Pressure Sensor Membrane With Underlying Electrical Connections
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Solution Overview
Problem
Pressure sensors used in harsh or corrosive environments often suffer from damage and inaccurate readings due to corrosion of leads and resistors, as well as unpredictable changes in membrane shape from electrical connections, making it difficult to maintain reliable measurements.
Innovation Solution
The pressure sensor design features a membrane with no electrical components on its top surface, instead locating them underneath, protected from harsh environments, with components like piezoresistors on the underside and metallization extending from a support frame to form connections at the bottom, reducing stress and exposure to corrosive substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If electrical connections are formed in close proximity to the membrane, then device dimensions can be reduced, but the membrane may be damaged or produce unpredictable output
Solution Approach 1:
The patent moves electrical connections from the traditional planar arrangement on the membrane surface to a three-dimensional configuration beneath the membrane, utilizing the vertical dimension. This allows connections to be positioned close to the membrane for compact device dimensions while maintaining sufficient separation to prevent damage and ensure reliable operation.
2Adaptability or versatility
If resistors and leads are placed in harsh or corrosive environments, then the pressure sensor can measure such environments, but the leads and resistors may corrode or degrade
Solution Approach 1:
The patent segments the pressure sensor into distinct functional zones: the membrane and cavity region that contacts harsh environments, and the component region beneath the membrane that remains protected. This spatial segmentation allows the device to measure pressures in corrosive substances while isolating sensitive electronic components from direct environmental exposure.
3Ease of manufacture
If components are located on the membrane, then electrical connections can be made, but the membrane shape may change leading to unpredictable output
Solution Approach 1:
The patent extracts electrical connections from the membrane surface and relocates them to the region beneath the membrane. This separation removes the source of mechanical stress that connections on the membrane surface would impose, allowing the membrane to deflect freely in response to pressure changes without being constrained by attached leads or components, thereby maintaining measurement precision.
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 allows pressure sensors to operate reliably in harsh environments with reduced damage and stress on the membrane, providing accurate and consistent pressure readings by isolating electrical components from corrosive substances and minimizing distortion from connection formation.
Implementation Method 1
Often, the electronic components are resistors that are configured as a Wheatstone bridge located on the membrane. As the membrane distorts due to a pressure, the resistance of the resistors change.
Data Source
AI summary
Pressure sensors that may be used in harsh or corrosive environments. One example may provide a pressure sensor having membrane with a top surface that may be free of components or electrical connections. Instead, components and electrical connections may be located under the membrane. By providing a top surface free of components and electrical connections, the top surface of the pressure sensor may be placed in harsh or corrosive environments, while components and electrical connections under the membrane may remain protected.