Magnetic Field Sensor Manufacturing via Alloy Deposition
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Solution Overview
Problem
The manufacturing of magnetometers is complex and costly due to the assembly of thin magnetic cores and the need for heat treatment, which can be unstable, especially when using amorphous alloys, and the assembly of multiaxial probes is challenging.
Innovation Solution
A method involving the deposition of magnetic alloy cores on a non-magnetic support plate, with strips extending along concurrent axes connected by an intersection zone, allowing for easy assembly and detachment, and incorporating windings such as tubular or flat windings, with options for nanocrystalline alloys or screen-printed magnetic powders, enabling a simple and cost-effective production of magnetic field sensors with multiple probes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thin magnetic cores are assembled using traditional methods, then magnetic field sensor functionality is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
Multiple magnetic cores are integrated onto a single support plate with shared intersection zones, merging what would traditionally be separate assembly operations into one unified structure. This reduces manufacturing complexity while maintaining sensor functionality.
Solution Approach 2:
Magnetic cores are deposited directly onto the support plate in predetermined positions before final assembly, pre-establishing the geometric relationships between cores. This preliminary positioning simplifies subsequent assembly steps and reduces manufacturing complexity.
2Reliability
If heat treatment is applied to restore magnetic properties, then magnetic performance is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent changes the material parameter from traditional crystalline alloys requiring heat treatment to amorphous or nanocrystalline alloys that inherently possess stable magnetic properties. This parameter change eliminates the heat treatment step while maintaining magnetic performance.
Solution Approach 2:
The patent employs materials (amorphous or nanocrystalline alloys) that are designed to be stable without requiring post-processing heat treatment. These materials accept their as-deposited state as final, eliminating the need for additional manufacturing steps.
3Adaptability or versatility
If multiple probes are assembled to form multiaxial magnetometer, then measurement capability is improved, but assembly complexity increases
Solution Approach 1:
Multiple probes are merged into a single integrated structure on one support plate, with all probe cores and their respective windings arranged in predetermined spatial relationships. This merging eliminates the need for separate assembly operations for each probe.
Solution Approach 2:
The geometric arrangement of multiple probes is predetermined during the core deposition stage, with cores positioned at specific locations and orientations on the support plate. This preliminary configuration simplifies subsequent assembly and reduces overall complexity.
4Measurement precision
If thin magnetic cores are used, then sensor precision is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent replaces mechanical assembly methods with magnetic field deposition techniques. Magnetic cores are deposited directly onto the support plate using field-based processes rather than mechanical handling, which simplifies manufacturing while enabling precise thin core formation.
Solution Approach 2:
Thin magnetic cores are formed with precise dimensions and positions during the deposition process itself, before assembly. This preliminary formation of precise features eliminates the need for subsequent precision machining or adjustment operations.
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 method simplifies the manufacturing process, allows for reliable and safe assembly of probes, and enables the production of magnetic field sensors with improved precision and sensitivity by ensuring precise positioning of probes relative to each other, facilitating accurate determination of magnetic field orientation and intensity.
Implementation Method 1
a vacuum deposition of the alloy on all or part of the support plate
Implementation Method 2
bonding at least one layer of nanocrystalline alloys or of another type of magnetic alloy to the support plate
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for making a field sensor (1) that comprises a series of n electrodes (2), with n > = 3, each including a core of magnetic alloys (3) associated with a winding (4). According to the invention, the method comprises the following steps: depositing the cores of magnetic alloys (3) onto a non-magnetic bearing plate on at least a portion or the entirety of a surface corresponding to a series of n strips (6) extending along axes (x, y, z) concurrent at an intersection point and connected together by an intersection area (z); before or after said deposition, cutting the n strips (6) into said bearing plate while maintaining them connected to the bearing plate by at least one connector; assembling each strip (6) with a winding (4); folding at least one strip (6) along a folding line perpendicular to the axis thereof.