Gapped Current Sensor Core With Resin Bridge Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for forming gaps in current sensors using dicing blades are limited by blade thickness, preventing the creation of wider gaps and resulting in residual resin mold portions that cannot be removed, which hinders insulation between the core and bus bar.
Innovation Solution
A gapped core design featuring a resin bridge portion with a void that extends along the annular direction of the core, allowing for adjustable gap width and providing insulation between the core and bus bar, while preventing deformation during cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a dicing blade is used to form a gap in the core main body, then insulation between the core and bus bar is provided, but the gap width is limited by the blade thickness and cannot be widened
Solution Approach 1:
The invention divides the resin mold portion into two functional segments: a resin mold portion that covers the outer circumference of the core main body and provides insulation, and a resin bridge portion that extends from the resin mold portion to the bus bar opening. This segmentation allows the gap width to be independently controlled by the spacing between cutting portions, while the resin bridge portion maintains insulation functionality without being constrained by dicing blade thickness.
Solution Approach 2:
The resin bridge portion acts as an intermediary structure between the resin mold portion and the bus bar opening. It provides a continuous insulating path while allowing the gap width to be determined by the spacing between cutting portions rather than by dicing blade thickness, thus enabling adjustable gap widths.
2Manufacturing precision
If the core main body is cut to form a wider gap, then gap width is increased, but the resin mold portion cannot be completely removed and remains connected
Solution Approach 1:
By segmenting the resin mold portion into a resin mold portion and a resin bridge portion with distinct functions, the invention enables the resin bridge portion to remain connected to provide insulation while the gap width is increased. The resin bridge portion is specifically designed to extend to the bus bar opening, ensuring it remains as an insulating barrier.
Solution Approach 2:
The invention applies local quality by giving different regions of the resin mold portion different properties: the resin mold portion is designed to be removed after cutting, while the resin bridge portion is designed to remain connected. This localized differentiation allows wider gaps to be formed while maintaining insulation through the remaining resin bridge portion.
3Manufacturing precision
If two dicing blades are used to form a wider gap, then gap width exceeds blade thickness, but the resin mold portion remains connected at circled portions and cannot be removed
Solution Approach 1:
The invention segments the resin mold portion structure to anticipate the cutting process, creating a resin bridge portion that is designed from the beginning to remain connected. This pre-segmentation eliminates the need for complex post-cutting operations and simplifies the overall manufacturing process despite using multiple cutting blades.
Solution Approach 2:
The resin bridge portion is formed in advance during the molding process, before cutting occurs. This preliminary formation of the insulating structure ensures that after cutting with multiple blades, the resin bridge portion remains intact and provides continuous insulation, avoiding the need for complex post-cutting assembly operations.
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The present invention provides a core member, a gapped core, and a current sensor in which the gap width of a core main body that is entirely or partially covered by a resin mold portion can be set as appropriate, and insulation between the core main body and a bus bar opening can be achieved. A core member 10 according to the present invention is a core member that includes a gap forming region C in which a gap 21 is formed. The core member includes an annular the core main body 20 having a bus bar opening 12 in which a bus bar 62 is disposed, a resin mold portion 30 that entirely or partially covers the core main body, the resin mold portion covering at least a portion of the gap forming region, and a resin bridge portion 40 whose both ends are continuously connected to the resin mold portion, and that is formed between an inner circumference side of the core main body and the bus bar opening, the resin bridge portion including a void 42 that is formed at a position opposing the gap forming region, and extends through the core member in a thickness direction of the core member between the resin bridge portion and the core main body or the resin mold portion.