Method for Manufacturing a Sensor Element or an Active Component of a Sensor Element

Abstract

A method for manufacturing a composite material, a sensor element or an active component of a sensor element. The sensor element is applied in a field device of automation technology. At least two materials with different physical and chemical properties are predetermined depending on a functionality of the sensor element or the active component of the sensor element. An outer shape, into which the at least two materials should be formed, is predetermined. The outer shape is divided into a plurality of virtual spatial regions, wherein in each virtual spatial region the material distribution of the at least two materials occurs homogeneously and periodically according to predetermined rules corresponding to a microstructure. The predetermined rules are ascertained via a computer supported method depending on the predetermined functionality of the sensor element or the active component of the sensor element, wherein digital data, which describe the ascertained distribution of the at least two materials, are transferred to at least one 3D printer. As a printed product the sensor element or the active component of the sensor element is created by the 3D printer based on the digital data.

Claims

1-14. (canceled)

15. A method for manufacturing a composite material, a sensor element or an active component of a sensor element, wherein the sensor element is applied in a field device of automation technology, comprising the steps of: predetermining at least two materials with different physical and chemical properties depending on a functionality of the sensor element or the active component of the sensor element; predetermining an outer shape, into which the at least two materials should be formed; the outer shape being divided into a plurality of virtual spatial regions; in each virtual spatial region the material distribution of the at least two materials occurs homogeneously and periodically according to predetermined rules corresponding to a microstructure; ascertaining the predetermined rules via a computer supported method depending on the predetermined functionality of the sensor element or the active component of the sensor element; transferring digital data, which describe the ascertained distribution of the at least two materials, to at least one 3D printer; and creating as printed product the sensor element or the active component of the sensor element by the 3D printer based on the digital data.

16. The method as claimed in claim 15, wherein: the dimensions of a virtual spatial region manufactured via 3D printing are so selected that the physical and chemical properties of each virtual spatial region correspond to the physical and/or chemical properties of the sensor element or the active component of the sensor element.

17. The method as claimed in claim 15, wherein: the dimensions of each virtual spatial region of the composite material manufactured via the 3D printing are less by at least a factor of greater than/equal to 5, preferably a factor of greater than/equal to 10, than the dimensions of the printed sensor element, or the active component of the sensor element.

18. The method as claimed in claim 15, wherein: the dimensions of the sensor element or the active component of the sensor element are described via the outer shape.

19. The method as claimed in claim 15, wherein: the dimensions of a material block are described via the outer shape; and a number of sensor elements or active components of the sensor element are formed from the material block.

20. The method as claimed in claim 15, wherein: a selective laser melting, or a selective laser sintering, is used as the 3D printing method for the case, in which at least one of the two materials is a metal or a plastic.

21. The method as claimed in claim 15, wherein: a fused deposition modeling or a multi-jet modeling is used as the 3D printing method for the case, in which at least one of the two materials is a plastic.

22. The method as claimed in claim 15, wherein: a color jet printing (CJP) is used as 3D printing method for the case, in which at least one of the at least two materials is a ceramic.

23. The method as claimed in claim 15, wherein; particles of the at least two materials are each blended into liquid media, the liquid media with the particles of the materials are printed in accordance with the predetermined material distribution; and the printed material block, or the sensor element or the active component of the sensor element, is subjected to a sinter process.

24. The method as claimed in claim 15, wherein: used as one of the at least two materials is a material, which transfers in the case of a heating process into the gaseous phase, so that in the sensor element or in the active component of the sensor element a defined fraction of hollow spaces with defined geometry and size remains.

25. The method as claimed in claim 15, wherein: the material distribution in the sensor element or in the active component of the sensor element is so calculated that the at least two materials are arranged in the sensor element or in the active component of the sensor element in defined microstructures.

26. The method as claimed in claim 25, wherein: the microstructures are matched to the environmental conditions at the location of use of the field device.

