Ferromagnetic Over-Mold Current Sensor for Busbar Integration
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Solution Overview
Problem
Conventional current sensing systems in electric vehicles are costly, bulky, and impose design restrictions due to large magnetic cores, leading to accuracy issues and space constraints, particularly affecting busbar routing.
Innovation Solution
A current sensing system integrating a magnetic field sensor with a ferromagnetically impregnated epoxy core, using a dielectric material and a flux-concentrating ferromagnetic over-mold to enhance accuracy and sensitivity, allowing for compact and flexible design without the need for separate ferromagnetic cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional current sensing systems use large magnetic cores, then measurement accuracy is improved, but device size and weight increase
Solution Approach 1:
The patent merges the ferromagnetic core and housing into a single integrated component. The ferromagnetic material forms both the magnetic core and the structural housing, eliminating the need for separate ferromagnetic cores and reducing overall device volume while maintaining measurement accuracy through the preserved magnetic path.
Solution Approach 2:
The patent employs composite material construction by combining ferromagnetic material with non-magnetic housing materials. This composite approach allows the ferromagnetic component to provide magnetic functionality while the non-magnetic material provides structural support and isolation, achieving compact design without compromising sensing accuracy.
2Reliability
If conventional current sensing systems use separate ferromagnetic cores, then magnetic functionality is ensured, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines multiple functions into a single integrated component where the ferromagnetic material simultaneously serves as the magnetic core, structural housing, and magnetic shielding. This integration reduces the number of parts and assembly steps while ensuring reliable magnetic functionality through the continuous ferromagnetic path.
Solution Approach 2:
The ferromagnetic component performs multiple functions: it provides the magnetic core for current sensing, serves as the structural housing for the sensor elements, and acts as magnetic shielding. This multi-functionality reduces device complexity by eliminating the need for separate components for each function.
3Volume of moving object
If compact sensor design is implemented, then space constraints are reduced, but measurement accuracy may deteriorate
Solution Approach 1:
The patent uses composite material structures to achieve compact design without sacrificing accuracy. The ferromagnetic material provides efficient magnetic pathways in a compact form factor, while the non-magnetic housing materials provide structural support, allowing small sensor footprint while maintaining adequate magnetic flux paths for accurate measurement.
Solution Approach 2:
The patent applies local quality optimization by concentrating ferromagnetic material specifically where it is needed for magnetic flux pathways, rather than uniformly throughout the entire housing. This localized approach maintains measurement accuracy by preserving critical magnetic paths while reducing overall material usage and device volume.
4Measurement precision
If ferromagnetic over-mold is used to encapsulate the corner, then magnetic field concentration is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the ferromagnetic core with the housing structure, eliminating the need for separate ferromagnetic components and assembly steps. The ferromagnetic material is integrated directly into the housing formation process, simplifying manufacturing while maintaining magnetic field concentration capabilities through the unified ferromagnetic path.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces packaging requirements, increases design flexibility, and improves the accuracy and sensitivity of current sensing, while minimizing weight and volume penalties, allowing for more efficient busbar routing and integration with electric vehicles.
Implementation Method 1
a ferromagnetic over-mold encapsulating the corner and the dielectric material
Implementation Method 2
a magnetic field sensor disposed in an inner portion of the corner and spaced away from the legs
Data Source
AI summary
An electrical current sensing arrangement includes a busbar, a dielectric material containing therein a magnetic field sensor, and a ferromagnetic over-mold encapsulating a portion of the busbar and the dielectric material. The dielectric material is disposed against the busbar such that the magnetic field sensor is spaced away from the busbar and the ferromagnetic over-mold is not between the busbar and the magnetic field sensor.