Patent Publication Number: US-8534130-B2

Title: Joint between a pressure sensor and a pressure port of a sensor assembly

Description:
TECHNICAL FIELD 
     The present disclosure relates generally to sensors, and more particularly to sensor assembly structures. 
     BACKGROUND 
     Sensors are commonly used today to sense environmental parameters such as temperature, humidity, pressure, flow, thermal conductivity, gas concentration, light, magnetic fields, electric fields, as well as many other environmental parameters. Such sensors are used in a wide variety of applications including, for example, medical applications, flight control applications, industrial process applications, combustion control applications, weather monitoring applications, water metering applications, as well as many other applications. 
     SUMMARY 
     This disclosure is directed to several alternative designs, materials and methods of manufacturing electrically responsive sensor assemblies. Although sensor assemblies are known to exist, there is need for improvement to such sensor assemblies. 
     Accordingly, one illustrative aspect of the disclosure includes a pressure sensor assembly having a carrier, a pressure sensor, a pressure port, and an internal side of the pressure port having a recess in which a second end of a carrier having an end face may extend. In addition to the carrier having the second end, it may include a first end and form a fluid path extending from the first end to the second end. Similarly, the pressure port may also have a fluid path extending from an external side to an internal side of the pressure port. The pressure port and the carrier may be secured together through an adhesive layer layered between the end face and a bottom wall of the recess, such that the fluid path of the pressure port may be in fluid communication with the fluid path of the carrier. Further, the pressure sensor may include a sense element and may be in fluid communication with the fluid path of the carrier and may be secured to the first end of the carrier. 
     In some instances, the recess of the pressure port may have a bottom wall that may intersect the fluid path of the pressure port. The bottom wall may additionally have an upwardly extending lip that may extend around the fluid path of the pressure port. Further, when the second end of the carrier extends into the recess of the pressure port, the end face of the carrier may be positioned adjacent the bottom wall of the recess and the side walls of the carrier may be positioned adjacent to side walls of the recess. 
     In some instances, the second end of the carrier may have an end face that includes a shoulder with a protrusion extending from the shoulder. The protrusion of the shoulder may extend around and at least partially define the fluid path of the carrier. Further, the protrusion may extend along and adjacent the bottom wall of the recess of the pressure port and extend into the fluid path of the pressure port, such that the fluid path of the carrier may be in fluid communication with the fluid path of the pressure port. 
     In some further instances, the adhesive layer may extend along a first plane between two substantially parallel surfaces of the internal side of the pressure port and the second end of the carrier. Additionally, an adhesive layer may extend along a second plane between two substantially parallel surfaces of the internal side of the pressure port and the second end of the carrier, where the second plane may be at least substantially perpendicular to the first plane. 
     In some further instances, either the second end of the carrier or the pressure port may define at least one spacer element. The spacer element(s) may define spacing between the two substantially parallel first surfaces and/or the two substantially parallel second surfaces, where the spacers may determine the thickness of the adhesive layer. 
     The preceding summary is provided to facilitate an understanding of some of the innovative features unique to the present disclosure and is not intended to be a full description. A full appreciation of the disclosure can be gained by taking the entire specification, claims, drawings, and abstract as a whole. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure may be more completely understood in consideration of the following description of various illustrative embodiments of the disclosure in connection with the accompanying drawings, in which: 
         FIG. 1  is a perspective view of an illustrative sensor assembly and cable harness; 
         FIG. 2  is a schematic cross-sectional view of the illustrative sensor assembly and cable harness of  FIG. 1 ; 
         FIG. 3  is a perspective view of an illustrative sensor assembly; 
         FIG. 4  is an exploded perspective view of the illustrative sensor assembly of  FIG. 3 ; 
         FIG. 5  is a schematic cross-sectional view of the illustrative sensor assembly of  FIG. 3 ; 
         FIGS. 6A-6C  are cross-sectional views of alternative illustrative connection features between a port and a carrier of an illustrative sensor assembly; 
         FIG. 7  is a perspective view of an illustrative sensor subassembly; 
         FIG. 8  is an exploded perspective view of the illustrative sensor subassembly of  FIG. 7 ; 
         FIG. 9  is a top view of the illustrative subassembly of  FIG. 7 ; 
         FIG. 10  is a bottom view of the illustrative subassembly of  FIG. 7 ; 
         FIG. 11  a top perspective view of an illustrative protective cover of the illustrative subassembly of  FIG. 7 ; 
         FIG. 12  is a bottom perspective view of the illustrative protective cover of  FIG. 11 ; 
         FIG. 13  is a flow diagram showing steps of an illustrative fabrication process for an illustrative electrical connector/housing subassembly; 
         FIGS. 14A and 14B  are top and bottom views, respectively, of the assembled illustrative electrical connector/housing subassembly of  FIG. 13 . 
         FIGS. 15A and 15B  are perspective and exploded perspective views, respectively, of an illustrative sensor/port subassembly; 
         FIG. 16  is a bottom view of the port of the illustrative sensor/port subassembly of  FIG. 15A ; 
         FIG. 17  is a top view of the port of the illustrative sensor/port subassembly of  FIG. 16 ; 
         FIG. 18  is a partial exploded perspective view of an illustrative sensor assembly; 
         FIG. 19  is a top view of an illustrative cable cover of the illustrative cable harness of  FIG. 1 ; 
         FIG. 20  is a bottom view of the illustrative cable cover of  FIG. 19 ; 
         FIG. 21  is a bottom perspective view of the illustrative cable cover of  FIG. 19 ; 
         FIG. 22  is a partial top perspective view of the illustrative cable harness of  FIG. 1 ; and 
         FIG. 23  is a partial top perspective view of the illustrative sensor assembly and cable harness of  FIG. 1 . 
     
    
    
     While the disclosure is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit aspects of the disclosure to the particular embodiments described herein. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure. 
     DESCRIPTION 
     The following description should be read with reference to the drawings wherein like reference numerals indicate like elements throughout the several views. The description and drawings show several embodiments which are meant to be illustrative of the disclosure. 
     Referring to the Figures, and in one illustrative embodiment, a sensor assembly  10  may include a sensor unit  20 , pressure port  110 , an electrical connector  120  and an outer housing  130 , as depicted in  FIGS. 1-5 . In some instances, pressure port  110  may be mechanically connected to sensor unit  20 , and at a first end  120   a , electrical connector  120  may be mechanically and electrically connected to sensor unit  20 , and at a second end  120   b , electrical connector  120  may mechanically and electrically connect to a cable harness  160 , as best seen in  FIGS. 1 and 2 . It is contemplated that sensor assembly  10  may be any suitable type of sensor assembly. For example, sensor assembly  10  may be a pressure sensor assembly, a humidity sensor assembly, a force sensor assembly, a pressure switch assembly, a light sensor assembly, a gas concentration sensor assembly, a magnetic or electrical field sensor assembly, a conductivity sensor assembly, or another other suitable sensor assembly. 
