Flexible Detection Substrate for Accurate Current Measurement
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Solution Overview
Problem
Conventional current detection sensors, such as Rogowski coils, face challenges in accurately detecting current changes through semiconductor devices while maintaining a compact device size.
Innovation Solution
A detection substrate with a winding wire part and a winding return wire part on a flexible body film, allowing for increased turns per unit length and accurate current detection, is developed. The substrate includes a through hole for the winding wire part and a return wire part that can be positioned on the surface or within the body film, facilitating compact design and high versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the number of turns per unit distance is increased to improve sensitivity, then detection accuracy is improved, but device size increases
Solution Approach 1:
The patent transitions from planar winding to three-dimensional spherical winding. The winding wire is wrapped around a spherical mandrel, creating a spherical coil structure that utilizes spatial volume more efficiently. This dimensional change allows for increased turn density without proportionally increasing the device's footprint, as the spherical geometry packs more turns within a compact volume compared to traditional flat woundings.
Solution Approach 2:
The patent employs a nested structure where the winding wire is wrapped around a spherical mandrel, and the entire coil assembly is integrated within a compact housing. The spherical mandrel itself can be nested within the detection substrate, creating a compact nested arrangement that maximizes turn density while minimizing overall device volume.
2Ease of manufacture
If a coreless Rogowski coil structure is used to improve flexibility, then ease of manufacture is improved, but structural stability deteriorates
Solution Approach 1:
The patent uses a spherical mandrel that can be made from flexible or removable materials, allowing the winding process to be performed easily without requiring a rigid permanent core. The mandrel acts as a temporary form that can be inserted, wound around, and then removed or retained based on the application, providing manufacturing flexibility while maintaining structural integrity during the winding process.
Solution Approach 2:
The spherical mandrel serves as an intermediary object during manufacturing. It provides the necessary structural support during the winding process to maintain the spherical shape and ensure uniform turn distribution, but can be removed after winding is complete. This intermediary structure enables easy manufacturing of the spherical coil without requiring a permanent core that would complicate the design or reduce flexibility.
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 enables accurate detection of current changes in semiconductor devices with a compact and versatile detection substrate, allowing for miniaturization and efficient current measurement, even in tight spaces, while reducing manufacturing complexity and costs.
Implementation Method 1
a current detection sensor using a Rogowski coil has been known. The Rogowski coil is a coreless coil, and has a winding core, a winding wire wound around the winding core
Data Source
AI summary
A detection substrate 150 has a body film 1a having a through hole 91; a winding wire part 10 provided on a surface of one side of the body film 1a, on a surface of another side of the body film 1a and in the through hole 91, and disposed so as to surround a current to be detected; and a winding return wire part 50, provided on the body film 1a, connected at a terminal end part of the winding wire part 10 and returning from the terminal end part toward a starting end part side.