Pressure Sensor Lead Frame with Segmented Inlet Holes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Pressure sensors used in washing machines and tire pressure monitoring systems face challenges in precise water level sensing due to sensitivity limitations and potential damage from excessive pressure, particularly in steam washing machines.
Innovation Solution
A pressure sensor apparatus with a lead frame directly connected to a wire connector, featuring a housing with separate inlet holes for reference and target media, a pressure transfer medium for protection, and an integrated chip for signal conversion, allowing precise pressure measurement while omitting a substrate or bracket for reduced costs and increased durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional pressure sensor structure is used, then the sensor can detect pressure variations, but the measurement precision is insufficient due to non-linear quadratic curve output and sensitivity limitations
Solution Approach 1:
The housing is divided into separate reference pressure chamber and target pressure chamber with independent inlet holes. The reference medium inlet hole is provided in a first surface while the target medium inlet hole is provided in a second surface, allowing independent pressure application to each chamber and enabling precise differential pressure measurement.
Solution Approach 2:
A pressure transfer medium is introduced as an intermediary substance between the target medium inlet hole and the pressure sensing element. This medium transfers pressure from the target medium to the sensing element while protecting it from direct contact with the target medium, improving both measurement precision and reliability.
2Reliability
If the pressure sensor is exposed to excessive pressure from continuous water supply or steam generation, then the sensor can continuously measure pressure, but the sensor may be damaged or broken
Solution Approach 1:
The pressure transfer medium serves as a cushioning layer that absorbs and distributes excessive pressure before it reaches the pressure sensing element. This protective medium prevents direct impact of high pressure on the sensing element, avoiding damage while allowing continuous operation.
Solution Approach 2:
The pressure transfer medium acts as a protective intermediary between the target medium and the pressure sensing element. It transfers pressure gradually and protects the sensing element from direct exposure to excessive pressure, thereby improving reliability and preventing damage.
3Ease of manufacture
If a substrate or bracket is used in the pressure sensor structure, then the sensor provides structural support, but production costs increase and productivity decreases
Solution Approach 1:
The housing structure is merged with the lead frame, eliminating the need for separate substrates or brackets. The lead frame serves dual purposes as both electrical connection structure and mechanical support, thereby reducing component count, production costs, and assembly complexity while maintaining structural integrity.
Solution Approach 2:
The lead frame is designed to perform multiple functions simultaneously: providing electrical connections, structural support, and mechanical stability. This multi-functional design eliminates the need for separate structural components like substrates or brackets, reducing manufacturing complexity and costs.
4Ease of manufacture
If the lead frame is directly connected to the wire connector, then assembly is simplified and costs are reduced, but the connection strength may be insufficient
Solution Approach 1:
The insertion terminals are pre-formed with pointed tips on the lead frame during manufacturing. This preliminary shaping enables easy insertion into the wire connector while ensuring strong connection, as the pointed tips facilitate both straightforward assembly and reliable electrical and mechanical bonding.
Solution Approach 2:
The insertion terminals are designed with localized pointed tips at specific locations on the lead frame where connection to the wire connector is needed. This local quality enhancement provides strong connection points without requiring complex overall structure, maintaining assembly simplicity while ensuring connection strength.
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 solution enables precise sensing of water levels and tire pressures, reduces production costs, and prevents damage from excessive pressure, while achieving a compact design and lower power consumption.
Implementation Method 1
a pressure sensing element mounted on the lead frame to measure a relative pressure between a first part and a second part
Implementation Method 2
a housing including a reference medium inlet hole to apply a pressure of a reference medium to the first part
Implementation Method 3
including a target medium inlet hole to apply a pressure of a target medium to the second part
Implementation Method 4
a pressure transfer medium to transfer the pressure of the target medium to the second part and to protect the pressure sensing element
Data Source
AI summary
Provided is a pressure sensor apparatus including a lead frame, a pressure sensing element mounted on the lead frame to measure a relative pressure between a first part and a second part, and a housing including a reference medium inlet hole to apply a pressure of a reference medium to the first part, and including a target medium inlet hole to apply a pressure of a target medium to the second part, wherein the reference medium inlet hole is provided in a first surface of the housing, wherein the target medium inlet hole is provided in a second surface of the housing other than the first surface, and wherein the lead frame includes one or more insertion terminals configured to be inserted into and electrically connected to terminal holes of a wire connector.