Strain Gauge Pressure Sensor Assembly Without Glass Sintering
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Solution Overview
Problem
Existing strain gauge pressure sensors face manufacturing complexity, low efficiency, and quality control issues due to the use of glass sintering processes, leading to problems like bubbles and looseness, which affect accuracy and stability.
Innovation Solution
A strain gauge pressure sensor design utilizing a prefabricated element to connect the elastic diaphragm and strain gauge into a monolithic structure, simplified by using a sacrificial solvent and high-temperature bonding, eliminating issues related to glass morphology control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glass paste or glass powder sintering process is used to manufacture strain gauge pressure sensors, then the sensor can be manufactured with traditional methods, but the manufacturing process becomes complex with many process steps, low preparation efficiency, and quality control difficulties due to bubbles and looseness
Solution Approach 1:
The strain gauge is pre-formed on a prefabricated element (such as a ceramic substrate or metal diaphragm) before assembly into the final sensor. This preliminary preparation allows the strain gauge to be manufactured separately with optimized processes, then integrated into the pressure sensor structure, thereby simplifying the overall manufacturing process and improving preparation efficiency by avoiding complex in-situ sintering steps
Solution Approach 2:
The manufacturing process is divided into separate segments: the strain gauge is manufactured independently on a prefabricated element, then assembled with the pressure-sensitive diaphragm and housing. This segmentation eliminates the need for complex multi-step sintering processes involving glass paste, reducing both process complexity and improving production efficiency while maintaining quality control
2Manufacturing precision
If glass paste or glass powder sintering process is used, then traditional manufacturing methods are applied, but the morphology of glass is difficult to control, leading to bubbles and looseness that affect quality
Solution Approach 1:
The traditional thermal sintering process using glass paste is replaced with mechanical bonding methods such as adhesive bonding or friction stir welding. This substitution eliminates the need for high-temperature sintering that causes glass morphology control issues, bubbles, and looseness, thereby improving manufacturing precision and ensuring consistent sensor quality and reliability
Solution Approach 2:
The manufacturing process parameters are changed from high-temperature sintering (typically 400-600°C for glass paste) to room temperature or low-temperature adhesive bonding processes. This parameter change eliminates the formation of bubbles and looseness associated with glass sintering, enabling precise control of the bonding interface and ensuring stable sensor quality
3Measurement precision
If complex glass sintering processes are used, then traditional manufacturing approaches are followed, but the accuracy and stability of the sensor cannot be effectively guaranteed due to quality control issues
Solution Approach 1:
The strain gauge is pre-calibrated and pre-tested on the prefabricated element before final assembly. This preliminary action ensures that the strain gauge meets accuracy specifications before integration, simplifying the manufacturing process by eliminating complex post-assembly calibration steps and effectively guaranteeing sensor accuracy
Solution Approach 2:
The complex glass sintering process is replaced with simpler mechanical bonding methods that provide consistent bonding strength and dimensional stability. This substitution reduces manufacturing process complexity while maintaining or improving sensor accuracy and stability by eliminating variables associated with glass paste formulation, sintering temperature control, and cooling rates
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 approach simplifies processing steps, avoids defects like bubbles and porosity, ensuring high accuracy and stability, thus enhancing the overall quality of the strain gauge pressure sensor.
Implementation Method 1
an elastic diaphragm provided at an end of the pressure seat away from the base and corresponding to the pressure guiding channel, wherein the elastic diaphragm is deformable in response to a change of pressure
Implementation Method 2
a strain gauge provided on a surface of the prefabricated element away from the elastic diaphragm, wherein the strain gauge is configured to generate an electrical signal in response to deformation of the elastic diaphragm
Implementation Method 3
performing high-temperature treatment on the integrated structure to remove the sacrificial solvent and bonding the elastic diaphragm, the prefabricated element, and the strain gauge into a monolithic structure
Data Source
AI summary
A strain gauge pressure sensor and a preparation method therefor, the strain gauge pressure sensor (100) comprising a base (10), a pressure seat (20), an elastic diaphragm (30), a prefabricated element (40), a strain gauge (50), and a circuit board (60). In the strain gauge pressure sensor and the preparation method therefor, connection between the elastic diaphragm (30) and the strain gauge (50) is achieved by using the pre-prepared prefabricated element (40), and the use of the pre-prepared prefabricated element (40) can effectively simplify a processing process. The processing difficulty is reduced, the occurrence of conditions such as bubbles and looseness caused by glass morphology being difficult to control is completely avoided, the overall processing precision and processing stability of the strain gauge pressure sensor are effectively guaranteed, and the overall quality of the strain gauge pressure sensor is ensured.