Magnetic Flux Concentrator for Hall Sensor Amplification
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Solution Overview
Problem
Existing magnetic field sensors face challenges in cost-effectively amplifying magnetic flux for Hall sensors in mass production, particularly in maintaining efficiency and electromagnetic compatibility while keeping the sensor structure flat.
Innovation Solution
A magnetic field sensor design incorporating a magnetically permeable magnetic flux concentrator with a trapezoidal or hyperboloid cross-sectional area, mounted on a circuit board using SMD technology, which amplifies the magnetic field through the active area of the Hall sensor without complex integration, and optionally using a second flux concentrator for further optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetic flux concentrator is integrated into a semiconductor housing above a Hall sensor, then magnetic field amplification is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The magnetic flux concentrator is separated from the Hall sensor component, allowing independent manufacturing and assembly. The concentrator is mounted on the circuit board in a recess area while the Hall sensor remains in its housing, dividing the system into manufacturable segments that can be produced separately and combined through standard SMD processes
Solution Approach 2:
A circuit board with a recess serves as an intermediary structure between the Hall sensor and magnetic flux concentrator. The recess in the circuit board provides the mounting location for the concentrator, enabling magnetic field amplification without direct integration into the sensor housing, thus simplifying manufacturing
2Adaptability or versatility
If multiple Hall sensors are integrated within a housing for differential measurements, then measurement capability is improved, but manufacturing complexity increases
Solution Approach 1:
Multiple Hall sensors are housed in separate SMD packages rather than being integrated into a single complex housing. Each sensor can be manufactured and tested independently, then mounted on the circuit board in specific positions to enable differential measurements, greatly simplifying mass production
Solution Approach 2:
The solution moves from vertical integration (multiple sensors in one housing) to planar arrangement (multiple sensors on circuit board). By utilizing the circuit board plane and positioning sensors at different locations, differential measurement capability is achieved without increasing housing complexity
3Measurement precision
If the magnetic flux concentrator has a large surface area to amplify magnetic field, then magnetic field amplification is improved, but the sensor structure becomes non-flat and larger
Solution Approach 1:
The magnetic flux concentrator is nested within the recess area of the circuit board. The concentrator fits into the recess space, utilizing the vertical depth of the recess to accommodate the concentrator's volume without increasing the overall planar footprint of the sensor assembly, maintaining a compact flat structure
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 enhances the resolution and signal-to-noise ratio of Hall sensors, improves electromagnetic compatibility, and allows for cost-effective, flat sensor structures with effective magnetic field amplification, suitable for differential measurements.
Implementation Method 1
a first magnetic flux concentrator made of magnetically permeable material, which is arranged on the side of the first surface on the circuit board opposite to the Hall sensor component, and which has a lateral surface, which faces away from the circuit board, having a first surface area and a lateral surface, which faces toward the circuit board, having a second surface area, the first surface area being greater than the second surface area
Implementation Method 2
Hall sensors are frequently used, which generate an electrical voltage or an electrical current as an output signal on the basis of the Hall effect of a conductor loop permeated by a magnetic flux
Data Source
AI summary
A magnetic field sensor includes: a circuit board having a first surface, a second surface opposite to the first surface, and a recess extending from the first surface to the second surface; a Hall sensor component having a Hall sensor situated in a housing, the Hall sensor component having an active sensor area situated parallel to the first surface and in the area of the recess on the side of the second surface on the circuit board; and a first magnetic flux concentrator made of a magnetically permeable material and situated on the side of the first surface opposite to the Hall sensor component, the magnetic flux concentrator having a lateral surface which faces away from the circuit board and includes a first surface area and a lateral surface which faces toward the circuit board and includes a second surface area which is smaller than the first surface area.