Magnetic Sensor Insulating Layers Prevent Cracking

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Solution Overview

Problem

Magnetic sensors with insulating layers formed on metal layers often crack during manufacturing due to material differences, affecting the reliability and durability of the sensors.

Innovation Solution

A sensor configuration with multiple insulating layers of different materials, where the first and third insulating layers contain a high-fracture-toughness material and the second insulating layer contains a material with even higher fracture toughness, preventing cracking by minimizing material differences and defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If an insulating layer is formed on a metal layer to create a support member, then the support member can be constructed, but the insulating layer cracks during the manufacturing process

Engineering Contradiction:

Improvesupport member constructionVSAvoidinsulating layer integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The insulating layer is divided into multiple segments (first insulating layer, second insulating layer, third insulating layer) arranged in order along a first direction. Each layer contains insulating material and is positioned between the metal layer and sensor element, distributing mechanical stress across multiple interfaces rather than concentrating it in a single layer, thereby preventing crack formation during manufacturing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulating layers are constructed using composite material structures with different insulating materials arranged in specific sequences. The first and third insulating layers contain a first insulating material, while the second insulating layer contains a second insulating material, creating a composite structure that combines the advantages of different materials to resist cracking while maintaining electrical insulation properties

Inventive Principle:

Principle #40Composite materials

2Device complexity

If a single insulating material is used in the insulating layer, then the manufacturing process is simplified, but the insulating layer is prone to cracking

Engineering Contradiction:

Improveinsulating layer structureVSAvoidcrack prevention

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The insulating layer is segmented into three distinct layers (first, second, and third insulating layers) arranged in order along a first direction between the metal layer and sensor element. This segmentation allows each layer to be optimized for specific functional requirements while distributing mechanical stresses, preventing crack propagation that would occur in a single-layer structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the insulating structure are assigned different materials based on local requirements. The first and third insulating layers contain a first insulating material, while the second insulating layer contains a second insulating material, creating local quality variations that optimize both mechanical integrity and electrical insulation properties at different positions within the structure

Inventive Principle:

Principle #3Local quality

3Reliability

If insulating layers are used between the metal layer and sensor element, then electrical insulation is provided, but cracking occurs during sensor manufacturing

Engineering Contradiction:

Improveelectrical insulationVSAvoidmanufacturing process stability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The insulating structure is segmented into three layers arranged in order along a first direction, with the first and third insulating layers containing a first insulating material and the second insulating layer containing a second insulating material. This segmentation provides electrical insulation while distributing mechanical stresses across multiple interfaces, preventing crack formation during the manufacturing process

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulating structure employs composite materials with the first and third insulating layers made of a first insulating material and the second insulating layer made of a second insulating material. This composite construction maintains electrical insulation properties while the combination of different materials provides complementary mechanical properties that resist cracking during manufacturing

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12164009B2Sensor including a plurality of insulating layers made of different insulating materials

Publication Date: 2024.12.10 TDK CORP

AI summary

A magnetic sensor includes a first insulating layer, a second insulating layer, a third insulating layer, a lower coil element located on an opposite side of the first insulating layer from the second insulating layer, and a second MR element. The second MR element includes a magnetization pinned layer and a free layer. The magnetization pinned layer and the free layer are located on an opposite side of the third insulating layer from the second insulating layer. The first and third insulating layers each contain a first insulating material. The second insulating layer contains a second insulating material.