     In some instances, parts of sensor assembly  10  may be assembled into various subassemblies, as discussed further herein. For example, a sensor housing subassembly  12 , as seen in for example  FIG. 18 , may include pressure port  110 , electrical connector  120  and an outer housing  130 , among other features; a connector subassembly  14 , as best seen in  FIGS. 4 and 13 , may include outer housing  130  and electrical connector  120 , among other features; a pressure sensor subassembly  16 , as best seen in  FIGS. 15A and 15B , may include sensor unit  20  with a carrier  32  and pressure sensor  50 , and pressure port  110 , among other features; and a further sub-assembly, as best seen in  FIGS. 7-10 , which may be installed into sensor housing  12 , may include sensor unit  20 , among other features. 
     Sensor Unit 
     Generally, a pressure sensor unit subassembly or sensor unit  20 , as seen in the illustrative embodiment of  FIGS. 7-10 , may include one or more electrical terminals  92 , a carrier  32 , a pressure sensor  50  including a sense element  52 , a first printed circuit board (a “PCB”)  60  that may at least partially define a second side  20   b  of the sensor unit subassembly  20 , a second PCB  70  that may at least partially define first side  20   a  of the sensor unit sub-assembly  20 , and a cover  90 , among other features. When assembling sensor unit  20 , cover  90  may be positioned between first PCB  60  and second PCB  70 , as seen in  FIG. 8 , or at another desirable location capable of facilitating and maintaining a space between first PCB  60  and second PCB  70 . 
     In some cases, sensor unit  20  may illustratively include pressure sensor  50  having pressure sense element  52  for measuring pressure of a fluid applied at pressure input port  22  and traveling through fluid path  34 , where sense element  52  may provide one or more electrical pressure signals in response to sensing the pressure of the fluid applied at pressure input port  22  (e.g., see  FIG. 5 ). In some cases, pressure sensor  50  including sense element  52  may be secured to first side  32   a  of carrier  32  in any manner. For example, pressure sensor  50  may be secured to carrier  32  through the use of an attach or an adhesive  54  or through another desirable connection technique such that pressure sense element  52  may be in fluid communication with fluid path  34  extending through carrier  32  (as depicted in  FIG. 5 ). It is contemplated that any suitable adhesive  54  or attaching material may be utilized for connecting pressure sensor  50  to carrier  32  that facilitates allowing sense element  52  to maintain its connection to carrier  32  while not transferring an inordinate amount of stress to the sense element  52  when pressure is applied thereto. 
     Carrier  32  of sensor unit  20  may have a first side or end  32   a  and a second side or end  32   b  having an opening extending from first side  32   a  to second side  32   b , as best seen in  FIGS. 5 and 10 . Opening  44  may be at least partially defined by carrier  32  and opening  44  may create a carrier fluid path  34  that travels at least from an input port  22  to sense element  52  abutting or adjacent to opening  44  at first side  32   a . Input port  22  may be located at or near second side  32   b  (e.g., an end of carrier  32  of sensor unit  20  that abuts or is connected to or is in communication with pressure port  110  and through which fluid path  34  may travel from pressure port  110  to sensor unit  20 ) having end face  33 . As mentioned, sense element  52  may be positioned at or near first side  32   a , which may be located at a side of carrier  32  substantially opposite second side  32   b . End face  33  of carrier  32  may be at least substantially flat (e.g., at least substantially planar), as shown in  FIG. 6A , or end face  33  may have a recess  37  therein defined by a bottom wall  39  and side walls  40 , where bottom wall  39  may abut or intersect fluid path  34  and may be at least substantially flat (e.g., at least substantially planar) and non-coplanar with end face  33 , as depicted in  FIG. 6B . Alternatively, or in addition, second end  32   b  of carrier  32  may include a second shoulder  41  (a first shoulder  38  is discussed below) with a protrusion  43 , where protrusion  43  may extend around fluid path  34  and may define at least part of fluid path  34 , as seen in  FIG. 6C . Moreover, protrusion  43  may be at least partially defined by fluid path  34  and side walls  35 . 
     In some instances, carrier  32  of sensor unit  20  may include an alignment feature  46  for aligning carrier  32  with first PCB  60 , as best seen in  FIG. 8 . For example, alignment feature  46  may be a shape of a part of a portion of carrier  32  that may engage first PCB  60 . In the example shown, the shape of the part of the portion of carrier  32  engaging first PCB  60  may be rounded or have a curve while the remaining parts of the portion of carrier  32  engaging first PCB  60  have a different shape (e.g., a flat or straight shape), as best seen in  FIG. 8 . Alternatively, alignment feature  46  may include a flat part of the portion of carrier  32  engaging first PCB  60  while the other parts are rounded. Further, first PCB  60  may have an alignment feature  67  (e.g. aperture) corresponding to alignment feature  46  of carrier  32 . Additionally, or alternatively, any other suitable alignment features may be used for aligning carrier  32  with first PCB  60 , when so provided. 
     Carrier  32  of pressure sensor subassembly  16  may be formed in various shapes or configurations. In an illustrative example, second end  32   b  of carrier  32  may have various shapes or configurations; for example, second end  32   b  may be planar, may have one or more recess or may have one or more protrusion, as best shown in  FIGS. 6A-C , or may take on other geometric shapes, sizes and configurations. The shapes and configurations of second end  32   b  may be such that second end  32   b  may be configured to engage or connect to an internal side  114  or end of pressure port  110 . For example, second end  32   b  of carrier  32  may have an end face  33  and side walls  35 , such that second end  32   b  of carrier  32  may extend into a recess  115  of pressure port  110 . Such configurations may form a butt joint, a tube joint, a hole joint or other type of joint between carrier  32  and pressure port  110 . 
     Further, carrier  32  may be made of any type of material. For example, carrier  32  may be made of a ceramic material or any other suitable material. In addition, and in some cases, at least a portion of end face  33  and/or bottom wall  39  may have a textured surface or non-textured surface, where a textured surface may facilitate adhering carrier  32  to pressure port  110 . The textured surface may be formed using any suitable technique including, for example, one or more of an abrasive etch, grit blasting, a chemical etch, a laser etch, machining or other similar or different texturing technique. 
     In some instances, sensor unit  20  may include at least one printed circuit board (PCB). For example, sensor unit  20  may include a first PCB  60  and a second PCB  70 , but this is not required in all embodiments. First PCB  60  may have a first side  60   a  and a second side  60   b  and a hole or opening  61  extending from first side  60   a  to second side  60   b . Opening  61  may be any shape or size. For example, opening  61  may be a shape and size capable of receiving carrier  32  such that carrier  32  abuts an interior perimeter  63  of opening  61 , or opening  61  may have any other desirable configuration consistent with the features of pressure sensor assembly  10 . In some cases, first PCB  60  may include various electronic components and/or circuitry. For example, first PCB  60  may include an application specific integrated circuit (ASIC), a compensation circuit  62 , and/or other electronic component(s). In one example, first side  60   a  of first PCB  60  may include compensation circuit  62  that may be electrically coupled to an output of the pressure sensor  50  for providing a compensated pressure sensor output signal, and/or first side  60   a  may include any other suitable circuitry. Further, with respect to the structural relationship of the other features of sensor unit  20 , second PCB  70  may be vertically positioned or spaced above or from first PCB  60 , as best seen in  FIG. 8 . 