27. A composite material produced by the method comprising the steps of a method for manufacturing a composite material, a sensor element or an active component of a sensor element, wherein the sensor element is applied in a field device of automation technology, comprising the steps of: predetermining at least two materials with different physical and chemical properties depending on a functionality of the sensor element or the active component of the sensor element; predetermining an outer shape, into which the at least two materials should be formed; the outer shape being divided into a plurality of virtual spatial regions; in each virtual spatial region the material distribution of the at least two materials occurs homogeneously and periodically according to predetermined rules corresponding to a microstructure; ascertaining the predetermined rules via a computer supported method depending on the predetermined functionality of the sensor element or the active component of the sensor element; transferring digital data, which describe the ascertained distribution of the at least two materials, to at least one 3D printer; and creating as printed product the sensor element or the active component of the sensor element by the 3D printer based on the digital data.

28. A sensor element or active component of a sensor element produced by the method comprising the steps of: a method for manufacturing a composite material, a sensor element or an active component of a sensor element, wherein the sensor element is applied in a field device of automation technology, comprising the steps of: predetermining at least two materials with different physical and chemical properties depending on a functionality of the sensor element or the active component of the sensor element; predetermining an outer shape, into which the at least two materials should be formed; the outer shape being divided into a plurality of virtual spatial regions; in each virtual spatial region the material distribution of the at least two materials occurs homogeneously and periodically according to predetermined rules corresponding to a microstructure; ascertaining the predetermined rules via a computer supported method depending on the predetermined functionality of the sensor element or the active component of the sensor element; transferring digital data, which describe the ascertained distribution of the at least two materials, to at least one 3D printer; and creating as printed product the sensor element or the active component of the sensor element by the 3D printer based on the digital data.

Description

[0031] The invention will now be explained in greater detail based on the appended drawing, the figures of which show as follows:

[0032] FIG. 1 a flow diagram illustrating a preferred embodiment of the method of the invention,

[0033] FIG. 2 schematic representations of composite material,

[0034] a) wherein all three dimensions are less than the manufactured printed product

[0035] b) wherein two dimensions are less than the manufactured printed product

[0036] c) wherein one dimension is less than the manufactured printed product.

[0037] FIG. 3a a composite material of the invention composed of a piezoelectric material and a magnetostrictive material,

[0038] FIG. 3b a sensor element of the invention composed preferably of the composite material of FIG. 3a,

[0039] FIG. 4a a sensor element of the invention composed of a porous piezoelectric ceramic composite material with a first defined material distribution, and

[0040] FIG. 4b a sensor element of the invention composed of a porous piezoelectric ceramic composite material with a second defined material distribution.

[0041] FIG. 1 shows a flow diagram illustrating a preferred embodiment of the method of the invention. After starting at point 10, at point 20 at least two materials are selected, which are suitable for manufacture of the sensor material or the active component of the sensor element. At point 30, the outer shape, thus the outer dimensions, of the sensor element, or the active component of the sensor element, are specified, i.e. predetermined. At point 40, a virtual subdividing of the outer shape of the sensor element, or the active component of the sensor element, into virtual spatial regions is performed. At point 50, predetermined rules are created by means of a finite elements model FEM depending on the functionality of the sensor element or the active component of the sensor element. Then, each virtual spatial region is embodied homogeneously and periodically according to the predetermined rules ascertained via the finite elements model FEM.

[0042] The corresponding digital data are transmitted to a 3D printer and correspondingly printed (point 70). At point 80, the sensor element, or the active component of the sensor element, is sintered. Point 70 and point 80 can, in given cases, also be executed simultaneously, or always directly following one another, and, indeed, until the sensor element, or the active component of the sensor element, is complete as regards the predetermined dimensions.

[0043] FIG. 2 shows schematic representations of a composite material, [0044] a) wherein all three dimensions of the microstructure are less—here by a factor of 5—than the printed product manufactured of the composite material; [0045] b) wherein two dimensions of the microstructure are significantly less than the completed printed product. The remaining dimension is comparable with the dimensions of the printed product. [0046] c) Wherein one dimension of the microstructure is less than the completed printed product. The two other dimensions are comparable with the dimensions of the printed product.

