In addition to electric vehicles, hydrogen vehicles, better known as fuel cell cars, trucks and buses, can also be a promising alternative for zero-emission transportation. Here, a fuel cell with a hydrogen tank generates the electricity, which in turn is used to power the vehicle's electric drive. A decisive factor for the safe operation of such vehicles is the continuous monitoring of the pressure in the hydrogen tanks. Very compact and robust thin-film pressure sensors are usually used here, which enable precise measurement of pressures of up to 1000 bar. In addition, they must operate reliably in the demanding environment of the high-pressure hydrogen environment.
Material selection for robustness and thin-film technology for functionality
Use under challenging environmental conditions means that the housing of the sensors and the diaphragm of the measuring cell must be made of a particularly resistant material. Stainless steel 1.4435 is generally used here, as it guarantees outstanding mechanical stability (overload capacity) and resistance to extreme pressure conditions (burst pressure behavior). Furthermore, this material is an austenitic steel that does not become brittle on contact with hydrogen and therefore also has above-average corrosion and media resistance when handling aggressive media. In addition, the stainless steel housing and the stainless steel diaphragm must be directly welded, eliminating the need for additional seals. All these aspects are particularly important to ensure the longevity and reliability of the pressure sensors.
For the functionality of the pressure sensors, resistors are applied to the stainless steel diaphragm using thin-film technology. This can be done in a multi-stage coating process using sputter technology with a sometimes extremely thin layer thickness of less than 1 µm, which is then structured either directly by laser or using a wet-chemical process.
Precise laser processing for thin-film pressure sensors: expertise from LCP Laser-Cut-Processing GmbH
The production of pressure sensors with thin-film structures requires high-precision processing technology, including the use of laser technology. The latter requires many years of comprehensive expertise in the gentle laser processing of complex, delicate and sensitive precision components using various laser processing technologies, which are crucial in the manufacture of thin-film pressure sensors. And this is where LCP Laser-Cut-Processing GmbH comes into play as an expert and long-standing laser application center.
Our expertise lies in the wide range of laser processes paired with the procurement and processing of sensitive special materials as well as our continuous R&D activities for process development, innovative material processing or new processing technologies. The following processes are used to process stainless steel membranes or metallic circuit boards for pressure sensors:
- Laser fine cutting: Several individual membranes or circular blanks are cut from the metal foil or metallic circuit board using a laser. The advantage: Clean cut edges thanks to innovative fiber and disk lasers. Minimal degree formation can be easily removed by simple post-processing.
- Laser structuring: Structuring of coated components (de-coating or layer removal) or the creation of defined and complex surface structures as well as the creation of microstructures. The advantage: No or hardly any thermal damage to the material thanks to minimized heat input through USP laser technology. No burr formation or melt adhesion.
- Laser marking: Laser marking allows a data matrix or QR code to be applied to the respective component, which ensures complete traceability of the component. Advantage: Permanent marking that is resistant to abrasion and chemicals. Non-contact and therefore material-friendly process.
- Laser welding: With laser welding, the stainless steel membrane is permanently bonded directly to the sensor base body, the housing. Advantage: Non-contact process, no tool wear, high welding speed.
We also offer other laser technologies for a wide range of materials:
- Laser scribing: This involves the insertion of scribe lines for the mechanical separation of ceramic payloads in the individual components for the production of circuit carriers thanks to proven CO2 laser technology.
- Laser drilling: Laser drilling, also known as micro-drilling, is a non-contact and post-processing-free process for the insertion of precision holes, so-called vias, using USP laser technology.
In addition to laser processing, our range of services is rounded off by mechanical finishing technologies such as wafer dicing, milling, turning, bending/edging, brushing, precision finishing and glass bead blasting.
Laser fine machining of components for pressure sensors
- Laser-welded sensor housing -
Your full-service partner in laser fine machining
Full service from start to finish: as a reliable manufacturing service provider and agile development partner, we are at your side along the entire process chain, from initial technical consultation and intensive process support to prototype production and series production. Additional services such as contract measuring and component cleaning as well as access to an extensive network of cooperation partners for alternative processing methods or surface finishing round off the whole package. In addition, with our many years of process expertise in the gentle laser fine machining of sensitive materials with the most delicate structures, we stand for high-class, precise machining and excellent component quality.
Wide range of applications for pressure sensors
- Automotive: Pressure sensors are used in the automotive industry for precise pressure and level measurement. This includes monitoring various pressure parameters such as fuel, brake, tire, filter and oil pressure, which helps to optimize the performance and safety of vehicles
- Air conditioning technology: In air conditioning technology, pressure sensors are used to measure air pressure in heating and cooling systems. These measurements help to increase the efficiency and performance of heating, ventilation and air conditioning systems by accurately monitoring the pressure in the systems.
- Hydraulics and pneumatics: Pressure sensors play a crucial role in the control and regulation of pressure in pumps and hydraulic and pneumatic systems. This ensures that these systems function precisely and reliably in various applications. Examples in the mobile sector include excavators, agricultural machinery, cranes and clamping devices in processing machines for stationary use.
- Medicine: In medicine, pressure sensors are used to monitor the system pressure in dialysis machines and sterilizers. This precise pressure control is essential to ensure the safety and effectiveness of medical devices.
- Chemicals, food and pharmaceuticals: Pressure sensors are used in a wide range of applications in the chemicals, food and pharmaceuticals industries, for example to monitor and control processes in which pressure plays a crucial role. This includes areas such as the production of medicines, food and chemical products.
- Aerospace: In aerospace technology, pressure sensors are used in various applications, including monitoring air pressure in aircraft cabins, rockets and spacecraft. These sensors contribute to the safety and performance of the systems.
- Water and environment: Pressure sensors are used to monitor pressure in water supply systems and measure environmental impact. This enables precise control and monitoring of water resources and environmental conditions.
- Plant and equipment engineering: In plant and equipment engineering, pressure sensors are used to monitor the pressure in various industrial plants and equipment. This is crucial for optimizing processes and ensuring safe and efficient operation.
![[Translate to English:] Silizium Wafer](/fileadmin/_processed_/4/5/csm_silizium_wafer_842_aca3d0cb65.jpg)