     Referring to  FIG. 8 , lower PCB  60  may be connected to carrier  32  and the connection may be formed by any suitable connection technique. For example, first PCB  60  may connect to carrier  32  in a manner that allows first side  32   a  of carrier  32  and sense element  52  to extend through opening  61 , such that pressure sense element  52  may be positioned adjacent first side  60   a  of first PCB  60 , and a first shoulder  38  of carrier  32  may be positioned adjacent second side  60   b  of first PCB  60 . Sense element  52  may be positioned adjacent first side  60   a  of first PCB  60  to facilitate wire bonding sense element  52  to first side  60   a  or it may be so positioned for another purpose. Further, first shoulder  38  may be permanently or semi-permanently connected to second side  60   b  of first PCB  60  through the use of a first PCB attach or adhesive or glue  68 , or through any other suitable connection or adhering technique. 
     Second, upper PCB  70  may have a first side  70   a  and a second side  70   b , where first side  70   a  may have one or more electro-mechanical clips  76 . For example, one or more electro-mechanical clips  76  may be capable of engaging one or more electro-mechanical clip  84  of a third PCB  80  (e.g., see  FIG. 2 ). Further, first side  70   a  of second PCB  70  may support a ground terminal  28 , a power terminal  26 , one or more pressure sensor output terminal  30  and one or more test pad (not shown) on or near first side  20   a  of sensor unit subassembly  20 , as best seen in  FIGS. 15A and 15B . 
     In some instances, first PCB  60  and/or second PCB  70  may include circuitry that may be configured to format the one or more pressure output signals provided by pressure sense element  52  into a particular output format. For example, circuitry of first PCB  60  and/or second PCB  70  (e.g., all of the circuitry may be on first PCB  60  or all of the circuitry may be on second PCB  70  or the circuitry may be on first PCB  60  and/or second PCB  70 ) may be configured to format the one or more than one pressure output signal provided by pressure sense element  52  into a ratio-metric output format, a current format, a digital output format and/or any other suitable format. In some cases, the circuitry of first PCB  60  and/or second PCB  70  may be configured to regulate an output voltage. Circuitry on first PCB  60  and/or second PCB  70  for providing a ratio-metric (or other) output may include traces and/or other circuitry that may serve as a conduit to test pads on the first side  70   a  of second PCB  70 , and/or for providing the ratio-metric (or other) output to electrical connector  120 , where the circuitry does not necessary reformat the output. 
     When a particular sensor unit  20  is selected to be installed in sensor housing  12 , first PCB  60  and/or second PCB  70  may provide a formatted one or more pressure output signal (e.g., formatted into a first output format and/or a second output format that may be different than the first output format) to one or more selected electrical terminals  122  of electrical connector  120  via an electrical connection with one or more pressure signal output terminals  30 . The circuitry on first PCB  60  and/or second PCB  70  may be configured to format the one or more pressure signals provided by pressure sense element  52  into multiple voltage or current formats. In addition, circuitry on first PCB  60  and/or second PCB  70  may be configured to regulate a power supply voltage incoming from electrical connector  120  prior to or before providing the regulated voltage to power pressure sense element  52 . 
     In some instances, sensor unit  20  may include a cover  90 , as best seen in  FIGS. 11 and 12 . Cover  90  may be positioned within sensor unit  20  between first PCB  60  and second PCB  70 , as best seen in  FIGS. 7-8 . Cover  90  may be positioned such that it may act to maintain a mechanical spacing between first PCB  60  and second PCB  70 , or cover  90  may be used for any other similar or different purpose. Cover  90  may have a body  91  having a first, upper side  91   a  and second, lower side  91   b , where upper side  91   a  may be configured to contact or engage second PCB  70  at one or more locations and lower side  91   b  may be configured to contact or engage first PCB  60  at one or more locations. Further, and in some instances, body  91  may have a perimeter portion  93  that extends around a portion (e.g., a quarter, a half, at least a majority, etc.) of first PCB  60  and extends around a portion (e.g., a quarter, a half, at least a majority, etc.) of second PCB  70 . Body  91  may be generally electrically insulating, but may include one or more electrical terminals  92  that may be capable of transmitting one or more electrical signal between first PCB  60  and second PCB  70 . Electrical terminals  92  may be any electrical terminal configured to transmit one or more electrical signal between first PCB  60  and second PCB  70 . For example, electrical terminals  92  may include compliant pins  94 , which are discussed in greater depth in U.S. Pat. No. 7,458,274, issued on Dec. 2, 2008 to Lamb et al. and titled PRESSURE SENSOR INCORPORATING A COMPLIANT PIN, which is hereby fully incorporated by reference. Compliant pins  94  may be supported by body  91  (e.g., insert molded in body  91  or supported in another manner), as seen in  FIGS. 11 and 12 , and may extend into electrically conductive corresponding holes  64 ,  72  on first PCB  60  and second PCB  70 , respectively. Compliant pins  94  may form electrical and mechanical connections with first PCB  60  and second PCB  70 , as best seen in  FIGS. 6-8 . In some cases, compliant pins  94  may be the sole (e.g., only) mechanical mechanism that secures first PCB  60  to second PCB  70 . 
     Cover  90  of sensor unit  20  may include body  91  having first side  91   a  (e.g., upper side) facing second side  70   b  of second PCB  70  and second side  91   b  (e.g., lower side) facing first side  60   a  of first PCB  60  (e.g., lower PCB), where one or more support features  96  may extend from at least second side  91   b  toward first PCB  60 . Support features  96  may extend from second side  91   b  in any configuration and may provide support for first PCB  60  by spreading or dispersing out the force load while a fluid force is applied to pressure sensor  50  (e.g. without pressure port  110  connected). For example, support features  96  may extend from second side  91   b  in a manner such that support features  96  may be capable of at least partially contacting first side  60   a  of first PCB  60  and may be capable of extending across a portion (e.g., a quarter, a half, a majority, at least a majority, etc.) of first side  60   a  of first PCB  60 . Further, support features  96  may contact first PCB  60  in such a manner so as to apply or transmit a force from second side  91   b  of body  91  to first PCB  60 . It is contemplated that the force from second side  91   b  may be at least sufficiently large to hold pressure inlet/input port  22  of pressure sensor  50  on a pressure source exerting pressure at a level of pounds per square inch (PSI) of ten (10) PSI or any other PSI including, but not limited to, 1, 2, 4, 8, 10, 20, 40, 50, 100, 1000, 2000, 5000 PSI or more, for example, without effecting the accuracy of the output of the pressure sensor by more than 0.01 percent, 0.1 percent, 1 percent, 5 percent, 10 percent or more, as desired. 
