Abstract:
System, apparatus and method for capacitive sensing, where a sensor includes an upper and lower housing, each respectively equipped with upper and lower pressure ports. The lower housing is electrically coupled to an active shield. An insulating material is provided on or near a conductive diaphragm for insulating the conductive diaphragm from the lower housing. The insulating material may be an insulator or a dielectric material, where a sensing electrode is positioned such that the sensing electrode extends laterally across at least a portion of the insulating material, and is separated from the insulating material by a predetermined distance to form an air gap.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure is directed to techniques for improving operation of sensors. More specifically, the disclosure is directed to techniques for improving operation of capacitive pressure sensors. 
       BACKGROUND INFORMATION 
       [0002]    Sensors have long been used in the art to sense and measure a variety of environmental and/or physical states. Capacitive sensors have been particularly advantageous for having the capability to directly measure a variety of states, such as motion, chemical composition, electric field, etc., and, indirectly, sense many other variables that may be converted into motion or dielectric constants, such as pressure, acceleration, fluid level, fluid composition and the like. Additional applications for capacitive sensors include flow measurement, liquid level, spacing, scanned multiplate sensing, thickness measurement, ice detection, and shaft angle or linear position. 
         [0003]    Generally speaking, during a typical design process for a capacitive sensor, electrode plates (or other surface types) use used to measure a desired variable. The capacitance for the plates is maximized by using the largest area allowed for the application, with the plates positioned in a close-space configuration. The sensor is preferably surrounded with appropriate guard or shield electrodes to handle stray capacitance and/or crosstalk from other circuits. Taking into consideration the sensor capacitance, stray capacitance and output signal swing, the sensor may be configure to operate according to a specified transfer function (area-linear, spacing-linear, etc.), and a plurality of balanced capacitors may be used for increased accuracy. The sensor may be further configured to operate at an excitation frequency high enough for low noise. As excitation frequency increases, external and circuit generated noise decreases. 
         [0004]      FIG. 1  show an exemplary capacitive pressure sensor  100  as is known in the art. Sensor  100  comprises an upper housing  101  with an upper pressure port  103  and a lower housing  102  with a lower pressure port  102 . Both the upper  101  and lower  102  housings may be constructed from stamping, casting, or machining a passivated metal such as stainless steel. The upper and lower housings are separated by a conductive diaphragm  109 , and all of them are electrically coupled to a common reference, such as ground ( 110 A-C). A sensing electrode  108  is configured to be positioned separately from diaphragm  109 , and is separated therefrom by a small air gap. 
         [0005]    During operation, as the relative pressure between the upper cavity and the lower cavity changes, the conductive diaphragm deflects to the side with lower pressure, resulting in a change in the gap between the sensing electrode and the conductive diaphragm. This change causes a change in capacitance between the sensing electrode and conductive diaphragm. By measuring this change in capacitance, the deflection of the diaphragm may be determined, indicating a relative pressure between the upper and lower cavities. Sensing electrode  108  is typically connected to a drive circuit  105  via electrical conductor  106 . The electrical conductor  306  is typically shielded with an active shield  107  to protect from stray capacitance, which may comprise an in-phase signal buffered from the drive signal. Since the voltage differential between the electrode conductor  208  and the active shield  107  remain constant, there is no appreciable increase in measured capacitance. 
         [0006]    Although the lower cavity  102  is separated from the sensing electrode  108  by a distance that is significantly greater than the distance that the sensing electrode  108  is separated from the conductive diaphragm  209 , it has been found that the configuration of the lower cavity contributes parasitic capacitance to the sensing electrode  108 . This parasitic capacitance becomes disadvantageous in that it forces a tradeoff between the size of the sensing electrode  108  and base capacitance. The size of the sensing electrode is important in that it affects capacitive change in the sensor, and consequently immunity from noise. Larger sensing electrodes will provide a greater change in capacitance with a given deflection of the conductive diagram. The larger capacitive change, as a result, will provide more noise immunity in the measurement. Accordingly, there is a need in the art to address these and other disadvantages in prior art capacitive sensors 
       BRIEF SUMMARY 
       [0007]    Accordingly, under one exemplary embodiment, a capacitive pressure sensor is disclosed, comprising an upper housing comprising an upper pressure port and a lower housing comprising a lower pressure port, with the lower housing being coupled to an active shield. A conductive diaphragm positioned between the upper and lower housing, and an insulator is positioned in the pressure sensor to insulate the conductive diaphragm from the lower housing. A sensing electrode, preferably positioned in the lower housing, extends laterally across at least a portion of the conductive diaphragm, and is separated from the conductive diaphragm by a predetermined distance. 
