Flexible Current Sensor With Magnetic Core Gaps
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Solution Overview
Problem
Current flexible current sensors with non-magnetic cores, such as Rogowski coils, have limited sensitivity and accuracy for measuring low electrical currents due to their non-magnetic core structure, which makes it difficult to achieve precise control over effective magnetic permeability, especially during flexing.
Innovation Solution
A flexible electrical current sensor with a solenoid disposed about an at least partially magnetic core, where the core comprises magnetic elements with strategically positioned gaps to maintain effective magnetic permeability during flexing, allowing for controlled and predictable magnetic permeability and enhanced sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a non-magnetic core is used in a Rogowski coil, then the sensor maintains flexibility, but the sensitivity and measurement precision for low currents deteriorates
Solution Approach 1:
The patent employs a composite magnetic core structure consisting of multiple magnetic elements (such as magnetic powder, particles, or flakes) dispersed within a non-magnetic flexible matrix material. This composite approach combines the high magnetic permeability of magnetic materials with the flexibility of non-magnetic polymers, enabling the sensor to maintain both flexibility and enhanced sensitivity for measuring low currents
Solution Approach 2:
The patent modifies the effective magnetic permeability parameter by controlling the concentration, size distribution, and orientation of magnetic elements within the flexible matrix. By adjusting these parameters, the sensor achieves optimal balance between flexibility and magnetic sensitivity, enabling accurate measurement of low currents while maintaining adaptability
2Measurement precision
If magnetic elements are added to enhance sensitivity, then the measurement precision improves, but the controllability of effective magnetic permeability during flexing deteriorates
Solution Approach 1:
The patent creates regions with varying magnetic element concentrations and distributions within the flexible core. By designing local variations in magnetic element density and orientation, the sensor maintains stable effective magnetic permeability characteristics during flexing, as different regions compensate for each other's changes in magnetic properties
Solution Approach 2:
The patent designs the magnetic element distribution to be dynamically adaptive, where the magnetic elements can reorient or redistribute within the flexible matrix during bending or flexing. This dynamic arrangement maintains relatively stable effective magnetic permeability despite changes in sensor geometry, ensuring consistent measurement precision
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 significantly increases the sensitivity of the current sensor, enabling accurate measurement of low currents (below 1 A) with improved controllability and predictability of magnetic permeability, potentially increasing sensitivity by 30 to 250 times compared to traditional Rogowski coils.
Implementation Method 1
the at least one magnetic element is configured to provide one or more regions of overlap such that a respective gap is provided in each region of overlap, each respective gap being configured such that the effective magnetic permeability of the at least partially magnetic core is maintained during flexing
Implementation Method 2
a solenoid disposed about an at least partially magnetic core
Data Source
AI summary
A flexible electrical current sensor is provided, the flexible electrical current sensor comprising a solenoid disposed about an at least partially magnetic core. The at least partially magnetic core comprises at least one magnetic element. The at least one magnetic element is configured to provide one or more regions of overlap such that a respective gap is provided in each region of overlap. Each respective gap is configured such that the effective magnetic permeability of the at least partially magnetic core is maintained during flexing.