Pressure Sensor Carrier Recess Adhesive Bonding
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Solution Overview
Problem
Existing sensor assemblies lack improvements in design and manufacturing methods, particularly in the integration of pressure sensors, which can affect their accuracy and durability under varying pressure conditions.
Innovation Solution
A pressure sensor assembly design featuring a carrier with a pressure port and an adhesive layer for fluid communication, where the carrier's second end extends into a recess of the pressure port, ensuring fluid paths are connected and secured, with spacer elements defining the adhesive layer's thickness for enhanced stability and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the carrier and pressure port are secured together through an adhesive layer, then the fluid path connection is maintained and stability is improved, but the manufacturing precision and alignment accuracy may be compromised
Solution Approach 1:
The recess is pre-formed in the pressure port with precise dimensions and positioning, allowing the carrier to be accurately positioned before adhesive application. This preliminary structural preparation ensures alignment precision is maintained while still allowing adhesive bonding for reliable fluid communication.
Solution Approach 2:
The adhesive layer acts as an intermediary element between the carrier and pressure port, providing both mechanical bonding and precise positioning. The adhesive compensates for minor dimensional variations while maintaining the required alignment precision for fluid path connection.
2Stability of the object's composition
If the carrier extends into the recess of the pressure port, then the structural stability and fluid communication are enhanced, but the device complexity increases
Solution Approach 1:
The pressure port is segmented into an external side and an internal side with a recess, allowing the carrier to extend into the recess for enhanced stability. This segmentation enables the fluid path to be divided into sections (external to internal transition) while maintaining overall structural integrity and simplifying the assembly process.
3Manufacturing precision
If spacer elements are used to define adhesive layer thickness, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The spacer elements are integrated into the carrier or pressure port structure, allowing them to automatically define the adhesive layer thickness during assembly. The spacers perform their function of precise thickness control as part of the normal assembly process, eliminating the need for separate positioning operations or additional adjustment mechanisms.
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 enhances the accuracy and durability of pressure sensors by maintaining fluid communication and stability under pressure, reducing output errors to less than 10% and ensuring reliable performance across a range of pressure conditions.
Implementation Method 1
The pressure port and the carrier may be secured together through an adhesive layer layered between the end face and a bottom wall of the recess
Data Source
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AI summary
The present disclosure relates to sensors including pressure sensors, humidity sensors, flow sensors, etc. In some illustrative cases, a sensor assembly may include a pressure port connected to a sensor unit, an electrical connector connected to the sensor unit and an outer housing encompassing at least portions of the pressure port, sensor unit and electrical connector. In one example, the sensor unit may include a carrier carrying a sense element, where the carrier may extend into a recess of the pressure port and may be secured to the pressure port at an internal side thereof through the use of an adhesive layer.