Integrated Magnetic Sensor with Dual-Substrate Architecture
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Solution Overview
Problem
Conventional current sensors and magnetic field sensors are large, have restricted dynamic range, and lack accuracy, particularly at high and low current levels, due to their size and material limitations.
Innovation Solution
The integration of multiple magnetic field sensing elements with different sensitivities on substrates made of varying materials, such as Silicon and Gallium Arsenide, within an integrated circuit structure, along with flux concentrators and underfill materials, to enhance sensitivity and dynamic range while minimizing size and packaging stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional current sensors use Hall effect elements or magnetoresistance elements mounted on dielectric material, then the sensor structure is simple and easy to manufacture, but the sensor size is large and dynamic range is restricted
Solution Approach 1:
The patent combines multiple magnetic field sensing elements (Hall effect element and magnetoresistance element) into a single integrated sensor assembly mounted on a common substrate. This merging allows the sensor to achieve extended dynamic range and improved accuracy without requiring separate sensor housings and mounting structures, thereby reducing overall sensor size while maintaining ease of manufacture through standardized integration processes
Solution Approach 2:
The patent uses composite material structures including ferrous core materials with specific permeability characteristics combined with dielectric materials for mounting. This composite approach enables flux concentration that improves sensitivity and extends dynamic range while keeping the sensor compact, as the ferrous core directs magnetic flux efficiently through a reduced volume
2Device complexity
If conventional current sensors use single substrate mounting, then the structure is simple, but the accuracy is limited particularly at high and low current levels
Solution Approach 1:
The patent implements local quality by positioning different types of magnetic field sensing elements (Hall effect and magnetoresistance) at specific locations around the ferrous core, where each element type is optimally positioned to detect magnetic fields in specific ranges. This localized optimization enables accurate measurement across the full dynamic range from low to high current levels, with each sensing element contributing to precision in its optimal operating region
Solution Approach 2:
The patent segments the measurement function by using multiple independent sensing elements (Hall effect element and magnetoresistance element) that can be individually optimized for different current ranges. This segmentation allows each element to operate in its optimal range, with the Hall effect element handling higher currents and the magnetoresistance element handling lower currents, thereby improving overall measurement accuracy across the extended dynamic range
3Ease of manufacture
If conventional sensors are mounted on circuit boards, then the mounting is straightforward, but the sensor height and circuit board area are large
Solution Approach 1:
The patent merges the magnetic field sensing elements, ferrous core, and mounting substrate into a single compact integrated assembly that mounts to the circuit board as one unit. This integration dramatically reduces the circuit board area required compared to separate mounted components, while the standardized assembly interface maintains straightforward mounting procedures similar to conventional sensor installation
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 approach results in a compact, high-accuracy current sensor with extended dynamic range, capable of accurately measuring a wide range of currents and magnetic fields, reducing size and material-related inaccuracies.
Implementation Method 1
one type of conventional current sensor uses a Hall effect element, which generates a voltage in response to a magnetic field associated with a current passing through a conductor
Implementation Method 2
Another type of conventional current sensor uses a magnetoresistance element, which changes resistance in response to a magnetic field associated with a current passing through a conductor
Implementation Method 3
Conventional current sensors of this type use an anisotropic magnetoresistance (AMR) element mounted on a dielectric material
Data Source
AI summary
An integrated circuit can have a first substrate supporting a magnetic field sensing element and a second substrate supporting another magnetic field sensing element. The first and second substrates can be arranged in a variety of configurations. Another integrated circuit can have a first magnetic field sensing element and second different magnetic field sensing element disposed on surfaces thereof.