     Support features  96  may include a first support feature  98 , and a second support feature  100  that may be spaced (e.g., laterally spaced) from one another by a gap  102 , as best seen in  FIG. 12 . Gap  102  may be configured to receive pressure sensor  50  and have pressure sensor  50  situated therein when cover  90  has been applied to first PCB  60 , where cover  90  may provide mechanical protection from large, gross objects, or other objects, that may otherwise strike wire bonds  56  connecting sensor  50  to first PCB  60  and other devices interior to cover  90 . Support features  96  may abut first side  60   a  along a substantial entirety of their path, or support features  96  may abut or contact first side  60   a  at two or more places using contacts  97  of support features  96 . Further, support features  96  may also include a perimeter support feature  101 . Further, support features  96 , 101  may at least partially define one or more openings or vents  104  in cover  90 . Openings  104  may be utilized for any purpose, including but not limited to, allowing air to flow between first PCB  60  and second PCB  70  and to pressure sensor  50 . 
     As second side  91   b  of body  91  of cover  90  may be configured or shaped to distribute forces that may be applied to first PCB  60  via support features  96  across first PCB  60 , first PCB  60  may remain sufficiently flat and cause less than a particular percentage error in the output of pressure sensor  50  when cover  90  is applied to first side  60   a  and a pressure is applied to pressure sensor  50  (e.g. without a pressure port  110  attached to the carrier). The particular percentage error may be ten (10) percent (%) or less error in the output of pressure sensor  50 , or another desirable limit on error including, but not limited to less than 0.001%, 0.01%, 0.1%, 1.0%, 2.0%, 5.0%, 10.0%, 20.0% or another level of error. 
     Sensor unit  20  may also include one or more PCB alignment features  99  capable of aligning cover  90  with first PCB  60  and/or second PCB  70 . PCB alignment feature of cover  90  may extend from sides  91   a ,  91   b  of body  91  and engage or contact respective first and second PCBs  60 ,  70 . PCB alignment features  99  may engage corresponding cover alignment features  65 ,  75  of first and second PCBs  60 ,  70 , respectively. 
     In some instances, sensor unit  20  may include at least one exterior alignment feature  95  capable of engaging a first alignment feature  150  of outer housing  130  to align sensor unit  20  with outer housing  130 , where outer housing  130  may or may not be part of a parent pressure sensor subassembly  16 . Exterior alignment feature  95  of sensor unit  20  may be positioned on or near an exterior of cover  90 ; for example, exterior alignment feature  95  may be positioned on an exterior of cover  90 , as best seen in  FIG. 4 . First alignment feature  150  of outer housing  130  may be positioned to engage or contact exterior alignment feature  95  of sensor unit  20  from an interior  131  of outer housing  130 , also best shown in  FIG. 4 . 
     Sensor unit  20  may be formed or put together through the use of any suitable technique. For example, a carrier  32  may be provided and die attach  54  (e.g., glue or adhesive) may be applied to a top or first side  32   a  of carrier  32 . After die attach  54  or other connection facilitating system has been applied to carrier  32 , sense die or element  52  of pressure sensor  50  may be positioned on die attach  54  and then cured (if necessary) to make a permanent or semi-permanent connection therebetween. Once sense element  52  has been connected to carrier  32 , first PCB attach  68  (e.g., glue or adhesive) or other connection facilitating system may be applied to first shoulder  38  of carrier  32  and first PCB  60  may be positioned on first shoulder  38  and cured (if necessary) in place. First PCB  60  may be connected to carrier  32  in any a manner. For example, second side  60   b  may be positioned on first PCB attach  68  on carrier  32  and accordingly, sensor element  52  and carrier  32  may be inserted through opening  61  so as to be adjacent first side  60   a . After first PCB  60  has been placed on first PCB attach  68 , first PCB attach  68  has been cured and first PCB  60  has been permanently or semi-permanently attached to carrier  32 , sense element  52  may be connected to first side  60   a  in any electrically conductive manner. For example, bond pads of sense element  52  may be connected to bond pads on the first side  60   a  via wire bonding or any other similar or different technique. For example, two or more wire bonds  56  may be used to bond first side  60   a  of first PCB  60  to sense element  52 . Wire bonds  56  may be free from contact with cover  90  while cover  90  engages first side  60   a  of first PCB  60 . Cover  90  may engage electrically conductive holes  64  of first PCB  60  through compliant pins  94  extending from cover  90  toward first PCB  60 . Further, electrically conductive holes  72  of second PCB  70  may engage cover  90  through compliant pins  94  extending from cover  90  toward second PCB  70 . Once second PCB  70  has been electrically and mechanically connected to cover  90  and first PCB  60  through compliant pins  94 , a sensor unit subassembly  20  may have been formed. 
     The structural relationships of features of sensor unit  20  described herein may be illustrative examples of embodiments and the structure may be organized in other relatively similar and advantageous manners that may allow sensor unit  20  to sense a pressure presented at pressure input port  22  and provide one or more pressure output signal on one or more pressure signal output terminals  30  electrically connected to electrical terminals  122  of electrical connector  120  when sensor unit  20  is installed within sensor housing  12 , as best seen in  FIGS. 2 and 5 . Further, sensor unit  20  may be a subassembly as described or it may be considered a stand alone sensor capable of operating on its own or in another assembly, as sensor unit  20  may be considered a sensor capable of sensing and/or receiving a temperature, humidity, pressure, flow, thermal conductivity, gas concentration, light, magnetic fields, electric fields, as well as many other environmental parameters and providing an output proportional to or otherwise related to a presence of the condition or parameter being measured. In addition, sensor  20  may take on other configurations not explicitly discussed herein. For example, sensor  20  may have a differently configured pressure sensor  50  or sense element  52 , such as a sensor having an oil-filled metal diaphragm or other design. 
     Pressure Port 
     Pressure sensor assembly  10  may have pressure port  110  configured to be assembled with sensor unit  20 , where pressure port  110  may at least partially define fluid path  116  extending from an external side  112  (e.g., a second side) of pressure port  110  to an internal side  114  (e.g., a first side) of pressure port  110 , as best seen in  FIGS. 15-17 . Second side  32   b  of carrier  32  may be secured to pressure port  110  with respect to internal side  114 , and fluid path  116  may align with fluid path  34  of carrier  32  such that fluid path  116  is in communication with fluid path  34 . 
