Magnetic Sensor Shield Structure to Prevent Insulating Layer Cracks

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Solution Overview

Problem

The increase in thickness of magnetic layers in magnetic sensors leads to increased thickness of insulating layers, which are prone to cracking during manufacturing, thereby increasing the number of manufacturing steps and costs.

Innovation Solution

The use of a surrounding layer made of an organic or glass material that covers the side surfaces of the magnetic layer, positioned closer to the first surface than the second surface, allowing for a larger magnetic layer thickness without the need for multiple formations, thus reducing manufacturing steps and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the thickness of the magnetic layer is increased to achieve desired magnetic sensor characteristics, then the magnetic layer provides better magnetic shielding and yoke functionality, but the thickness of the insulating layer increases, making it prone to cracking during manufacturing

Engineering Contradiction:

Improvemagnetic shielding performanceVSAvoidinsulating layer crack resistance

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent divides the magnetic layer into multiple thinner layers (first magnetic layer and second magnetic layer) separated by a nonmagnetic layer. This segmentation allows each layer to be thinner and less prone to cracking while collectively providing the required magnetic shielding performance. The insulating layer thickness is reduced for each segment, preventing cracks during manufacturing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses a composite structure combining magnetic layers with nonmagnetic layers. The nonmagnetic layer has lower magnetic permeability than the magnetic layers, creating a composite structure that maintains magnetic shielding effectiveness while allowing thinner overall insulating layers, thus preventing cracks during manufacturing.

Inventive Principle:

Principle #40Composite materials

2Reliability

If the thickness of the magnetic layer is increased to achieve desired characteristics, then magnetic shielding and yoke functionality are improved, but the number of manufacturing steps increases when forming multiple thin layers, leading to higher costs

Engineering Contradiction:

Improvemagnetic layer performanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines multiple magnetic layers and nonmagnetic layers into a single integrated magnetic shielding structure. This merging approach allows the entire magnetic shielding function to be achieved in one manufacturing step rather than requiring multiple separate steps to form individual thin layers, thereby reducing manufacturing complexity and cost while maintaining performance.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If multiple thin magnetic layers are formed to prevent insulating layer cracking, then crack resistance is improved, but the number of manufacturing steps increases, causing higher production costs

Engineering Contradiction:

Improveinsulating layer crack resistanceVSAvoidnumber of manufacturing steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent incorporates the nonmagnetic layer between the magnetic layers during the initial magnetic layer formation process. This preliminary action of including the nonmagnetic layer in the structure from the beginning allows subsequent insulating layers to be thinner and crack-resistant without requiring additional separate steps to prevent cracking, thus reducing overall manufacturing complexity.

Inventive Principle:

Principle #10Preliminary action

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 configuration enables the magnetic layer to be formed in a single step with a larger thickness, reducing manufacturing costs and minimizing the risk of insulating layer cracking.

Implementation Method 1

at least one magnetic detection element configured to detect a target magnetic field

Methodology Applied

Scientific EffectMagnetic field detection: Magnetic Field

Implementation Method 2

a yoke that converts the perpendicular magnetic field into a parallel magnetic field in the direction parallel to the surface of the substrate

Methodology Applied

Scientific EffectMagnetic field conversion: Magnetic Field

Implementation Method 3

a magnetic shield to selectively attenuate such another parallel magnetic field that is not a detection target

Methodology Applied

Scientific EffectMagnetic field attenuation: Magnetic Field

Data Source

PatentUS20250355067A1Magnetic sensor

Publication Date: 2025.11.20 TDK CORP

AI summary

A magnetic sensor includes: a magnetic detection element; a magnetic layer having a first surface and a second surface located opposite to each other in a reference direction and a side surface connecting the first surface and the second surface; and a surrounding layer that is formed of an organic material or a glass material and that is disposed entirely covering the side surface of the magnetic layer. The magnetic detection element is disposed at a position closer to the first surface than the second surface. The surrounding layer is not provided between the first surface of the magnetic layer and the magnetic detection element in the reference direction.