Interconnection construction to thick film substrate

Claim 2

An interconnection structure for a thick film substrate mounted in a housing having a housing wall and a base plate, said interconnection structure comprising: a lead frame having a first portion in the interior of said housing for contacting said thick film substrate, a second portion integrally coupled to said first portion and positioned within said housing wall, and a third portion integrally coupled to said second portion extending beyond said housing wall for coupling to an external circuit, said lead frame being formed of one piece of material having a substantially uniform original thickness; said first portion including a terminal with an arcuate hoop portion and a reduced width portion for providing stress relief; said second portion including stepped segments for providing connection between the plane of said first portion and the plane of said third portion; and said third portion including a connector blade with a thickness greater than the thickness of said terminal of said first portion.

Claim 3

An interconnection structure as recited in claim 1 wherein: said connector blade has a double thickness compared to said terminal and is formed by folding over the substantially uniform thickness material forming said lead frame.

Claim 4

An interconnection as recited in claim 2 wherein: said lead frame is made of a brass material.

Claim 5

An interconnection as recited in claim 3 wherein: said second portion includes an upward step from the level of an adjacent coupling to said first portion up to the level of an adjacent coupling to said third portion so that a protective gel material covering said first portion and said thick film substrate can have a level lower than the level of said third portion.

Claim 6

An interconnection as recited in claim 4 wherein: said second portion includes a downward step from the level of an adjacent coupling to said first portion down to the level of an adjacent coupling to a ground contact of said third portion so that electrical contact can be made to the base plate which supports said thick film substrate and there is no material between the base plate and said ground contact which may deform in response to a mounting force.

Claim 7

An interconnection structure as recited in claim 5 wherein: said first portion includes a terminal having a top arm extending in the plane of the adjacent portion of said second portion, a hoop extending up from said top arm in an arcuate trajectory, a leg extending down from said hoop to a foot for connection to said thick film substrate substantially all of said leg and said hoop having a width less than said adjacent portion of said second portion, and said leg including a pair of opposing notches further reducing the width of said leg.

Claim 8

An interconnection structure for a thick film substrate mounted in a housing having a housing wall and positioned on a mounting plate, said interconnection structure comprising: a plurality of lead frames each having a first portion within said housing for contacting said thick film substrate, a second portion integrally coupled to said first portion and positioned within said housing wall, and a third portion integrally coupled to said second portion extending beyond said housing wall for coupling to an external circuit; said lead frames each being formed of one piece of material having substantially uniform original thickness; said first portions having terminals having entry into said housing wall at substantially the same entry plane; and said second portions including a step for connecting an associated one of said first portions to a segment of an associated one of said third portions at an exit plane adjacent said housing wall, said exit plane being offset and spaced from said entry plane of said first portion.

Claim 9

An interconnection structure for a thick film substrate mounted in a housing having a housing wall and positioned on a mounting plate, said interconnection structure comprising: a plurality of lead frames each having a first portion within said housing for contacting said thick film substrate, a second portion integrally coupled to said first portion and positioned within said housing wall, and a third portion integrally coupled to said second portion extending beyond said housing wall for coupling to an external circuit; said lead frames each being formed of one piece of material having substantially uniform original thickness; said first portions having terminals having entry into said housing wall at substantially the same entry plane; and said second portions including a step for connecting an associated one of said first portions to a segment of an associated one of said third portions at an exit plane adjacent said housing wall, said exit plane being offset and spaced from said entry plane of said first portion.

Claim 10

An interconnection structure as recited in claim 7 wherein: said step is an upward step for coupling said first portion to connectors in said third portion located in a plane higher than said entry plane.

Claim 11

An interconnection structure as recited in claim 7 wherein: said step is a downward step for coupling said first portion to a ground connection in said third portion located in a plane lower than said entry plane and adjacent the mounting plane of said thick film substrate.

Claim 12

An interconnection structure as recited in claim 8 wherein: said first portions each have terminals with an arcuate hoop portion, a reduced width portion and a pair of opposing notches in said reduced width portion further reducing the width of said leg so as to provide stress relief for said interconnection structure.