     In some instances, internal side  114  of pressure port  110  may have a recess  115 , as best seen in  FIGS. 6A-6C ,  15 B and  17 . Recess  115  may be at least partially defined by a bottom wall  113  and side walls  117 , where bottom wall  113  may intersect and/or may be adjacent to fluid path  116  of pressure port  110 . In some cases, bottom wall  113  may include and/or define a lip  119  upwardly extending and/or extending toward carrier  32  when carrier  32  has been attached to pressure port  110 . Lip  119  may be adjacent to and extend around fluid path  116  of pressure port  110 , where lip  119  may define an upward end of fluid path  116  of pressure port  110 , as best seen in  FIGS. 6A ,  6 B and  17 . Recess  115  of pressure port  110  may receive a portion of second end  32   b  of carrier  32  that may extend therein. When second end  32   b  has been extended into recess  115 , end face  33  may be situated adjacent bottom wall  113  of recess  115 , and side walls  35  of carrier  32  may be positioned adjacent to side walls  117  of recess  115 , as best seen in  FIGS. 6A-6C . 
     Pressure port  110  may be made out of any material. For example, pressure port  110  may be made out of aluminum, stainless steel, plastic or any other suitable material. In some cases, at least a portion of a bottom wall  113  of internal side  114  of pressure port  110  may have a textured surface or non-textured surface, where the textured surface may facilitate adhering pressure port  110  to carrier  32  and may be formed from one or more processes including, for example, an abrasive etch, grit blasting, a chemical etch, a laser etch, machining, and/or any other suitable texturing technique. 
     As discussed, pressure port  110  and carrier  32  may be assembled to at least partially form a pressure sensor subassembly  16  (e.g., see  FIG. 4 ), where pressure port  110  may be a stainless steel and carrier  32  may be a ceramic, or pressure port  110  and carrier  32  may be made from other materials having similar or different properties. To facilitate the assembly, an adhesive layer  36  or other connection facilitating material may be situated in a first plane between end face  33  of carrier  32  and bottom wall  113  of recess  115  (e.g., see  FIGS. 6A ,  6 B,  6 C and  17 ). End face  33  and bottom wall  113  may be first surfaces of second end  32   b  and interior side  114 , respectively, that may be substantially parallel (e.g., two parallel first surfaces). When pressure port  110  and carrier  32  are assembled, end face  33  may engage a lip  119  of bottom wall  113 , such that lip  119  may define a spacing between end face  33  and bottom wall  113  and as a result, a thickness of adhesive layer  36  between end face  33  and bottom wall  113 , as best seen in  FIGS. 6A and 6B . Alternatively or in addition, a spacer element  180  may define or help define at least part of a thickness of adhesive layer  36  and/or a spacing between side walls  35  and side walls  117  and/or between second end face  33  and bottom wall  113  of pressure port  110  (e.g. see  FIG. 6B ) or at another location. In addition to adhesive layer  36  being disposed in a first plane between end face  33  and bottom wall  113  (e.g., between two substantially parallel or parallel first surfaces), adhesive layer  36  may extend up and between side walls  117  of recess  115  and side walls  35  of carrier  32  in a second plane at least substantially perpendicular to the first plane (e.g., between two substantially parallel or parallel second surfaces at least substantially perpendicular to the substantially parallel or parallel first surfaces), as shown in  FIG. 6A , for example. In a further instance, when second end  32   b  of carrier  32  includes a recess  37  in end face  33  (e.g. see  FIG. 6B ), a bottom wall  39  may intersect fluid path  34 , and recess  37  may receive at least a portion or part of lip  119  and bottom wall  39  may be spaced from lip  119  or may engage lip  119  (not shown). In this illustrative instance, adhesive layer  36  may extend up between side walls  40  of recess  37  and lip  119  extending upward. 
     In an illustrative example of a pressure sensor subassembly  10 , carrier  32  may include a second shoulder  41  with protrusion  43  having side walls  45 , as best seen in  FIG. 6C . In this instance, when carrier  32  is assembled with pressure port  110 , second shoulder  41  may extend along and adjacent to bottom wall  113 , and protrusion  43  may extend into fluid path  116  such that fluid path  116 , as may be defined by side walls  182 , may be in fluid communication with fluid path  34 . In this example, adhesive layer  36  may extend between at least side walls  45  and side walls  182 . In this example and others, alternatively or in addition to pressure port  110  including lip  119 , one or more of carrier  32  and pressure port  110  may define one or more spacer elements  180 , where spacer elements  180  may define or help define at least part of a thickness of adhesive layer  36  between side walls  35  and  117  and/or between second shoulder  41  and bottom wall  113  of pressure port  110  or at another location, such as shown in  FIG. 6C . 
     Adhesive layer  36  may be any adhesive capable of facilitating assembly of subassembly  16 , such as an epoxy adhesive or other similar or different adhesives. Illustrative example adhesives may include, but are not limited to, EP1330 LV available from RESINLAB® having the ingredients of at least Bisphenol-A type epoxy resin, Diglycidyl ether of neopentyl glycol, cycloaliphatic/aliphatic amine, aluminum oxide, carbon black, and amorphous silicon dioxide; SUP10HT available from Masterbond and having the ingredients of epoxy phenol novalac (25%-50% by weight), aluminum powder (10%-25% by weight), flexibilizer epoxy resin (10%-25% by weight), curing agent (2.5%-10% by weight), siloxane treated silicon dioxide (2.5%-10% by weight), silicon dioxide, chemically prepared (≦2.5% by weight), and curing agent (≦2.5% by weight); and 1469 SCOTCH-WELD available from 3M® and having the ingredients of epoxy resin (70%-90% by weight), non-volatile amide (10%-30% by weight) and amorphous silica (1%-5% by weight), or other suitable adhesives as desired. 
     Electrical Connector 
     Pressure sensor assembly  10  may have an electrical connector  120  with a body  121  having a first end  121   a  (e.g., adjacent or near sensor interface  125 ) and a second end  121   b  (e.g., adjacent or near a cable interface  127 ), as best seen in  FIGS. 13-14B , where body  121  may be made from any material. In one example, body  121  may be made from a plastic or metal or another similar or different material, as desired. 
     Electrical connector  120  may have at least a mechanical connector  124  with a first end  124   a  and a second end  124   b  and two or more electrical terminals  122 , as best seen in  FIGS. 2 and 5 . In one example, two or more electrical terminals  122  may be exposed at first end  124   a  of mechanical connector  124  (see  FIG. 14B ) and two or more electrical terminals  122  may be exposed at second end  124   b  of mechanical connector  124  (see  FIG. 14A ). Further, one or more of electrical terminal  122  may face first end  121  a or a sensor interface  125  and one or more of electrical terminal  122  may face second end  121   b  or cable interface  127 , where electrical terminals  122  facing second end  121   b  and/or cable interface  127  may be compliant pins  106 , as seen in  FIGS. 2 and 5 . Compliant pins  106  may be connected to connector body  121  in any manner; for example, compliant pins  106  may be insert molded in the electrical connector body  121 . At least one of electrical terminals  122  may be electrically connected to one or more pressure signal output terminals  30  of sensor unit  20  and sensor unit  20  may be mechanically secured to first end  121  a or sensor interface  125  of electrical connector body  121 . 
