Inductance element for magnetic sensor and current sensor including the same

Patent metadata

Field	Value
Publication number	US-10884077-B2
Application number	US-201715725568-A
Country	US
Kind code	B2
Filing date	Oct 5, 2017
Priority date	Oct 19, 2016
Publication date	Jan 5, 2021
Grant date	Jan 5, 2021

Abstract

Disclosed herein is an inductance element for a magnetic sensor. The inductance element includes a first core comprising a first soft magnetic material and having first and second connecting surfaces, a second core comprising a second soft magnetic material different from the first soft magnetic material and having third and fourth connecting surfaces facing the first and second connecting surfaces, respectively, and a coil wound around the first core between the first and second connecting surfaces, wherein the first core is larger in magnetic field strength at which magnetic saturation occurs than the second core, and wherein the second core is higher in permeability than the first core and has at least partially a meander shape.

First claim

What is claimed is:

1. An inductance element for a magnetic sensor, the inductance element comprising:
a first core comprising a first soft magnetic material and having first and second connecting surfaces;
a second core comprising a second soft magnetic material different from the first soft magnetic material and having third and fourth connecting surfaces facing the first and second connecting surfaces, respectively; and
a coil wound around the first core between the first and second connecting surfaces,
wherein the first core is larger in magnetic field strength at which magnetic saturation occurs than the second core, and
wherein the second core is higher in permeability than the first core and comprises at least a portion that has a meander shape when viewed from a direction perpendicular to the first to fourth connecting surface, the at least portion of the second core having the meander shape comprising a plurality of alternately-arranged parts extending in different directions to define a plurality of voids therebetween that extend through an entire thickness of the second core, and
wherein the third and fourth connecting surfaces cover the first and second connecting surfaces, respectively, and wherein the meander shape is defined between the third and fourth connecting surfaces such that a magnetic flux along the plurality of alternately-arranged parts follows a meandering path that is narrower than either of the third and fourth surfaces, that begins between respective ends of the third connecting surface and that ends between respective ends of the fourth connecting surface.

2. The inductance element for a magnetic sensor as claimed in claim 1 , wherein the portion of the second core having the at least partially meander shape is positioned between the third and fourth connecting surfaces.

3. The inductance element for a magnetic sensor as claimed in claim 1 ,
wherein the second core has a closed magnetic path part positioned between the third and fourth connecting surfaces and a protruding part positioned on an opposite side to the closed magnetic path part when viewed from the third or fourth connecting surface, and
wherein the portion of the second core having the at least partially meander shape is at least one of the closed magnetic path part and the protruding part.

4. The inductance element for a magnetic sensor as claimed in claim 1 ,
wherein the first core is a drum-shaped core having a winding core part around which the coil is wound and first and second flange parts provided respectively on both sides of the winding core part in an axial direction,
wherein the first flange part has a first terminal electrode connected with one end of the coil,
wherein the second flange part has a second terminal electrode connected with other end of the coil,
wherein a surface of the first flange part parallel to the axial direction constitutes the first connecting surface, and
wherein a surface of the second flange part parallel to the axial direction constitutes the second connecting surface.

5. The inductance element for a magnetic sensor as claimed in claim 1 , wherein the second core has a layered structure in a thickness direction.

6. The inductance element for a magnetic sensor as claimed in claim 1 , wherein the first and second cores are positioned relative to each other without an intervention of an adhesive.

7. The inductance element for a magnetic sensor as claimed in claim 6 , further comprising a support member for positioning the second core relative to the first core,
wherein the support member has an adhesive surface in which a concave part for housing the second core is formed, and
wherein the adhesive surface of the support member is adhered to the first and second connecting surfaces of the first core, whereby the second core is positioned, sandwiched between the concave part of the support member and the first core.

8. The inductance element for a magnetic sensor as claimed in claim 1 , wherein the first soft magnetic material is ferrite and the second soft magnetic material is amorphous magnetic metal.

9. The inductance element for a magnetic sensor as claimed in claim 1 , wherein the portion of the second core having the at least partially meander shape is configured such that a length of a magnetic path along a closed magnetic path part of the second core is longer than a linear distance between the first and second connecting surfaces.

10. An apparatus comprising:
a drum-shaped core including a winding core part and first and second flange parts provided respectively on both sides of the winding core part in a first direction;
a meander-shaped core stacked on the drum-shaped core in a second direction perpendicular to the first direction, the meander-shaped core including a first end connected to the first flange part and a second end connected to the second flange part; and
a coil wound around the winding core part,
wherein the meander-shaped core defines a plurality of pairs of facing surfaces that are separated from each other by respective voids that extend through an entire thickness of the second core such that a magnetic path length of the meander-shaped core between the first and second ends is greater than a direct distance between the first and second flange parts,
wherein the meander-shaped core covers the first and second flange parts, and wherein the meander-shape core causes a magnetic flux to be constrained along the plurality of alternately-arranged parts and to follow a meandering path that is narrower than either of the first and second flange parts, that begins between respective ends of the first flange part and that ends between respective ends of the second flange part.

11. The apparatus as claimed in claim 10 ,
wherein the meander-shaped core further includes first and second sections located between the first and second ends,
wherein the first section extends in the first direction, and
wherein the second section extends in a third direction.

12. The apparatus as claimed in claim 11 , wherein the first direction is substantially parallel with an axial direction of the drum-shaped core.

13. The apparatus as claimed in claim 10 ,
wherein the meander-shaped core further includes a plurality of first sections and a plurality of second sections located between the first and second ends,
wherein each of the first sections extends in the first direction, and
wherein each of the second sections extends in a third direction.

14. The apparatus as claimed in claim 13 , wherein the first and second sections are alternately arranged between the first and second ends.

15. The apparatus as claimed in claim 14 , wherein adjacent two of the first sections are connected to one of the second sections such that magnetic flux flows opposite directions in the two of the first sections.

16. The apparatus as claimed in claim 10 , wherein the meander-shaped core has higher permeability than the drum-shaped core.

17. The apparatus as claimed in claim 16 , wherein the drum-shaped core is larger in magnetic field strength at which magnetic saturation occurs than the meander-shaped core.

Assignees

• Tdk Corp

Inventors

• Hamamura Takahiro
• Osada Takashi
• Kami Masafumi
• Lo Adrian

Classifications

• G01R33/04 Primary

  using the flux-gate principle · CPC title

• G01R15/186

  using current transformers with a core consisting of two or more parts, e.g. clamp-on type (G01R15/142 - G01R15/16 take precedence; tong testers G01R1/22) · CPC title

• H01F17/045

  with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core · CPC title

• H01F1/14

  metals or alloys · CPC title

• G01R15/185

  with compensation or feedback windings or interacting coils, e.g. 0-flux sensors (using galvano-magnetic field sensors G01R15/20; conversion of DC into AC using transductors G01R19/20) · CPC title