3D CONNECTOR STRUCTURE, METHOD FOR PRODUCING A 3D CONNECTOR STRUCTURE AND TEMPERATURE SENSOR

Abstract

One aspect relates to a 3D connector structure for electrically connecting at least one flat electrode to at least one connection wire. The 3D connector structure has at least two connectors which are spatially separate from one another. The connectors in each case have an electrically conductive material, a first side and a second side. The second side of each connector is connected to an electrical connection element. A spacing of at least 100 μm is constructed between the first side and the second side of each connector.

Claims

1-17. (canceled)

18. A 3D connector structure for electrically connecting at least one flat electrode to at least one connection wire, the 3D connector structure comprising: at least two connectors that are spatially separate from one another; wherein the connectors in each case have an electrically conductive material, a first side and a second side; wherein the second side of each connector is connected to an electrical connection element; and wherein a spacing of at least 100 μm is constructed between the first side and the second side of each connector.

19. The 3D connector structure according to claim 18, wherein a spacing of at least 300 μm is constructed between the first side and the second side of each connector.

20. The 3D connector structure according to claim 18, wherein at least one connector is configured as a web, a pillar or a lamina.

21. The 3D connector structure according to claim 18, wherein the electrical connection element is the flat electrode or a connection pad, formed from a sintering paste.

22. The 3D connector structure according to claim 18, wherein the first sides of the connectors form a common plane and are connected to at least one bridge, which consists of electrically conductive material or the connection wire.

23. The 3D connector structure according to claim 22, wherein the connectors and the at least one bridge are constructed in one piece.

24. The 3D connector structure according to claim 22, wherein the at least one bridge for connecting to the connection wire has a contacting region, which is configured as a receptacle for fixing the connection wire, and wherein the receptacle is constructed as a channel, a bush or a groove.

25. The 3D connector structure according to claim 22, wherein the at least one bridge has an electrically conductive extension, which protrudes beyond the region of the connectors and has a section for contacting with the connection wire.

26. The 3D connector structure according to claim 18, wherein each connector has a contact surface on the second side for contacting with the at least one electrical connection element, wherein each contact surface is 100 μm.sup.2 to 0.5 mm.sup.2.

27. The 3D connector structure according to claim 18, wherein each connector has a contact surface on the second side for contacting with the at least one electrical connection element, wherein each contact surface is 1,000 μm.sup.2 to 50,000 μm.sup.2.

28. The 3D connector structure according to claim 18, wherein the electrically conductive material of at least one connector is a high-temperature alloy, an alloy 601 (2.4851), alloy 602 (2.4633) or AluChrom (1.4767).

29. The 3D connector structure according to claim 18, wherein the at least one flat electrode or the connection pad contains platinum, wherein the platinum proportion of the flat electrode is at least 20% by weight.

30. The 3D connector structure according to claim 18, wherein the at least one flat electrode or the connection pad contains platinum, wherein the platinum proportion of the flat electrode is at least 70% by weight.

31. The 3D connector structure according to claim 18, wherein the at least one connection wire comprises at least one of a high-temperature alloy, alloy 601 (2.4851), alloy 602 (2.4633), and AluChrom (1.4767), wherein the diameter of the connection wire is 100 μm to 800 μm.

32. A method for producing the 3D connector structure according to claim 18, comprising: producing at least two connectors, which are spatially separate from one another, from an electrically conductive material using an additive manufacturing method, wherein the connectors have a first side and a second side in each case; and producing a spacing of at least 100 μm between the first side and the second side of each connector using material deposition.

33. The method according to claim 32, further comprising applying the connectors on an electrical connection element.

34. The method according to claim 32 further comprising applying a bridge made from electrically conductive material onto the first sides of the connectors using an additive manufacturing method, wherein a contacting region is constructed, which is used for connecting to the connection wire.

35. The method according to claim 32, further comprising connecting the connection wire to the first sides of the connectors or to the bridge using laser welding.

36. The method according to claim 34, further comprising producing the connectors or the bridge from a powder which contains a high-temperature alloy material, alloy 601 (2.4851), alloy 602 (2.4633), or AluChrom (1.4767).

37. A temperature sensor having a 3D connector structure according to claim 18.

Description

[0055] The invention is described in more detail in the following on the basis of exemplary embodiments, with reference to the attached drawings.

