Hall Sensor Magnetic Concentrator Layers for Warpage Reduction
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Solution Overview
Problem
Conventional Hall sensors face issues with excessive warpage due to large dimensions of magnetic permeability material films, which affect their operational efficiency and reliability.
Innovation Solution
A Hall sensor design incorporating a combination of a thin magnetic permeability material film and a permalloy material layer forms a magnetic concentrator, mitigating warpage while maintaining sufficient magnetic coupling for effective field concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large magnetic permeability material film is used to provide sufficient magnetic coupling, then magnetic field concentration is improved, but warpage increases
Solution Approach 1:
The magnetic permeability material film is segmented into a multi-layer structure consisting of a first magnetic permeability material layer and a second magnetic permeability material layer with different magnetic permeabilities. This segmentation allows each layer to contribute differently to magnetic coupling while the combined structure reduces overall warpage compared to a single large film.
Solution Approach 2:
The patent uses a composite magnetic permeability material structure where two different magnetic permeability materials are combined in layers. This composite approach enables the structure to achieve sufficient magnetic coupling for effective field concentration while mitigating warpage issues that would occur with a single large uniform film.
2Shape
If a thin magnetic permeability material film is used to reduce warpage, then shape stability is improved, but magnetic coupling becomes insufficient
Solution Approach 1:
Instead of using a single thin film that would reduce warpage but insufficient magnetic coupling, the patent segments the magnetic permeability material into multiple layers with different magnetic permeabilities. The first layer provides magnetic coupling while the second layer enhances field concentration, achieving both reduced warpage and sufficient magnetic coupling.
Solution Approach 2:
Different regions of the magnetic permeability material structure have different magnetic permeabilities. The first magnetic permeability material layer has one permeability value optimized for coupling, while the second layer has a different permeability value optimized for field concentration, allowing each layer to perform its specific function effectively.
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 layered structure ensures sufficient magnetic coupling for precise current measurement, reducing warpage and enhancing operational reliability of the Hall sensor.
Implementation Method 1
at least one magnetic permeability material film formed on the IC die. The Hall sensor can include at least one permalloy material layer formed on the respective at least one magnetic permeability material film, the at least one magnetic permeability material film and the at least one permalloy material layer combining to provide a magnetic concentrator providing concentration of the magnetic field
Implementation Method 2
The Hall Effect occurs when a magnetic field is oriented perpendicular to an electric current. Typical Hall sensors usually include a strip or plate of an electrically conductive material with an electric current flowing through the plate. When the plate is positioned in a magnetic field such that a component of the field is perpendicular to the plate, a Hall voltage is generated within the plate
Data Source
AI summary
In an example, a Hall sensor can include an IC die formed on a lead frame that is configured to conduct a current, the IC die being configured to sense a magnetic field resulting from the current. The Hall sensor can include at least one magnetic permeability material film formed on the IC die. The Hall sensor can include at least one permalloy material layer formed on the respective at least one magnetic permeability material film, the at least one magnetic permeability material film and the at least one permalloy material layer combining to provide a magnetic concentrator providing concentration of the magnetic field.