[0047] The terminology, printed product, is, in such case, the generic expression for composite material with defined outer dimensions, sensor element or active component of the sensor element, as the case may be.

[0048] FIG. 3a shows a composite material 101 of the invention. Composite material 101 is composed of a piezoelectric ceramic material 102 and a magnetostrictive ceramic material 103, which are connected layer-wise with one another. A virtual spatial region is indicated with the reference character 104. For example, the piezoelectric ceramic material 102 is PZT5 (lead-zirconate-titanate) and the magnetostrictive ceramic material 103 is cobalt-nickel ferrite. Both materials 102, 103 are dielectric materials.

[0049] After 3D printing corresponding to the method of the invention, the composite material 101 is sintered at temperatures from 1150-1300° C. Subsequently, the composite material can be processed further to sensor elements 201 or to active components 201 of sensor elements. The further processing occurs, for example, via mechanical methods or via laser methods.

[0050] FIG. 3b shows a sensor element 201, which is manufactured from the composite material 102, 103 illustrated in FIG. 3a, which, however, can also be manufactured from another composite material with other materials 202, 203. Sensor element 201 includes two oppositely lying, metal electrodes 204. The electrodes 204 are e.g. fired silver layers with a thickness of 2-10 μm, or sputtered gold, silver, copper, nickel or another conductive metal or another conductive alloy. After polarizing the piezoelectric ceramic material 102, 202, e.g. PZT5, by applying an electrical direct voltage field of about 1 MV/m to the electrodes 204, the piezoelectric ceramic layer material 102, 202 acquires permanent piezoelectric properties. The layers of the two materials 102, 103, or 202, 203, are bonded together as a result of the manufacturing process.

[0051] An above described sensor element 201, or composite material 101, can be used e.g. in a sensor for determining the strength of a magnetic field. If the sensor element 201 is placed in a magnetic field, then the layers of magnetostrictive ceramic material 103, 203 exert a mechanical stress on the layers of piezoelectric, ceramic material 102, 202. As a result of the mechanical stress, an electrical charge occurs on the electrodes 204 to serve as measurement signal for the evaluation of the magnetic field.

[0052] FIG. 4a shows a sensor element of the invention 301, which is composed of a piezoelectric ceramic material 302 with defined air inclusions 303. For example, the piezoelectric material 302 is a material based on PZT basis. The piezoelectric properties of porous piezo elements depend very strongly on pore geometry and pore distribution in the ceramic matrix. FIGS. 4a and 4b illustrate two different pore distributions and pore geometries in a piezoelectric element (active element of a sensor element) of PZT 302. FIG. 4a shows a piezoelectric element 301 with rod shaped pores 303 in the PZT material 302, while the piezoelectric ceramic 302 of FIG. 4b has rod shaped pores 303 and sphere shaped pores 305, which are arranged in a defined pattern relative to one another. The porous piezoelectric material is after sintering at 1150-1300° C. mechanically worked to the desired shape and coated with metal electrodes 304. Then, the sensor element 301 with electrodes is polarized in a direct voltage field of about 1 MV/M.

[0053] Correspondingly manufactured, porous, piezoelectric sensor elements 301, or active components 301 of sensor elements, possess a high hydrostatic sensitivity and can be used as microphone- or hydrophonic sensors. Using the manufacturing process of the invention, the pore geometry and the pore distribution can be created exactly according to mathematical simulations (e.g. by means of FEM). This enables the reproducible manufacturing of piezoelectric sensors 301 with exactly defined properties. In such case, sensor elements 301 or active components 301 of sensor elements can be formed with highly periodic or, however, also with aperiodic, pore distributions. Of course, it is also possible to implement any pore distribution in the piezoelectric element 301, such that the piezoelectric element 301 has the desired physical and/or chemical properties.