Sensor Module Resistor Connector Orthogonal Conductor Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sensor modules with pressure sensors face issues due to misalignment of resistor element and conductor patterns, leading to variations in resistor element outputs, which require complex adjustment processes.
Innovation Solution
The sensor module design includes strain gauges and resistor element connectors formed on a diaphragm using vapor-deposit, with an electric conductor covering parts of the connectors, arranged such that linear portions are orthogonal to the conductor edges, maintaining consistent areas and resistances despite misalignment, allowing for easier output adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the pattern of the resistor element and the pattern of the conductor are formed using vapor-deposit, then the manufacturing process is simplified, but misalignment between patterns occurs leading to variation in resistor element outputs
Solution Approach 1:
The patent applies preliminary action by designing the conductor pattern with predetermined offset amounts before the actual deposition process. The offset values are calculated in advance based on expected misalignment scenarios, allowing the system to compensate for alignment errors without requiring high-precision alignment during manufacturing. This enables the use of simpler vapor-deposit processes while maintaining consistent resistor element areas.
Solution Approach 2:
The patent changes the geometric parameters of the conductor pattern by introducing offset amounts in the orthogonal direction relative to the resistor element pattern. By adjusting these offset parameters, the design accommodates potential misalignment while maintaining the intended electrical characteristics and resistor element areas, thus resolving the contradiction between manufacturing simplicity and alignment precision.
2Measurement precision
If the areas of the resistor elements vary due to misalignment, then the resistance values deviate from desired values, but complex output adjustment processes are required to correct this
Solution Approach 1:
The patent performs preliminary compensation by pre-calculating and incorporating offset amounts into the conductor pattern design. This preliminary action ensures that even if misalignment occurs during manufacturing, the resistor element areas remain consistent with desired values, eliminating the need for complex post-manufacturing adjustment processes and maintaining measurement precision.
Solution Approach 2:
The patent converts the potential harm of misalignment into a benefit by deliberately designing the conductor pattern with offset amounts. This approach transforms what would normally be a source of error into a compensatory mechanism that actually improves consistency, allowing the system to achieve accurate resistor element outputs without complex adjustments.
3Ease of manufacture
If the electric conductor is shifted vertically or horizontally with respect to the strain gauge and resistor element connector, then the areas of the regions change, but this causes variation in the outputs of the strain gauges
Solution Approach 1:
The patent changes the positional parameters of the conductor pattern by introducing offset amounts in the orthogonal direction. This parameter modification allows the conductor to be positioned flexibly relative to the strain gauge and resistor element connector while maintaining consistent region areas and strain gauge output consistency, thus resolving the contradiction between manufacturing flexibility and 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 reduces variations in strain gauge outputs, simplifies the production process, and maintains consistent resistances, improving detection accuracy and ease of adjustment.
Implementation Method 1
a diaphragm, four strain gauges for detecting a strain
Implementation Method 2
the strain gauge and the resistor element connector of the sensor module may be formed on the diaphragm using vapor-deposit
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
A detector (20) provided on a flat portion of a diaphragm (10) includes a plurality of strain gauges (3), resistor element connectors (4) connecting adjacent ones of the strain gauges (3), and an electric conductor (6) covering a part of the resistor element connectors (4). First linear portions (411, 421, 431, 441) and second linear portions (412, 422, 432, 442) of the resistor element connectors (4) exposed from the electric conductor (6) are orthogonal to the edges (61A, 61B, 62A, 62B, 63A, 63B, 64A, 64B) of the electric conductor (6) extending across the first linear portions (411, 421, 431, 441) and the second linear portions (412, 422, 432, 442). Even when a pattern of the resistor element connector (4) and a pattern of electric conductor (6) are misaligned in X direction or in Y direction, an area of the resistor element connector (4) exposed from the electric conductor (6) does not change.