Smart Solutions for Sensors
Don Salladin
Engineering Sales Representative
Ellsworth Adhesives
Eric Traxler
Engineering Sales Representative
Ellsworth Adhesives
Electronic sensors are essential for collecting all sorts of data across industries, but employing them in harsh operating conditions can pose unique challenges. Often, sensors must be protected from heat, moisture, impacts, chemicals, and other factors, but they must remain sensitive and accurate.
Many sensors are also part of mission-critical or life-saving systems, complicating the challenge for engineers looking for a low-cost, manufacturing-friendly method of protection.
Protecting Vulnerable Sensors
Fragile, expensive sensors require a delicate balance between durability and accuracy. This narrow margin of error can be easily upset by poor assembly practices, hardware constraints, and hostile conditions.
Ellsworth Adhesives offers a wide range of solutions for protecting sensors ranging from board-level coatings to thermal management and beyond. Explore the chart below and read our white paper at the bottom to learn more about your many options for protecting sensors.
| Sensor type | Example application | Protection from | Properties needed |
| Ultrasonic, Electromagnetic Acoustic Transducer (EMAT) | Position detection in assembly line | Impacts; vibration; contaminants | Acoustically permeable |
| Load cell | Scales | Thermal expansion; overstrain | Deformation transfer to strain gauge |
| Turbidity | Water quality testing | Water ingress; oxidation | Optical transmission |
| Moisture/temperature (wireless) | Determining wet road conditions | Vibration/shock; compression; corrosives (road salt); weather; temperature | Thermally conductive; RF permeance |
| Inertial | Defense | Shock; temperature | Disposable (low cost) |
| Myocardial | Monitor patient temperature changes during heart surgery | Contaminants; fluid ingress | Sterility (adhesive unaffected by biocides) |
| Airspeed | Aircraft speed | Extreme temperatures; weather | Instrument exposure to air flow |
Find Your Sensor Protection Solution
The right adhesives and protection solutions can cut defects and dramatically expand product lifespan with minimal additional cost.
Explore some options offered by Ellsworth Adhesives:
Adhesives and Bonding
Essential for securing sensors and replacing problematic mechanical fasteners during assembly.
- Replace costly rivets and welds with strong bonds
- Enable quicker assembly with UV curing material
- Bond difficult plastics with advanced epoxies
- Simplify designs by reducing part counts
Thermal Management
Critical in many sensors and PCBs where heat needs to be dissipated to prevent damage.
- Match and dampen thermal expansion between materials
- Protect sensitive parts from thermal cycling damage
- Route excess heat away from sensitive areas
Encapsulation & Potting
Multifunctional materials that surround entire circuit boards when cured providing rigorous protection.
- Maintain optical clarity with non-yellowing options
- Protect against harsh environments and impacts
- Resist temperature cycles and ease thermal expansion
Conformal Coatings
A thin layer of protection preventing corrosion, dust, and moisture from damaging circuit boards.
- Prevent dendrite formation from shorting circuits
- Cure with light, moisture, or heat
- Spray, brush, or dip components
Converted Tapes, Films & Pads
Custom shaped and stacked materials engineered for multi-faceted challenges and complex geometries.
- Tailor protection to unique environments and designs
- Streamline processes with prefabricated parts
- Die-cutting, kiss-cutting, lamination & more
Low Pressure Molding
A gentler, higher-throughput alternative to traditional potting for sealing and protecting boards, wires, and sensors.
- Create custom protection around sensitive parts
- Protect against ingress with less material
- Simplify assembly and speed up production
To learn more about smart sensor solutions, download the white paper.
For help identifying the right material for your sensor assembly, contact us.