         [0008]    Under another exemplary embodiment, a capacitive pressure sensor is disclosed, comprising an upper housing comprising an upper pressure port, and a lower housing comprising a lower pressure port, with the lower housing being coupled to an active shield. A conductive diaphragm is positioned between the upper and lower housing, where a dielectric material is coupled to the conductive diaphragm for insulating the conductive diaphragm from the lower housing. A sensing electrode is preferably positioned in the lower housing, wherein the sensing electrode extends laterally across at least a portion of the dielectric material, and is separated from the dielectric material by a predetermined distance to form an air gap. 
         [0009]    Under yet another exemplary embodiment, a method of forming a capacitive pressure sensor is disclosed, comprising the steps of providing an upper housing comprising an upper pressure port, and providing a lower housing comprising a lower pressure port, wherein the lower housing is coupled to an active shield. A conductive diaphragm is positioned between the upper and lower housing, and an insulating material is coupled to the conductive diaphragm for insulating the conductive diaphragm from the lower housing, wherein the insulating material comprises one of (i) and insulator and (ii) a dielectric material. A sensing electrode is positioned preferably in the lower housing, such that the sensing electrode extends laterally across at least a portion of the insulating material, and is separated from the insulating material by a predetermined distance to form an air gap. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The present invention is illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which: 
           [0011]      FIG. 1  illustrates a capacitive pressure sensor as is know in the art; 
           [0012]      FIG. 2  illustrates one embodiment of a capacitive pressure sensor having a configuration for reducing parasitic capacitance during operation; 
           [0013]      FIGS. 2A-B  illustrate an exemplary construction and electronic equivalent of sensing capacitive elements under one exemplary embodiment; 
           [0014]      FIG. 3  illustrates another exemplary embodiment of a capacitive pressure sensor having a configuration for reducing parasitic capacitance during operation; and 
           [0015]      FIG. 4  illustrates an exemplary capacitance-to-digital converter for processing signals received from a capacitive sensor. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    Turning to  FIG. 2 , an exemplary embodiment is provided for a capacitive sensor that minimizes parasitic capacitance between a sensing electrode and conductive diaphragm. Sensor  200  comprises an upper housing  201  with an upper pressure port  203  and a modified lower housing  202  with a lower pressure port  204 . Similar to  FIG. 1 , both the upper  201  and lower  202  housings may be constructed from stamping, casting, or machining a passivated metal such as stainless steel. The upper and lower housings are separated by a conductive diaphragm  209 . Here, upper housing  201  and conductive diaphragm  209  are electrically coupled to a common reference, such as ground ( 210 A-B). A sensing electrode  208  is configured to be positioned separately from diaphragm  209 , and is separated therefrom by a small air gap. 
         [0017]    In the embodiment of  FIG. 2 , lower housing  202  is modified to be electrically coupled to active shield  207 , which minimizes the lower housing from influencing the overall capacitance of sensing electrode  208 . In order to allow proper operation, insulator  211  is preferably placed between modified lower housing  202  and conductive diaphragm  209 . In order for conductive diaphragm  209  to be connected to a common reference (e.g., ground) ground, it may be mounted to the upper housing  201  in a manner that allows for electrical coupling between them. By connecting the modified lower housing  202  to the active shield  207 , the sensing electrode  208  may be placed significantly closer to the modified housing, without being materially affected by the aforementioned tradeoffs associated with parasitic capacitance. Under a preferred embodiment, the modified lower housing  202  is not grounded and is configured such that it does not come in contact with either the conductive diaphragm  209  or the upper housing  201 . 
         [0018]    The reduced parasitic capacitance for the configuration in  FIG. 2  is advantageous not only for the sensor itself, but also to any surrounding circuitry. Typically, a capacitive sensor is operatively coupled to a capacitance-to-digital (C/D) converter, which operates to convert the output of a capacitance sensor into a form usable by a microcontroller. In nearly all cases, the ability of the converter to resolve very low capacitances is limited by the overall capacitance of the sensor, which may include the capacitance of the sensing electrode to conductive diaphragm, as well as the parasitic capacitance between the sensing electrode and lower housing. Generally, if the overall capacitance is lower, the ability to measure at higher resolutions becomes possible. 
         [0019]    While the embodiment provided uses an insulator for advantageous effect, similar results may be obtained from using dielectric materials as all. This effect is exemplified in the embodiment of  FIG. 2A , which illustrates a physical construction of sensing capacitive elements, comprising substantially parallel disks  251 ,  252 , separated by air and dielectric  250 . Here, the capacitance for the disks of  FIG. 2A  may be expressed as 
         [0000]    
       
