Integrated Magnetic Sensor Chip for Weak Current Detection
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Solution Overview
Problem
Magnetic sensors struggle to detect weak magnetic fields with high sensitivity due to the large size of the magnetic gap in annular magnetic cores, causing the leakage magnetic field to spread widely and reduce the magnetic component applied to the sensing element.
Innovation Solution
A magnetic sensor design integrating a sensor chip with magnetically coupled first and second magnetic layers and a magnetic sensing element, along with external magnetic members and measuring current coils, allows for a compact magnetic gap and concentrated magnetic field application to the sensing element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a large magnetic gap is formed in the annular magnetic core, then the structure is easier to manufacture and assemble, but the leakage magnetic field spreads widely reducing measurement precision
Solution Approach 1:
The patent transitions from a planar annular magnetic core to a three-dimensional structure with stacked magnetic cores and integrated magnetic sensing elements. By adding the vertical dimension and integrating the sensing elements within the magnetic gap space, the design achieves a small effective magnetic gap while maintaining manufacturability through modular stacking of core layers.
Solution Approach 2:
The magnetic sensing element is nested within the magnetic gap formed by the stacked magnetic cores. The sensing element is positioned inside the hollow cylindrical space created by the annular cores, allowing the magnetic field to be concentrated at the sensing element location while the overall structure remains compact and manufacturable.
2Measurement precision
If a small magnetic gap is formed to concentrate the magnetic field, then measurement precision improves, but the manufacturing difficulty increases
Solution Approach 1:
The magnetic core is segmented into multiple stacked annular layers, each contributing to the overall magnetic circuit. This segmentation allows the small magnetic gap to be achieved through precise layer stacking rather than requiring a single complex component, thereby improving manufacturability while maintaining the concentrated magnetic field necessary for high measurement precision.
Solution Approach 2:
The annular magnetic cores serve multiple functions: they provide the magnetic circuit path, create the magnetic gap structure, and support the winding of measuring current coils. This multi-functionality reduces the number of separate components needed, simplifying manufacturing while achieving the small magnetic gap required for high precision measurement.
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 design enables detection of weak magnetic fields with high sensitivity by efficiently applying leakage magnetic fields to the sensing element, even when the current is weak.
Implementation Method 1
a magnetic sensor that detects a magnetic field generated by a current for generating a weak magnetic field to be measured
Implementation Method 2
a sensor chip having first and second magnetic layers magnetically coupled to each other through a magnetic gap
Data Source
AI summary
A magnetic sensor includes: a sensor chip having magnetic layers magnetically coupled to each other through a magnetic gap and a magnetic sensing element disposed on a magnetic path formed by the magnetic gap; an external magnetic member magnetically coupled to one of the magnetic layer 21; and a measuring current coil wound around the external magnetic member and through which a current for generating a magnetic field to be measured flows. The magnetic sensing element 31 and the magnetic layers are thus integrated in the sensor chip, so that the magnetic gap can be designed to be very small in width, and a leakage magnetic field can be applied in large amounts to the magnetic sensing element. Thus, even when the current I flowing in the measuring current coil is weak, a magnetic field generated by the current I can be detected with high sensitivity.