     In some instances, electrical connector  120  may include an alignment feature  128  for engaging a second alignment feature  152  of outer housing  130 . Alignment feature  128  may engage or contact corresponding second alignment feature  152  of outer housing  130  at interior  131  of outer housing  130 , as best depicted in  FIG. 13 . In addition, and in some instances, electrical connector  120  may include an external vent  146 , as seen in  FIGS. 3-5 , where vent  146  may extend from outside of aperture  136  of outer housing  130  to an interior  131  of aperture  136  of outer housing  130 . Further, and in some instances, electrical connector  120  may include an internal vent  184 , as seen in FIGS.  5  and  13 - 14 B. Internal vent  184  may extend from inside connector  120  and release into cable harness  160 , such that exhausted fluid may be capable of flowing through cable  162  to an open atmosphere. As seen in  FIG. 5 , vents  146 ,  184  are depicted as being closed and the dotted circles adjacent vents  146 ,  184  represent areas of connector  120  where material may be removed to open vents  146 ,  184 . In addition,  FIG. 14A  depicts internal vent  184  in a closed position and a dotted circle is placed between terminals  122  to represent a possible position of vent  184  if it were in an open position. 
     In some cases, a third PCB  80  (e.g., an electrical connector PCB) or more PCBs, may be included in pressure sensor assembly  10 . In the illustrative example shown, third PCB  80  may be connected to and/or positioned within electrical connector  120  and may be connected or secured to electrical connector  120  in any manner at first end  121  a of electrical connector body  121 . For example, as seen in  FIG. 13  (note, for clarity purposes only added features have reference numerals in each subsequent step of the flow), an electrical connector may be provided (S 10 ), and in an optional step, potting material  123  may be inserted into terminal recess  129  (S 11 ). Potting material  123  may be optionally used to fill or substantially fill recess  129  for any purpose. For example, potting material  123  may be inserted in recess  129  when internal vent  184  is in a closed position to create an environmental moisture seal and to increase the structural stability around terminals  122 . Further, a filter (not shown) covering external vent  146  at or near or about ledge  144  interior to first end  121  a of connector body  121  may be optionally utilized. For example, the filter covering external vent  146  may be utilized where vent  146  is open and creates a fluid path from an interior of outer housing  130  and connector body  121  to an exterior thereof. The filter optionally placed on external vent  146  may be any type of filter; for example, the filter may be a hydrophobic and/or oleophobic filter and/or the filter may be configured to filter out other non-desirable materials. After optionally adding potting material  123  and/or the filter to electrical connector  120 , third PCB  80  (S 12 ) may be mechanically secured to electrical connector  120  relative to first end  124   a  of mechanical connector  124  (S 13  and S 14 ). Third PCB  80  may be secured to electrical connector  120  through the use of compliant pins  106  or another mechanical connecting technique. In addition, third PCB  80  may be in electrical communication with one or more of the electrical terminals  122  of electrical connector  120 . For example, third PCB  80  may have one or more terminals  86  electrically connected to corresponding terminals of the two or more electrical terminals  122  exposed at first end  124   a  of mechanical connector  124 . Further, third PCB  80  may be in electrical communication with sense element  52  of carrier  32  of sensor unit  20  through one or more of the pressure signal output terminals  30 . Third PCB  80  may include one or more sensor electrical terminals  86  configured to connect to sensor unit  20 , where sensor electrical terminals  86  may be located at common locations relative to conductive outer housing  130  regardless of which electrical connector  120  may be utilized (e.g., electrical connectors  120  may take on various shapes and configurations of which a single electrical connector  120  may be selected for use in sensor assembly  10 ). 
     Third PCB  80  may be a multiple layer printed circuit board that includes a layer (not shown) that is substantially a metal layer (e.g. a ground layer). The metal layer, which may be a ground layer or may be used for any other purpose, may span across a portion (e.g., a quarter, half, majority, etc.) of third PCB  80  and may provide part of or facilitate providing, along with outer housing  130  and/or pressure port  110 , an Electro Magnetic Interference (EMI) barrier (or a “Faraday cage”) or shield around sensor unit  20 . In some cases, circuitry may be provided on third PCB  80  to assist in protecting against EMI, signal noise, and/or Electro-Static Discharge (ESD). For example, third PCB  80  may include one or more filter component, where the one or more filter component may be electrically coupled to at least one of the one or more terminals  86  of third PCB  80 , which are electrically connected to corresponding terminals  122  that are exposed at first end  124   a  of mechanical connector  124 . The filter components may include, for example, one or more inductors, capacitors, filter capacitors, ESD diodes and/or any other components suitable for preventing or mitigating incoming and outgoing noise. Such filter components may be utilized to filter power signals (e.g. power and ground), pressure output signal(s) and/or any other signals of the pressure sensor. 
     Outer Housing 
     Pressure sensor assembly  10  may include outer housing  130 , which may form at least a portion of connector subassembly  14 , as seen in  FIGS. 4 and 5 . Outer housing  130  may have an interior  131 , an exterior  133 , a first end  130   a  and a second end  130   b , where a wall  134  extending between first end  130   a  and second end  130   b  may define an aperture  136 . In the illustrative embodiment shown, outer housing  130  may extend between pressure port  110  and electrical connector  120 , and may be mechanically secured to mechanical connector  124  and electrically connected to the conductive metal layer of third PCB  80 , sometimes via a wave spring as further described below. In some cases, sensor unit  20  may be disposed within a space defined by pressure port  110 , electrical connector  120  and outer housing  130 . 
     Outer housing  130  may be made from any suitable material. In some cases, outer housing  130  may be made out of an electrically conductive or another material, and outer housing  130  may be electrically connected to pressure port  110 , as desired. There may be several purposes for utilizing outer housing  130 . Those purposes may include, for example, providing or facilitating a Faraday cage or shield around sensor unit  20 , providing a mechanical or protective shield over the sensor unit  20  to help protect the sensor unit from the external environment and/or debris. 
     In some instances, and as best depicted in  FIG. 5 , wall  134  of outer housing  130  may define a ridge  138  positioned between first end  130   a  and second end  130   b  of outer housing  130 . Ridge  138  may extend inward into aperture  136  and may have a first surface  138   a  facing or directed generally toward first end  130   a  and a second surface  138   b  facing or directed generally toward second end  130   b . Wall  134  may define aperture  136  such that third PCB  80  and at least a portion or part of mechanical connector  124  may extend through first end  130   a  of conductive outer housing  130  and into aperture  136 . First surface  138   a  of ridge  138  may act as a stop to stop the insertion of third PCB  80  and mechanical connector  124  into aperture  136 . Further, an o-ring  148  may be positioned or inserted on electrical connector  120  at first end  124   a  (S 15  and S 16 ), as seen in  FIG. 13 . O-ring  148  may provide a seal between mechanical connector  124  of electrical connector  120  and interior  131  of outer housing  130 . 