[0056] In the figures:

[0057] FIG. 2 shows a 3D connector structure in the already-contacted state according to a first embodiment according to the invention;

[0058] FIG. 3 shows a 3D connector structure in the already-contacted state according to a second embodiment of the invention according to the invention;

[0059] FIG. 4 shows a 3D connector structure in the already-contacted state according to a third embodiment of the invention;

[0060] FIGS. 5a-5c show a detail illustration of a 3D connector structure according to the invention in various views;

[0061] FIGS. 6a-6c show various embodiments with regards to the construction of the connectors of 3D connector structures according to the invention;

[0062] FIGS. 7a and 7b show a first possible embodiment of a receptacle of a bridge of a 3D connector structure according to the invention;

[0063] FIGS. 8a and 8b show a second embodiment of a receptacle of a bridge of a 3D connector structure according to the invention; and

[0064] FIGS. 9a and 9b show a third embodiment of a receptacle of a bridge of a 3D connector structure according to the invention.

[0065] The same reference numerals are used in the following for the same components and components with the same action.

[0066] A first possible embodiment with regards to a 3D connector structure 10 according to the invention is illustrated in FIG. 2. The 3D connector structure 10 is used for electrically connecting a flat electrode 15 to a connection wire 16. The flat electrode 15 is in this case particularly constructed as a platinum thin film structure, which is meander-shaped. The platinum thin film structure or the flat electrode 15 is located on an upper side 18 of a substrate 19, particularly a ceramic substrate.

[0067] A connection pad 25 is constructed on the flat electrode 15. In the example illustrated, the connection pad 25 is used as an electrical connection element 30.

[0068] The 3D connector structure 10 comprises at least two connectors 20. In the exemplary embodiment illustrated, the 3D connector structure 10 comprises six connectors 20. These connectors 20 are spatially separate from one another and are produced from an electrically conductive material. All connectors 20 have a first side 21 and a second side 22. The first side 21 is the upper side in other words. The second side 22 is the lower side of each connector 20 in other words. According to the exemplary embodiment of FIG. 2, the first sides 21 of the connectors 20 are connected to the connection wire 16. By contrast, the second sides 22 are connected to the connection pad 25.

[0069] A spacing A of at least 100 μm, in particular of at least 200 μm, in particular of at least 300 μm, is constructed between the first side 21 and the second side 22 of each connector 20. In other words, the spacing A corresponds in the connectors 20 illustrated to the height of the connectors 20. The connectors 20 are connected at their first sides 21 to the connection wire 16. Here, the connectors 20 are individually connected to the connection wire 16 by means of fusion welding, particularly by means of laser welding. The welding spots 35 are illustrated in this regard.

[0070] The flat electrode 15 contains noble metal, particularly platinum, wherein the proportion of noble metal of the flat electrode 15 is greater than 20% by weight. The connection pad 25 contains noble metal, particularly platinum, wherein the proportion of noble metal of the connection pad 25 is greater than 20% by weight. In the example illustrated, the connection pad 25 has an area of 1.0 mm×0.5 mm.

[0071] The connection wire 16 in turn contains a high-temperature alloy. Furthermore, it is possible that the connection wire 16 consists of nickel or high-grade steel and has a diameter of 100 μm to 800 μm, typically of 300 μm.

[0072] In the example illustrated, the connectors 20 are built directly on the connection pad 25 by means of an additive manufacturing method, particularly by means of 3D printing. A powder made from a metallic high-temperature alloy is used as powder in the additive manufacturing or in the 3D printing. In particular, a powder made from alloy 601 (2.4851) and/or alloy 602 (2.4633) and/or AluChrom (1.4767) is used. The powders preferably have a particle size distribution of up to 20 μm. A laser with an energy of for example 100 watts is preferably used for sintering the powdered material, wherein the laser focus is smaller than 20 μm.

[0073] In the exemplary embodiment illustrated, the connectors 20 are constructed as webs. The height of the connectors 20 in the present example is 500 μm. The connectors additionally preferably have a width of 500 μm and a length of 40 μm. The width and length in turn form the surface of the first side 21 and/or second side 22 in each case. Preferably, the connectors 20 have a spacing from one another of 20 μm.

[0074] The connection wire 16 is arranged perpendicular to the sides forming the heights of the connectors 20 and contacts the first sides 21 of the connectors 20 approximately in the middle.

[0075] The connection pad 25 is preferably formed from a platinum-containing sintering paste.

[0076] An alternative embodiment of a 3D connector structure 10 is illustrated in FIG. 3. The 3D connector structure 10 has a bridge 40. The first sides 21 of the connectors 20 here form a common plane E and are connected to this bridge 40 at this common plane E. The bridge 40 is likewise produced from electrically conductive material. Preferably, the bridge 40 is produced from the same material as the connectors 20.

