Thin-Film Fluxgate Sensor With Continuous Magnetic Cladding
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Solution Overview
Problem
Conventional thin film fluxgate sensors face challenges in achieving optimal performance due to the parasitic air gap effects from multiple layer deposition, leading to increased power requirements and non-uniform saturation, which complicates sensitivity variation and linearity of measurement signals.
Innovation Solution
A thin film fluxgate sensor design featuring a single continuous layer of saturable magnetic material cladding with feed-through channels allows the excitation current conductor to weave through, eliminating parasitic air gaps and enabling uniform saturation, with adjustable cladding lengths for varying sensitivity and linearity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple deposition steps are used to form cladding layers, then the sensor can be manufactured using conventional thin film techniques, but parasitic air gap effects are created that increase power requirements and reduce measurement uniformity
Solution Approach 1:
The patent merges multiple separate cladding layers into a single continuous cladding layer that completely surrounds the excitation conductor. This eliminates the air gaps that would exist between multiple deposited layers, thereby reducing the power required to saturate the magnetic material while maintaining manufacturability through conventional thin film deposition techniques.
Solution Approach 2:
The single continuous cladding layer is segmented into multiple deposition steps, where each step deposits a portion of the cladding material. By carefully controlling the deposition process and using intermediate support structures, the patent achieves a continuous cladding without creating parasitic air gaps, thus resolving the contradiction between manufacturability and power efficiency.
2Ease of manufacture
If multiple deposition steps are used to form cladding layers, then the sensor can be manufactured using conventional thin film techniques, but the magnetisation uniformity is reduced leading to signal distortion
Solution Approach 1:
The patent merges multiple separate cladding layers into a single continuous cladding layer that completely surrounds the excitation conductor. This eliminates the air gaps that would exist between multiple deposited layers, thereby reducing the power required to saturate the magnetic material while maintaining manufacturability through conventional thin film deposition techniques.
3Adaptability or versatility
If the sensor length is increased to vary sensitivity and measurement range, then the measurement range can be adjusted, but maintaining uniform saturation and signal linearity becomes difficult
Solution Approach 1:
The patent employs parameter changes in the cladding geometry, specifically varying the cross-sectional shape and dimensions of the cladding layer along the length of the sensor. By adjusting parameters such as cladding thickness, width, and curvature, the magnetic path length and saturation characteristics can be optimized for different sensor lengths, thereby maintaining signal linearity and uniform saturation across various sensitivity ranges.
4Volume of moving object
If a compact sensor design is achieved, then the sensor size is reduced, but the manufacturing complexity may increase
Solution Approach 1:
The patent utilizes thin film deposition techniques to create a compact cladding structure that completely surrounds the excitation conductor in a planar or near-planar configuration. This thin film approach enables compact sensor design while maintaining manufacturability through conventional semiconductor fabrication processes, avoiding the need for complex three-dimensional structuring.
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
This design results in a compact, power-efficient, and cost-effective sensor with improved sensitivity and linearity, capable of being easily configured for different operating ranges.
Implementation Method 1
a layer of saturable magnetic material cladding (6) having a plurality of feed-through channels extending between opposed faces of the layer
Implementation Method 2
an electrical excitation current conductor (4) and a layer of saturable magnetic material cladding (6)
Data Source
Figure 1~2
Figure 3~6
Figure 7~8
AI summary
A fluxgate magnetic field sensor including an excitation current conductor (4) and a layer of saturable magnetic material cladding (6) having a plurality of feed-through channels (16) extending between opposed faces of the cladding layer, the excitation current conductor weaving through a plurality of said feed- through channels.