Pressure Sensor Module with Molding Compound Encapsulation
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Solution Overview
Problem
Existing pressure detection devices for fluid media face challenges such as high space requirements and manufacturing costs due to the use of ceramic substrates, which can lead to increased complexity and expense.
Innovation Solution
A device comprising a housing with two pressure feeds and a sensor module that includes a carrier element with a substrate and molding compound, featuring a pressure sensor element with a membrane and a control and evaluation unit, where the sensor module is partially embedded in a molding compound to reduce space requirements and protect components from media exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ceramic substrate is used in the pressure detection device, then the device structure is stable and reliable, but the device occupies more space and has higher manufacturing costs
Solution Approach 1:
The patent replaces the expensive ceramic substrate with a cost-effective printed circuit board (PCB) that can be manufactured using standard industrial processes. The PCB serves as the carrier for the sensor element and electronic components, achieving the same structural and functional purposes at lower cost and smaller size.
Solution Approach 2:
The patent changes the material parameter from ceramic to PCB material, fundamentally altering the physical and chemical properties of the carrier. This parameter change enables reduced device volume, lower manufacturing costs, and improved integration while maintaining the necessary mechanical stability and electrical functionality.
2Reliability
If a ceramic substrate is used in the pressure detection device, then the device structure is stable and reliable, but the manufacturing cost increases
Solution Approach 1:
The patent replaces the expensive ceramic substrate with a cost-effective printed circuit board (PCB) that can be manufactured using standard industrial processes. The PCB serves as the carrier for the sensor element and electronic components, achieving the same structural and functional purposes at lower cost and smaller size.
Solution Approach 2:
The PCB serves multiple functions simultaneously: it provides mechanical support for the sensor element, acts as an electrical connection network for signal transmission, and serves as a mounting platform for additional electronic components. This multi-functionality eliminates the need for separate ceramic substrates and reduces overall device complexity.
3Measurement precision
If the sensor module is exposed to the fluid medium, then the pressure detection is direct and accurate, but the components are vulnerable to mechanical damage and media exposure
Solution Approach 1:
The patent introduces a transparent protective window as an intermediary between the fluid medium and the sensor module. This window allows the pressure sensor to detect medium pressure directly while protecting the electronic components from mechanical damage and chemical exposure. The window material is selected to be compatible with the fluid medium while maintaining optical transparency for optical-based sensing.
Solution Approach 2:
The device is segmented into distinct functional zones: a protected zone containing the electronic components and sensor element, and an exposed zone containing the pressure sensing membrane that interfaces with the fluid medium. This segmentation allows different parts of the device to have different levels of protection, optimizing both measurement accuracy and component safety.
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 significantly reduces space requirements and manufacturing costs by using a molding compound to encase the sensor module, providing protection from mechanical damage and media exposure, while maintaining effective pressure detection capabilities.
Implementation Method 1
at least one pressure sensor element for detecting a pressure, wherein the pressure sensor element has at least one membrane
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
Disclosed is an apparatus (146) for sensing a pressure of a fluid medium. Said apparatus (146) comprises: - at least one housing (148) that has at least two pressure inlets (168, 169); - at least one sensor module (110) which is accommodated in the housing (148) and which comprises: • at least one support element (112) which includes at least one substrate (114), at least one molded compound (116) and at least one passage (120) that penetrates the entire support element (112); • at least one pressure sensor element (128) for sensing the pressure, which pressure sensor element (128) comprises at least one membrane and covers the passage (120); • at least one control and evaluation unit (134) which is at least partly enclosed by the molded compound (116). Also disclosed is a method for manufacturing the apparatus (146).