomes too weak to handle large pressure differentials and the sensor size becomes impractical
Solution Approach 1:
The patent applies different seal sizes to different pins based on their functional requirements. Ground pins have smaller seals that allow ESD pulses to pass through, while signal pins have larger seals for pressure sealing. This local differentiation resolves the contradiction by making each seal's size appropriate to its specific function rather than uniformly large for all pins.
Solution Approach 2:
The patent creates asymmetric seal configurations where ground pins have smaller seal diameters than signal pins. This asymmetry is intentional and functional - the smaller seals on ground pins create a path of least resistance for ESD pulses while the larger seals on signal pins maintain pressure integrity. The asymmetric design directly addresses the contradiction by optimizing seal size for each pin's specific role.
2Reliability
If the size of the glass header seal is increased to withstand ESD pulses, then ESD resistance is improved, but the sensor size becomes impractical for many applications
Solution Approach 1:
Only the ground pins require small seals for ESD protection, while signal pins have larger seals for pressure sealing. This localized approach means the overall sensor size is not increased, as only specific areas have reduced seal sizes rather than the entire header requiring enlarged seals.
Solution Approach 2:
The asymmetric seal design allows the header to maintain a compact size while providing ESD protection. The variation in seal sizes across different pins creates a path of least resistance for ESD pulses without requiring uniformly large seals that would increase the overall sensor volume.
3Reliability
If glass seal size is increased to provide ESD protection, then ESD pulse shunting is improved, but the seal becomes too weak to handle large pressure differentials
Solution Approach 1:
Ground pins have smaller seals optimized for ESD pulse shunting, while signal pins have larger seals optimized for pressure differential handling. This local quality differentiation allows each seal to be optimized for its primary function without compromising the other.
Solution Approach 2:
The asymmetric seal configuration creates a functional differentiation where smaller seals on ground pins facilitate ESD pulse flow while larger seals on signal pins maintain pressure integrity. The asymmetric design resolves the contradiction by making seal strength and ESD shunting capability complementary rather than competing requirements.
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 configuration effectively shunts ESD pulses away from sensitive components, providing reliable ESD protection up to ±4kV, ensuring the sensor's integrity and functionality under harsh conditions.
Implementation Method 1
The sensor pins have first ends electrically connected to the pressure transducer in the pressure chamber and second ends electrically connected to sensor electronics outside the pressure chamber. The pins are electrically insulated from the header.
Implementation Method 2
The header is configured so that the electrical insulation of at least one pin from the header is less than the electrical insulation of the remaining pins from the header... the ESD pulse will follow the path of least resistance, the ESD pulse will be shunted safely through the electronics connected to the pin(s) with the smaller seals
Data Source
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Figure 3
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AI summary
A pressure sensor includes a housing, a pressure chamber defined within the housing, and a pressure transducer. The pressure sensor also includes a header that seals the pressure chamber and supports the pressure transducer in the pressure chamber. A plurality of pins extend through respective openings in the header. The sensor pins have first ends electrically connected to the pressure transducer in the pressure chamber and second ends electrically connected to sensor electronics outside the pressure chamber. The pins are electrically insulated from the header. The header is configured so that the electrical insulation of at least one pin from the header is less than the electrical insulation of the remaining pins from the header.