[0077] In a particularly preferred embodiment of the invention, the connectors 20 and the bridge 40 are constructed in one piece. The bridge 40 has a first side 41 and a second side 42. The connectors 20 are attached on the first side 21 of the connectors on the second side 42 of the bridge 40 or connected on this second side 42 to the bridge 40. By contrast, the connection wire 16 is attached on the first side 41, which corresponds to an upper side of a bridge 40. In the exemplary embodiment presented, the bridge 40 is connected to the connection wire 16 on the first side 41 by means of a welding spot 45.

[0078] In a particularly preferred embodiment of the invention, the bridge 40 together with the connectors 20 are produced in one process step by means of an additive manufacturing method.

[0079] In the exemplary embodiment illustrated, the bridge 40 covers the connectors 20, wherein the bridge has a height of approx. 300 μm. The connection of the connection wire 16 by means of the welding spot 45 preferably takes place by means of a laser welding method. To this end, the bridge 40 has a contacting region 43.

[0080] The remaining elements and components correspond to the exemplary embodiment according to FIG. 2, so these are not covered again separately.

[0081] A further embodiment of a 3D connector structure 10, which likewise has a bridge 40, is illustrated in FIG. 4. The bridge 40 and the connectors 20 are in turn manufactured from the same material. The bridge 40 has an electrically conductive extension 50, which protrudes beyond the region of the connectors 20. The extension 50 in addition has a section 51 for contacting with the connection wire 16. In FIG. 4, the section 51 for contacting with the connection wire 16 is constructed as an end side. At this end side or the section 51, the extension 50 and thus the 3D connector structure 10 is connected to the connection wire 16 by means of a welding spot 55. Also in this context, the connection may take place by means of a laser welding method.

[0082] The extension 50 is used in particular to construct the connection of the 3D connector structure 10 to the connection wire 16 in a region outside, i.e. not in direct vertical extension of the connection pad 25. The extension 50 is preferably produced in one process step together with the bridge 40 and preferably in one process step together with the connectors 20. This facilitates the later contacting in connection with the substrate 19.

[0083] A possible 3D connector structure 10 is illustrated enlarged in FIGS. 5a to 5c. In this case, FIG. 5a shows a side view of the 3D connector structure 10 according to the invention. A plan view is illustrated in FIG. 5b. FIG. 5c is in turn a rotated side view of FIG. 5a.

[0084] It can be seen that the 3D connector structure 10 has six connectors 20 with first sides 21 and second sides 22 in each case. The first sides 21 of the connectors 20 are connected to a second side 42 of a bridge 40. By contrast, the second sides 22 of the connectors 20 are in turn connected to the connection pad 25. As FIG. 5b makes clear, the bridge 40 is constructed in a rectangular manner on the first side 41.

[0085] This also relates to the extent with regards to the height H.sub.B of the bridge. The height H.sub.B of the bridge corresponds approximately to the height of the connector 20 and thus to the spacing A between the first side 21 and the second side 22 of the connector 20.

[0086] Various embodiments of the connectors 20 are illustrated in a plan view in FIGS. 6a-6c. Accordingly, the base of the connectors 20 is illustrated. In this case, the base may correspond to the shape of the first side 21 and/or the second side 22 of the connector 20. In FIG. 6a, the connectors 20 are illustrated as webs 26 in particular. The webs 26 are in particular constructed in such a manner that the widths B of the webs 26 have a larger dimension than the lengths L of the webs 26. The widths B of the webs 26 further correspond to the width of the connection pad 25. The lengths L of the webs 26 correspond approximately to the spacing A.sub.S between the webs 26. The spacing A.sub.S may also be smaller or larger than the length L of the webs 26.

[0087] In FIG. 6b, connectors 20 are illustrated, which are constructed as pillars 27. The pillars 27 have a round cross section in each case in this exemplary embodiment. It is also possible that the pillars 27 have a square cross section. In the exemplary embodiment illustrated, the 3D connector structure 10 has eight connectors 20 in the form of pillars 27.

[0088] In FIG. 6c, a further embodiment is illustrated with regards to possible connectors 20. The connectors 20 are constructed as laminae 28. These laminae 28 are arranged obliquely in relation to the connection pad 25. Eight connectors 20 are constructed in the form of laminae 28. The material thickness or material gauge of the connectors 20, 26, 27 and 28 is preferably 100 μm.