     Further, and in some instances, a conductive wave spring  140  may be provided (S 17 ) and situated or inserted between first surface  138   a  of ridge  138  and a conductive region of the third PCB  80  (S 17  and S 18 ) so as to electrically connect the outer housing  130  with the ground plane of the third PCB  80 , as seen in  FIG. 13 . Wave spring  140  may be inserted between first surface  138   a  and third PCB  80  prior to or when sliding electrical connector  120  into aperture  136  of outer housing  130  or at another time, such that one or more conductive regions of third PCB  80  electrically connect wave spring  140  to the ground layer of the third PCB  80 . In this construction, wave spring  140  may provide or facilitate an electrical connection between outer housing  130  and the conductive ground layer of third PCB  80 . Once wave spring  140  and electrical connector  120  have been inserted into aperture  136  of outer housing  130  (S 18 ), outer housing  130  may be formed (bent) around a shoulder  126  of mechanical connector  124  (S 19 ). Such a forming step may keep electrical connector  120  in place between ridge  138  and the formed portion of outer housing  130  at first end  130   a.    
     Cable Harness 
     Pressure sensor assembly  10  may include a cable harness  160 , as best shown in  FIGS. 1 ,  2 ,  22  and  23 . Cable harness  160  may include a cable  162  having a first end  162   a  and a second end  162   b  opposing first end  162   a , where cable  162  may include one or more wires  164  extending between first end  162   a  and second end  162   b  of cable  162 . In some cases, cable  162  may also include a cable sleeve  163  that may extend around wires  164  for at least a portion (e.g., a quarter, a half, a majority, more than a majority, etc) of a length of cable  162 . 
     Cable harness  160  may include a cable cover  166  (e.g., see FIGS.  2  and  19 - 23 ) having a first end  166   a  and a second end  166   b  at an opposing end from first end  166   a , with a wall  168  defining cavity  172 , where wall  168  may extend from second end  166   b  toward, but possibly not all the way to, first end  166   a  (e.g., see  FIGS. 2 ,  19 ,  22  and  23 ). Second end  166   b  of cable cover  166  may be connected or secured, in a mechanical or other manner, to second end  121   b  or cable interface  127  of electrical connector body  121 . For example, second end  166   b  cable cover  166  may overlap and may be secured to second end  121   b  or cable interface  127  of electrical connector body  121  through forming a joint by heat staking, thermal welding, ultrasonic welding, an adhesive, and/or using any other suitable connecting technique. It is contemplated that cable cover  166  may be made from any suitable material; for example, cable cover  166  may be a plastic or a metal or a similar or different material, as desired. 
     Cable cover  166  may include one or more rib  167  inside cavity  172  and near or adjacent to a cable receiving opening  170  that may extend from first end  166   a  of cable cover  166  into cavity  172 , as best seen in  FIGS. 20 and 21 . First end  162   a  of cable  162  may extend through cable receiving opening  170  in cable cover  166 , and a first end of wires  164  may be electrical connected to one or more than one electrical terminals  122  facing the second end  121   b  of electrical connector body  121 . 
     Cable  162  may be secured within cavity  172  by crimping a crimp ring  174  around and to cable  162  at a distance from first end  162   a  of cable  162  (e.g., see  FIGS. 22 and 23 ) or through another securing technique. Crimp ring  174  may be placed around cable sleeve  163  extending through cable receiving opening  170  of cable cover so as to secure cable sleeve  163  to wires  164 , as best seen in  FIG. 2 . Crimp ring  174  may be positioned on cable  162  within cavity  172  and sized so as to not be capable of passing through cable receiving opening  170 . It is contemplated that crimp ring  174  may engage at least one rib  167  inside the cavity  172  of cable cover  166  to assist or help prevent cable  162  from rotating relative to cable cover  166 . 
     Cable harness  160  may also include potting holes  175  extending into cavity  172  of cable cover  166 , as best shown in  FIGS. 19 and 20 , through which a potting material  176  (e.g., an electrically non-conductive epoxy liquid material or other non-conductive material capable of being used to fill a cavity) may be inserted to fill or substantially fill the open space of cavity  172 . Cavity  172  may be filled at anytime; for example, cavity  172  may be filled after second end  166   b  of cable cover  166  has been secured, attached or connected to second end  121   b  of electrical connector body  121 . Potting material  176  may be used for any purpose; for example, potting material  176  may be used to create an environmental moisture seal and/or for structural stability within cable cover  166 . 
     As alluded to, in an illustrative example, cable harness  160  may be assembled by inserting first end  162   a  of cable  162  through a cable receiving opening  170  in cable cover  166 . Further, crimp ring  174  may be secured at a distance from first end  162   a  of cable  162  such that crimp ring  174  may fit within cavity  172 , but not through cable receiving opening  170 . This may help prevent the first end  162   a  of the cable  162  from being pulled out of the cable receiving opening  170 . The assembly may include electrically connecting the first end  162   a  of cable  162  to one or more electrical terminal  122  of electrical connector  120  and securing the second end  166   b  of cable cover  166  to second end  121   b  of electrical connector body  121 . After connecting the cable cover  166  and electrical connector body  121  and making an electrical connection between terminals  122  and first end  162   a  of cable  162 , cavity  172  of cable cover  166  may be filled or substantially filled with potting material  176  through potting holes  175  in cable cover  166  or through another opening in cable cover  166 . As mentioned, potting material  176  may be used to provide an environmental moisture seal and/or to add structural stability to cover  166  or the structure, in general. 
     First end  162   a  of cable  162  may be connected to one or more electrical terminal  122  through a harness PCB  178  of electrical connector  120 , where one or more wires  164  at first end  162   a  of cable  162  extending through cable receiving opening  170  may be electrically connected to harness PCB  178 , as best seen in  FIG. 2 . Harness PCB  178  may be electronically connected to one or more of the electrical terminals  122  (e.g., one or more of the compliant pins  106 ) facing second end  121   b  or cable interface  127  of body  121  of electrical connector  120 . Electrical terminals  122  facing second end  121   b  or cable interface  127  of body  121  may include compliant pins  106 . Compliant pins  106  facing second end  121   b  or cable interface  127  may be configured to be inserted through corresponding conductive holes in harness PCB  178  to form an electrical connection with harness PCB  178 , as seen in  FIG. 2 . 
