Non-circular Resonator Pressure Transducer Batch Etching
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Solution Overview
Problem
Conventional resonator-based pressure transducers are costly due to complex geometry and large size, which requires extensive mechanical shaping and assembly, and are prone to damage in varying temperature and pressure environments.
Innovation Solution
A non-circular cylindrical pressure transducer design with a piezoelectric resonator housed in a rotationally symmetrical, non-axisymmetrical housing, utilizing a batch manufacturing process involving plasma etching and fusion or metal bonding to produce smaller, more cost-effective transducer units with non-circular cross-sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mechanical lapping and grinding processes are used to shape individual components, then manufacturing precision is achieved, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent replaces conventional mechanical lapping and grinding processes with chemical etching processes to shape the resonator and housing components. This substitution eliminates the need for expensive mechanical shaping equipment and reduces manufacturing complexity while achieving the required geometric precision through controlled chemical reactions.
Solution Approach 2:
The patent changes the manufacturing approach by transitioning from mechanical removal of material to chemical etching. This parameter change in the manufacturing process fundamentally alters how components are shaped, enabling more complex geometries to be created more efficiently and at lower cost.
2Manufacturing precision
If conventional mechanical shaping and assembly processes are used, then manufacturing precision is achieved, but productivity decreases and manufacturing cost increases
Solution Approach 1:
The patent merges multiple manufacturing operations into a single chemical etching process that can simultaneously shape multiple components. This consolidation of processes dramatically increases productivity by eliminating the need for separate mechanical shaping and assembly steps for each component.
Solution Approach 2:
By replacing mechanical shaping processes with chemical etching, the patent enables parallel processing of multiple components in a single batch operation, thereby significantly improving productivity compared to sequential mechanical processing.
3Measurement precision
If dual-mode oscillation resonators are used to minimize pressure measurement fluctuations, then measurement precision is improved, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent achieves dual-mode oscillation capability by changing the geometric parameters of the resonator through chemical etching, creating non-circular cross-sections that enable complex vibrational modes. This approach achieves the desired measurement precision while keeping the manufacturing process simple.
4Manufacturing precision
If conventional mechanical shaping processes are used for individual components, then manufacturing precision is achieved, but the transducer size increases and material usage increases
Solution Approach 1:
The patent replaces mechanical shaping with chemical etching, which allows for more precise control of material removal and enables the creation of smaller, more compact transducer geometries that would be difficult or expensive to achieve through mechanical processes alone.
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 significant cost savings through miniaturization and improved manufacturability, reducing material usage and assembly costs while maintaining performance in varying environmental conditions.
Implementation Method 1
a piezoelectric resonator, which according to some embodiments can be shaped bi-convex or planar-convex
Implementation Method 2
a resonator member located within the housing. The resonator member includes a piezoelectric resonator... configured or designed for vibrating in at least two modes
Data Source
AI summary
An improved manufacturing process for resonator-based pressure transducers is described. The process is a batch process in which several resonators are shaped simultaneously, using an etching process such as plasma etching. The end pieces are also shaped, if required, for several transducers. The end pieces and resonators are sandwiched together prior to separating the individual transducer units. The individual transducer units are then separated using a cutting process. The described process can be used to manufacture pressure transducers having a substantially smaller size, for example 5-6 mm outer dimensions and 2-3 mm resonators. The outer shape of the transducers can be a non-circular cylindrical shape such as that of a right square prism or an octagonal prism.