[0089] The cross section of the connectors 20, which is orientated parallel to the flat electrode or to the connection pad 25 in each case, does not have to be constant. The cross section may change starting from the first side 21 to the second side 22. Both a tapering and a widening of the cross-sectional area is possible. An average cross-sectional area of the connector parallel to the flat electrode or to the connection pad 25 is to be understood to mean the arithmetic mean of all cross-sectional areas, which are arranged equidistantly from the second side to the first side of the respective connector 20.

[0090] Different embodiments and views with regards to the configuration of bridges 40 and the associated receptacles 60 are illustrated in FIGS. 7a-9b.

[0091] In the embodiment according to FIGS. 7a and 7b, wherein 7b illustrates a side view of FIG. 7a, the bridge 40 has a receptacle 60 in the form of a bush 61. The bush 61 has an internal diameter of such a type that the connection wire 16 can be introduced into the bush 61. The cross section of the recess 62 of the bush 61 may be constructed in a circular manner in this case, so that a generally circular wire, namely a connection wire 16, can be introduced into the bush 61, i.e. into the recess 62. The connection wire 16 is welded to the receptacle 60/61 through the bush 61, i.e. through the wall 63. A welding spot 65 is in turn formed. The welding of the connection wire 16 to the bridge 40 is therefore simplified. In addition, the mechanical stability of the welding spot 65 or the weld seam is increased.

[0092] The bridge 40 according to the exemplary embodiments of FIGS. 8a and 8b likewise has a receptacle 60. In this case, the receptacle 60 is configured as a channel 66. The connection wire 16 is laid into the channel 66. The channel 66 has a U-shaped or half-round recess 67. After the connection wire 16 is introduced or laid into the channel 66, connection of the connection wire 16 to the bridge 40 can then in turn take place on the basis of the receptacle 60. A weld seam or a welding spot 65 is formed. The welding spot 65 covers the connection wire 16 and therefore the channel 66.

[0093] A receptacle 60 of a bridge 40 is in turn illustrated in FIGS. 9a and 9b. In the example illustrated, the receptacle 60 is constructed in the region of an extension 50. The receptacle 60 is configured as a groove 68. The recess 69 of the receptacle 60/68 has a square or rectangular cross section. The connection wire 16 can in turn be laid into the groove 68. In particular, one end 17 of the connection wire 16 is laid into the groove 68. In this configuration, the connection of the connection wire 16 to the bridge 40 or to the receptacle 60/68 can subsequently take place. Also in this regard, a weld seam/a welding spot 65 is formed for fixing the connection wire.

[0094] The groove 68 or the recess 69 can furthermore be configured in such a manner that a mechanical clamping of the connection wire 16 or the end 17 of the connection wire 16 to the bridge 40 takes place.

[0095] In a preferred embodiment of the invention, the temperature sensor according to the invention is used in an exhaust train of an internal combustion engine.

[0096] The details illustrated in FIGS. 2-9b with regards to a 3D connector structure 10 according to the invention can be realized in all possible combinations with one another.

REFERENCE LIST

[0097] 1 Ceramic substrate (prior art) [0098] 2 Platinum thin film structure (prior art) [0099] 3 Screen-printing paste (prior art) [0100] 4 Connection wire (prior art) [0101] 5, 6 Welding spot (prior art) [0102] 7 Wire extension (prior art) [0103] 10 3D connector structure [0104] 15 Flat electrode [0105] 16 Connection wire [0106] 17 Connection wire end [0107] 18 Substrate upper side [0108] 19 Substrate [0109] 20 Connector [0110] 21 Connector first side [0111] 22 Connector second side [0112] 25 Connection pad [0113] 26 Web [0114] 27 Pillar [0115] 28 Lamina [0116] 30 Electrical connection element [0117] 35 Welding spot [0118] 50 Bridge [0119] 41 Bridge first side [0120] 42 Bridge second side [0121] 43 Contacting region of the bridge [0122] 45 Welding spot [0123] 50 Extension [0124] 51 Section [0125] 55 Welding spot [0126] 60 Receptacle [0127] 61 Bush [0128] 62 Recess [0129] 63 Wall [0130] 65 Welding spot [0131] 66 Channel [0132] 67 Recess channel [0133] 68 Groove [0134] 69 Recess groove [0135] A Spacing first side to second side [0136] A.sub.S Spacing between webs [0137] E Common plane [0138] H.sub.B Bridge height [0139] B Web width [0140] L Web length