         
           
             
               C 
               = 
               
                 
                   
                     ɛ 
                     0 
                   
                    
                   
                     ɛ 
                     r 
                   
                    
                    
                    
                   
                       
                   
                    
                   
                     r 
                     2 
                   
                 
                 d 
               
             
             , 
           
         
       
     
         [0000]    where C is capacitance (farads), and ∈ 0  is the vacuum permittivity, (also referred to as permittivity of free space or electric constant), which is an ideal, (baseline) physical constant containing the value of the absolute dielectric permittivity of classical vacuum. Its value is generally expressed as ∈ 0 =8.854×10 −12  farads per meter (F/m). ∈ r  is the relative permittivity of the dielectric ( 250 ); as an example, ∈ 0 =1.0006 for air, and ∈ 0 =3.4 for polyimide. r is the radius of the disc in meters, while d is the separation (distance) between the faces of the discs. Regarding design considerations, by maintaining a very small distance (d) of separation between the faces of the disks, and arranging radii r diaphragm &gt;r electrode , the modified lower housing connected to the active shield minimizes fringing effects on the edges of the discs to the point that they may be ignored, and r electrode  may be used for the disc radius. The specific distance used for d would then largely depend upon a tradeoff between sensitivity to manufacturing tolerances and sensitivity to conductive diaphragm deflection. 
         [0020]    For a conductive diaphragm with a dielectric, the electronic equivalent combination may be treated as two capacitors in series, as shown in  FIG. 2B . Here, the dielectric capacitance C dielectric  acts as a constant  253 , having the characteristics 
         [0000]    
       
         
           
             
               C 
               dialectric 
             
             = 
             
               
                 
                   
                     ɛ 
                     dielectric 
                   
                    
                   
                     ɛ 
                     0 
                   
                    
                    
                    
                   
                       
                   
                    
                   
                     r 
                     2 
                   
                 
                 
                   d 
                   dielectric 
                 
               
               . 
             
           
         
       
     
         [0000]    The air capacitance C air , acts as a variable capacitor  254 , having the characteristics 
         [0000]    
       
         
           
             
               C 
               air 
             
             = 
             
               
                 
                   
                     ɛ 
                     air 
                   
                    
                   
                     ɛ 
                     0 
                   
                    
                    
                    
                   
                       
                   
                    
                   
                     r 
                     2 
                   
                 
                 
                   d 
                   air 
                 
               
               . 
             
           
         
       
     
         [0000]    Accordingly, the total capacitance may be expressed as 
         [0000]    
       
         
           
             
               C 
               total 
             
             = 
             
               
                 
                   ( 
                   
                     
                       C 
                       dielectric 
                     
                     + 
                     
                       C 
                       air 
                     
                   
                   ) 
                 
                 
                   ( 
                   
                     
                       C 
                       dielectric 
                     
                     × 
                     
                       C 
                       air 
                     
                   
                   ) 
                 
               
               . 
             
           
         
       
     