     Assembly of Sensor Assembly 
     In one illustrative example, a sensor housing assembly or assemblies  12  and two or more sensor unit sub-assemblies  20  may be provided. Where two or more sensor unit sub-assemblies  20  are offered, sensor units  20  may be substantially similar. For example, one or more pressure signal output terminals  30  of each of the two or more sensor unit sub-assemblies  20  may be provided at the same relative locations on respective sensor unit sub-assemblies  20  so that an electrical interface connection between the one or more pressure signal output terminal and the selected electrical terminal  122  of the electrical connector  120  of the sensor housing assembly  12  may be the same or substantially similar for each sensor unit sub-assembly  20 . Similarly, pressure input ports  22  of the first and second sensor unit sub-assemblies  20  may be provided at same relative locations on sensor unit sub-assemblies  20  so that a pneumatic interface connection between pressure ports  22  of sensor unit sub-assemblies  20  and pressure port  110  of sensor housing assembly  12  may be the same or substantially similar. The circuitry on first circuit boards  60  and/or second circuit boards  70  of each sensor unit  20  of the two or more sensor units  20 , however, may format one or more pressure signals provided by pressure sense element  52  in at least a first predetermined format in a first sensor unit  20  and at least a second predetermined format that may be different than the first format in a second sensor unit  20 . Further, the formatting circuitry may be changed per sensor unit  20  by swapping out or changing either or both first PCB  60  and second PCB  70  or through other circuit changing techniques. In addition, or alternatively, each pressure sensor unit sub-assembly  20  may include a same or different sense element  52  or any combination of different and same sense elements  52 . For example, a first sense element  52  of a first sub-assembly  20  may be more suited for a first pressure range and a second sense element  52  of a second sub-assembly  20  may be more suited for a second pressure range, where the first pressure range may includes ranges such as 1.0 PSI-9.0 PSI; 15 PSI-20 PSI, which may be ranges that are higher than the second pressure ranges of 0.1 PSI-0.9 PSI; 2.0 PSI-8 PSI. These are only examples. In some cases, the pressure ranges may be much higher such as 100-500 PSI, 1000-5000 PSI, etc. Also, and in an illustrative embodiment, the sense elements  52  may be selected from absolute pressure sense elements, gauge pressure sense elements, or other pressure sense elements. Example sense elements may include, but are not limited to, those described in U.S. Pat. Nos. 7,503,221; 7,493,822; 7,216,547; 7,082,835; 6,923,069; 6,877,380, and U.S. patent application publications: 2010/0180688; 2010/0064818; 2010/00184324; 2007/0095144; and 2003/0167851, all of which are hereby incorporated by reference. 
     As noted above, and in some instances, each of at least a first and second sensor unit  20  may provide differently formatted pressure output signals to one or more selected electrical terminal  122  of electrical connector  120 . Further, and alternatively or in addition, sensor housing assembly  12  may include a third sensor unit sub-assembly  20  that is similar to first and second sensor unit sub-assemblies  20 , however, the circuitry of the third sub-assembly  20  may format the one or more pressure output signal in a third output format that may be different from the first and second output formats and then transfer that pressure output signal in the third output format to selected electrical terminal(s)  122  of electrical connector  120 . In these illustrative examples, the first output format may be a ratio-metric output format and the second output format may be a current format, or the first output format may be a ratio-metric output format and the second output format may be a digital format, or the first output format may be a current output format and the second output format may be a digital format or the output formats may be different combinations of formats or different formats. 
     Assembling a pressure sensor assembly  10  having sensor housing assembly  12  comprising pressure port  110 , electrical connector  120  and outer housing  130  may include several selection steps. For example, the assembly may include selections for sensor housing assembly  12  of one of a plurality of pressure ports  110  (e.g., two or more pressure ports  110 ) where each of the plurality of pressure ports  110  at interior sides  114  have a fluid opening  118  that may be positioned at a common location across all of the plurality of pressure ports  110 . External sides  112  of different pressure ports  110  in the plurality of pressure ports  110  may have different configurations including, but not limited to, threading or no threading on the exterior of external sides  112 , threading or no threading on side walls  182  defining fluid path  116  at the external sides  112 , and/or various shapes and sizes of pressure port  110  at external sides  112 . 
     In one example, one of a plurality of electrical connectors  120  may be selected for housing assembly  12 , where each of the plurality of electrical connectors  120  (e.g., two or more electrical connectors  120 ) may include second end  121   b  of body  121  having a different mechanical shape, size and/or configuration (e.g., dimension, perimeter size, perimeter outline, etc.) than at least one other second end  121   b  of the plurality of electrical connectors  120 ; first end  121   a  of body  121  having a common mechanical shape (e.g., dimension, perimeter size, perimeter outline, etc.) relative to the plurality of electrical connectors  120 ; sensor electrical terminals  86  for connecting to sensor unit  20  of third PCB  80  at common locations relative to conductive outer housing  130 ; and two or more electrical terminals  122  extending out of first end  121   a  and second end  121   b  of body  121  at common locations across all of the plurality of electrical connectors  120 . For example, electrical terminals  122  in first end  121   a  of the plurality of electrical connectors  120  may be located at common locations relative to the common mechanical shape of first end  121   a.    
     The assembly may further include selecting one of the plurality of pressure unit sub-assemblies  20 , as discussed above. In some instances, once the parts or devices for pressure sensor assembly  10  have been selected or at least after selecting sub-assembly  20 , sub-assembly  20  may be conditioned, calibrated, configured or tested or have other initial processing performed thereon prior to final assembly of sensor assembly  10 . 
     Once the parts are selected and, if desired, calibration or testing has been performed on subassembly  20 , pressure sensor assembly  10  may be assembled by connecting or assembling the selected pressure port  110 , the selected electrical connector  120  and the selected pressure sensor unit subassembly  20 , where the connected sensor unit subassembly  20  may provide a formatted one or more pressure output signal to the selected electrical terminals  122  of connected electrical connector  120 . After or before connection of the selected parts, the parts may be slid into or positioned within aperture  136  of outer housing  130  to form pressure sensor assembly  10 . Further, once the parts are within outer housing  130 , conductive outer housing  130  may be secured relative to the selected electrical connector  120  and pressure port  110 . Securing outer housing  130  relative to electrical connector  120  may include forming (e.g., crimping, bending, etc.) outer housing  130  around shoulder  126  of electrical connector  120 , fastening outer housing  130  to electrical connector  120  and/or securing by another securing technique. Securing outer housing  130  relative to pressure port  110  may include forming or welding outer housing  130  around or to pressure port  110  and/or using any other suitable connection technique to secure housing  130  to pressure port  110 . 
     In some cases, no adjustment or calibration of the sensor unit subassembly  20  is required after final assembly of the pressure sensor  10 , e.g. after the selected pressure port  110 , the selected electrical connector  120 , the outer housing and the selected pressure sensor unit subassembly  20  are assembled together into a functioning unit. Also, and in some cases, the assembled pressure sensor assembly  10  may have no mechanism (e.g. device, pin and other mechanism) for adjusting and/or calibrating the sensor unit subassembly  20  after final assembly of pressure sensor assembly  10 . 
     Having thus described several illustrative embodiments of the present disclosure, those of skill in the art will readily appreciate that yet other embodiments may be made and used within the scope of the claims hereto attached. It will be understood that this disclosure is, in many respects, only illustrative. Changes may be made in details, particularly in matters of shape, size, and arrangement of parts without exceeding the scope of the disclosure. The disclosure&#39;s scope is, of course, defined in the language in which the appended claims are expressed.