Batch Fabrication Decreases Cost Per Sensor, Lowering Aircraft Fuselage Array Expenses
This improved packaging design protects and optimizes microphone sensors that are used in and around airplanes to help locate and reduce excessive aviation noise, an environmental and human health hazard. Passenger travel in airplanes is expected to increase from 732 million to 1.2 billion by 2032, and the comfort and safety of these passengers and their pilots, as well as the communities surrounding commercial airports, are vital to the continued progress of commercial flight. Widely-used noise detection technologies sacrifice durability and sensitivity for low production costs. Unfortunately, no available cost-effective aeroacoustics instrumentation solutions simultaneously protect microphone sensors and maintain superior sensitivity. Researchers at the University of Florida have developed a superior instrumentation packaging design that decreases production costs without sacrificing instrument sensitivity. This allows for more accurate capture of noise information by the sensor by avoiding the need for a protective encapsulant that dampens differential airflow measurement by the instrument’s sensing processes and makes the diaphragm a direct part of the sensing side of the device, closer to the surface on which the measurement is desired. Additionally, the developed packaging design creates an overall flush front surface of the microphone package, minimizing the impact of the sensor on the measurement. This transformative change is part of a microfabrication system that allows for mass production of these superior sensors at a lower cost than available instrumentation with protective encapsulants.
ApplicationSensor packaging for highly accurate aeroacoustics measurement
- Lowers cost of sensor production, eliminating prohibitive replacement costs and need for challenging repair of existing sensor installations
- Uses ultra-thin sensors, reducing surface airflow interference between neighboring sensors and increasing array measurement sensitivity
- Avoids requirement to house diaphragm in a protective cavity, decreasing risk for freezing and sensor failure
- Creates an overall flush front surface of entire microphone package, minimizing protrusions into the measurement environment and subsequent effects on the desired measurement