Method of forming a sensor for sensing signals on conductors

• US 6,176,004 B1
• Filed: 12/29/1998
• Issued: 01/23/2001
• Est. Priority Date: 04/07/1998
• Status: Expired due to Fees

• Current Assignee: Hanger Solutions, LLC (IP Investments Group LLC)
• Original Assignee: Harris Corporation (L3Harris Technologies, Inc.)
• Inventors: Davis, Larry, Blumstein, Theodore R., Rainhart, Robert L., Newton, Charles M.
• Primary Examiner(s): Young, Lee
• Assistant Examiner(s): Trinh, Minh
• Application Number:
  US09/222,224
• Time in Patent Office: 756 Days
• Field of Search: 296/00, 295/921, 298/46, 298/47, 338/14, 338/25, 343/700, 343/702, 343/846, 343/873, 343/895
• US Class Current: 29/600
• CPC Class Codes: G01R 29/0878 Sensors; antennas; probes; detectors wave guide measuring sections G01R1/24
• CPC Class Codes: G01R 3/00 Apparatus or processes specially adapted for the manufacture or maintenance of measuring instruments , e.g. of probe tips
• CPC Class Codes: H01Q 1/40 Radiating elements coated with or embedded in protective material
• CPC Class Codes: H01Q 21/0087 Apparatus or processes specially adapted for manufacturing antenna arrays manufacturing waveguides H01P11/00
• CPC Class Codes: H01Q 21/061 Two dimensional planar arrays
• CPC Class Codes: H01Q 21/062 using dipole aerials; H01Q21/067, H01Q21/068 take precedence
• CPC Class Codes: H01Q 9/30 with feed to end of elongated active element, e.g. unipole H01Q9/44 takes precedence
• CPC Class Codes: H05K 1/0219 Printed shielding conductors for shielding around or between signal conductors, e.g. coplanar or coaxial printed shielding conductors
• CPC Class Codes: H05K 1/0222 for shielding around a single via or around a group of vias, e.g. coaxial vias or vias surrounded by a grounded via fence
• CPC Class Codes: H05K 1/0306 Inorganic insulating substrates, e.g. ceramic, glass
• CPC Class Codes: H05K 1/115 Via connections; Lands around holes or via connections H05K1/112 takes precedence
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/49016 Antenna or wave energy "plumbing" making

Abstract

A method of forming a sensor for sensing signals on conductors includes the step of forming a plurality of antenna element openings in a plurality of green tape ceramic sheets. Each antenna element opening includes a central opening and annular opening surrounding the central opening. The method includes the step of stacking successive green tape ceramic sheets so that central and annular openings are aligned with each other while also forming a planar sensor face that is to be placed adjacent the conductors to be sensed. The central openings and annular openings are filled with conductive paste. The stacked green tape ceramic sheets are heated to cure the green tape ceramic sheets and conductive paste. A signal processing integrated circuit is mounted on the side opposite the planar sensor face that is to be placed adjacent the conductors to be sensed. The method also includes the step of connecting the cured conductive paste filling central opening to the signal processing integrated circuit.

Claims

1. A method of forming a sensor for sensing signals on conductors comprising:

forming a plurality of antenna element openings in a plurality of green tape ceramic sheets, wherein each antenna element opening comprises a central opening and annular opening surrounding the central opening;

stacking successive green tape ceramic sheets so that central and annular openings are aligned with each other while also forming a planar sensor face that is to be placed adjacent to conductors to be sensed;

filling the central openings and annular openings with conductive paste;

heating the stacked green tape ceramic sheets to cure the green tape ceramic sheets and conductive paste; and

mounting a signal processing integrated circuit on the side opposite the planar sensor face that is to be placed adjacent the conductors to be sensed and connecting the cured conductive paste filling the central opening to the signal processing integrated circuit.

2. The method according to claim 1, wherein said antenna element openings formed as a central opening and annular opening are formed by laser drilling.

3. The method according to claim 1, and further comprising the steps of forming the central openings in the green tape ceramic sheets that are stacked last at a greater diameter to form a greater central electrode area to enhance conductor testing.

4. The method according to claim 1 and further comprising the steps of forming the central openings as spiral openings after the green tape ceramic sheets are stacked to form spiral configured central electrodes after the conductive paste has been received within the central openings.

5. The method according to claim 1, and further comprising the step of stacking successive green tape ceramic sheets together, wherein each sheet is about 3 mills in thickness.

6. The method according to claim 1, and further comprising the step of stacking green tape ceramic sheets that have been precut into substantially rectangular configured green tape ceramic sheets.

7. The method according to claim 1, and further comprising the step of stacking a plurality of green tape ceramic sheets that have offset central openings, such that when the central openings are aligned, a spiral configuration is formed.