Strain Gauge Pressure Sensor Diaphragm Integration
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Solution Overview
Problem
Existing pressure transducers face challenges in minimizing size while maintaining performance and reliability, particularly in space-constrained environments, due to the configuration of internal components which can compromise integrity and increase the risk of wire damage during assembly.
Innovation Solution
The design features a pressure sensor assembly with a pressure port, fluid passageway, and diaphragm, where the sensing element is mounted on the outer surface of the diaphragm, and wire bonding pads are arranged in parallel planes with the diaphragm, allowing for simplified electrical coupling using wire bonding machines and reduced risk of wire damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the transducer size is reduced to meet space limitations, then the overall package size decreases, but the internal component arrangement becomes more constrained and complex
Solution Approach 1:
The patent merges the diaphragm and the electronics package mounting surface into a single integrated structure. The flat surface of the diaphragm serves dual purposes: as the pressure-sensitive element and as the mounting surface for the electronics package, eliminating the need for separate mounting structures and reducing overall complexity
Solution Approach 2:
The patent utilizes the planar dimension of the diaphragm surface to mount the electronics package, transitioning from a three-dimensional stacked arrangement to a two-dimensional planar integration. This reduces the height dimension of the transducer while maintaining all necessary functional separations
2Ease of manufacture
If conventional wire routing methods are used, then electrical connections are established, but the risk of wire damage during assembly increases
Solution Approach 1:
The patent introduces flat cables as an intermediary element between the sensing element and the electronics package. These flat cables route wires through a protective channel in the housing, shielding them from damage during assembly and operation while maintaining electrical connectivity
Solution Approach 2:
The patent provides protective channels and routing paths for wires before assembly is complete. The housing structure includes pre-formed channels that guide and protect wires from mechanical damage during the assembly process, preventing wire breakage before it occurs
3Reliability
If specialized connectors are used for electrical connections, then connection reliability improves, but device complexity and size increase
Solution Approach 1:
The patent extracts the connector function from the overall device design. By integrating wire bonding pads directly onto the diaphragm surface and using flat cables for connection, the design eliminates the need for specialized connectors while maintaining reliable electrical connections through simplified wire bonding technology
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 configuration enables a compact pressure transducer with improved reliability and reduced risk of wire damage during assembly, facilitating efficient electrical connections and maintaining performance without the need for specialized connectors.
Implementation Method 1
Pressure sensing transducers incorporating micro fused silicon strain gauge technology
Data Source
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AI summary
A pressure transducer assembly that includes a pressure-responsive diaphragm (34) to which a sensing element is mounted and an electronic package (36) that includes wire-bonding pads adapted be electrically connected to the sensing element by wire bonding equipment. The diaphragm and wire bonding pads are supported within the transducer so that they lie in proximity to each other and in non-intersecting planes.