         [0000]    As such, it can be noted that the capacitance of C dielectric  does not change with deflection of the diaphragm; only the capacitance of C air  changes. 
         [0021]    An alternate configuration for capacitive sensor  300  is illustrated in  FIG. 3 , where, similar to the embodiment in  FIG. 2 , an upper housing  301  is provided with an upper pressure port  303 , and a modified lower housing  302  with a lower pressure port  304 . Again, upper housing  301  and conductive diaphragm  309  are electrically coupled to a common reference, such as ground ( 310 A-B). A sensing electrode  308  is configured to be positioned separately from diaphragm  309 , and is separated therefrom by a small air gap. Sensing electrode  308  is connected to a drive circuit  305  via electrical conductor  306 . 
         [0022]    In this embodiment, dielectric material  311  may be bonded to conductive diaphragm  309  in order to provide insulation between modified lower housing  302  and conductive diaphragm  309 . In one exemplary embodiment, a pre-coated diaphragm assembly may be manufactures by bonding a polyethylene terephthalate (PET) or polypropylene (PP) film to a stainless steel conductive diaphragm. In an alternate embodiment, a conductive diaphragm is built on top of a polymide film (e.g., Kapton) utilizing flex circuit techniques. Generally speaking, circuits may be assembled by mounting circuit elements on flexible plastic substrates, such as polyimide, polyether ether ketone (PEEK) or transparent conductive polyester film. Additionally, flex circuits can be screen printed silver circuits on polyester. These flexible printed circuits (FPC) may be made with a photolithographic technology or similar techniques. An alternative way of making flexible foil circuits or flexible flat cables (FFCs) is laminating very thin (0.07 mm) copper strips in between two layers of PET. These PET layers, which may be 0.05 mm thick, are coated with an adhesive which is thermosetting, and will be activated during the lamination process. In one embodiment, the conductive diaphragm  309  would comprise a plated copper layer bonded to a polyimide film, where the copper would be plated with electro-less nickel and passivated with gold to prevent corrosion. One advantage to this configuration is that the gap between sensing electrode and conductive diaphragm may be minimized without resulting in electrical shorts between the two. As a practical matter, care should be taken so that the dielectric material does not creep over time and allow the modified lower housing to come in electrical contact with either the conductive diaphragm or the upper housing. 
         [0023]    As mentioned above, lower overall capacitance allows higher resolution for sensor measurements. Additionally, a lower overall capacitance may negate the need for using customized C/D converters. As an example, certain capacitive sensor elements may have a base capacitance of around 18±2 pF, with a span of ±(2.2±1 pF), yielding an operational range of 12.8 to 23.2 pF. The high base capacitance of such an element would effectively eliminate the use of off-the-shelf C/D converters. A significant portion of this base capacitance can be directly attributable to the effects of parasitic capacitance. For all types of conversion, the ratio of the span capacitance to the base capacitance is an indicator of how well the diaphragm position may be resolved; the closer the ratio approaches 1:2 for a bidirectional sensor, the better the resolution may for sensing diaphragm position. As a practical matter, a ratio of 1:4 of the span capacitance to the base capacitance will be acceptable given current manufacturing tolerances. 
         [0024]    Turning to  FIG. 4 , an exemplary block diagram for C/D converter  400  is illustrated for receiving signals from a capacitive sensor, such as the ones illustrated above in  FIGS. 2 and 3 . In one embodiment, C/D converter  400  is configured as a multi-bit (12, 16, 24 bit, etc.) sigma-delta (Σ-Δ) converter capable of measuring capacitance directly from the device inputs. The architecture should preferably be configured for high resolution and high linearity (±0.01-0.05%). C/D converter  400  may have multiple capacitance input ranges per operation (differential mode/single-ended mode). Input signals  401  from capacitive sensor may be received at a multiplexer  403 , operatively coupled to positive terminal (CAP+)  402  and negative terminal (CAP−)  404  of charge-pump circuit. The measured capacitance  401  is connected between an excitation source  405  and the modulator  406  input. A square-wave excitation signal may be applied on the capacitive measurement signal during the conversion and modulator  406  may be configured to continuously sample the charge going through the signal using voltage reference  408  and clock from  407 . Digital filter  409  may be configured to process the modulator output (streaming 0&#39;s and 1&#39;s), where the data from the digital filter  409  is scaled, applying the calibration coefficients via control logic  420 , and the final result (OUT) can be read through serial interface  411 . 
         [0025]    It is understood that the C/D converter of  FIG. 4  is merely one non-limiting example, and that a myriad of other suitable C/D converters may be used as well. Additionally, readings from multiple sensors may be combined in a C/D converter using multiple channels. Moreover, the disclosure is not limited to the specific capacitive pressure sensors disclosed herein, but may be applied to any other sensor utilizing the principles disclosed herein. 
         [0026]    While at least one example embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the example embodiment or embodiments described herein are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient and edifying road map for implementing the described embodiment or embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope of the invention and the legal equivalents thereof.