Hermetic Sensor Header Sealing With Elastomeric Cavity Inserts
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Solution Overview
Problem
Fabrication of hermetically sealed enclosures faces challenges such as cracking and damage to sealing joints, which can allow gas and moisture ingress, and existing methods like glass-to-metal sealing are time-consuming and material-intensive.
Innovation Solution
The use of a header with cylindrical cavities, terminals, and sealing materials like silicon rubber stoppers or glass-fiber reinforced polyester composites, along with features to prevent displacement, achieves a hermetic seal by press-fitting or curing the materials within the header.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass-to-metal sealing methods are used to achieve hermetic seal, then sealing reliability is improved, but manufacturing time increases and material consumption increases
Solution Approach 1:
The patent changes the sealing material from glass to elastomeric material, fundamentally altering the material parameter to achieve hermetic sealing without the time-consuming glass-to-metal bonding process. The elastomeric material can be directly molded and cured, significantly reducing manufacturing time while maintaining sealing reliability.
Solution Approach 2:
The patent uses composite materials including elastomeric sealing material combined with metal terminals and header. This composite approach allows the sealing function to be achieved through material properties rather than complex bonding processes, reducing both time and material consumption while maintaining reliability.
2Reliability
If glass-to-metal sealing methods are used to achieve hermetic seal, then sealing reliability is improved, but material consumption increases
Solution Approach 1:
The patent changes the sealing material from glass to elastomeric material, fundamentally altering the material parameter to achieve hermetic sealing without the time-consuming glass-to-metal bonding process. The elastomeric material can be directly molded and cured, significantly reducing manufacturing time while maintaining sealing reliability.
Solution Approach 2:
The patent uses composite materials including elastomeric sealing material combined with metal terminals and header. This composite approach allows the sealing function to be achieved through material properties rather than complex bonding processes, reducing both time and material consumption while maintaining reliability.
3Reliability
If sealing material is pressed into header cavities, then hermetic seal is achieved, but sealing material may become displaced during assembly
Solution Approach 1:
The patent incorporates retention features (protrusions and recesses) that are pre-designed into the sealing material and header structure. These features are created during the molding process, so the retention mechanism is already in place before assembly occurs, preventing displacement during the press-fit operation without requiring additional assembly steps.
Solution Approach 2:
The elastomeric sealing material acts as a flexible element that can be compressed during assembly and then maintains its position through elastic recovery. The flexibility allows the material to conform to the cavity while the retention features prevent permanent displacement, easing the assembly process.
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 provides a robust hermetic seal that protects sensing elements from contaminants, simplifying the fabrication process and ensuring effective sealing at high temperatures.
Implementation Method 1
the at least one sealing material and the at least one terminal are press fit into the header
Implementation Method 2
the at least one sealing material having the form of a stopper and having at least one entry region feature and at least one exit region feature
Implementation Method 3
at least one sensing element wire-bonded to the at least one terminal
Implementation Method 4
The at least one sealing material is at least one of: a glass-fiber reinforced polyester composite material; an epoxy-based potting material; or a silicon-based potting material
Data Source
AI summary
A hermetically sealed sensing device is provided. The hermetically sealed sensing device may comprise a header defining one or more substantially cylindrical cavities, at least one terminal, and/or a sensing element. In some examples, the hermetically sealed sensing device comprises a silicon rubber stopper configured to provide, along with the at least one terminal, a hermetic seal in the one or more substantially cylindrical cavities. In some examples, the hermetically sealed sensing device comprises threaded grooves along the one or more substantially cylindrical cavities such that a sealing material (e.g., glass-fiber reinforced polyester composite material, epoxy-based potting material, silicon-based potting material, etc.) and the at least one terminal may form a hermetic seal therein.