Patent Description:
There is known a magnetic sensor of a type having a compensation coil for canceling magnetic flux to be applied to a magneto-sensitive element to perform closed loop control. For example, a magnetic sensor described in Patent Document <NUM> has a magneto-sensitive element, a magnetic shield that shields a magnetic field to be measured, and a compensation coil disposed between the magnetic shield and the magneto-sensitive element. The magnetic shield plays a role of attenuating a magnetic field to be applied to the magneto-sensitive element, whereby it is possible to reduce a current to flow in the compensation coil even when a magnetic field to be measured is strong. Further magnetic sensors are described in Patent Documents <NUM> to <NUM>.

However, in the magnetic sensor described in Patent Document <NUM>, a magnetic field to be measured is attenuated by the magnetic shield, so that when the magnetic field to be measured is weak, measurement thereof becomes difficult.

It is therefore an object of the present invention to provide a magnetic sensor capable of detecting a magnetic field to be measured through closed loop control even when the magnetic field is weak.

A magnetic sensor according to the present invention is defined in appended claim <NUM> and includes, inter alia, first and second magnetic layers opposed to each other through a first magnetic gap, a first magneto-sensitive element disposed on a magnetic path formed by the first magnetic gap, and a compensation coil for canceling magnetic flux to be applied to the first magneto-sensitive element.

According to the present invention, magnetic flux flowing in the first and second magnetic layers each functioning as a yoke is applied to the magneto-sensitive element, so that even when a magnetic field to be measured is weak, it can be detected. In addition, closed loop control can be performed due to the presence of the compensation coil that cancels magnetic flux.

In the present invention, the first magnetic layer may is disposed at a position overlapping the inner diameter area of the compensation coil in a plan view, and the second magnetic layer is be disposed at a position overlapping the outside area of the compensation coil in a plan view. With this configuration, a canceling magnetic field directed from the first magnetic layer to the second magnetic layer through the first gap, or directed from the second magnetic layer to the first magnetic layer through the first magnetic gap can be generated.

The magnetic sensor according to the present invention further includes an external magnetic member that collects external magnetic flux to be measured in the first magnetic layer. This allows the external magnetic flux to be collected efficiently in the first magnetic layer.

The magnetic senor according to the present invention further includes a third magnetic layer opposed to the first magnetic layer through a second magnetic gap and a second magneto-sensitive element disposed on a magnetic path formed by the second magnetic gap, the compensation coil cancels magnetic flux to be applied to the second magneto-sensitive element, and the third magnetic layer is disposed at a position overlapping the outside area of the compensation coil in a plan view. With this configuration, magnetic fields in opposite directions are given to the first and second magneto-sensitive elements, so that it is possible to achieve higher detection sensitivity by bridge-connecting the first and second magneto-sensitive elements.

In the present invention, the first to third magnetic layers, the first and second magneto-sensitive elements, and the compensation coil are all provided on a sensor substrate. With this configuration, it is possible to constitute a magnetic sensor having high detection sensitivity simply by disposing the external magnetic member on the sensor substrate.

In the present invention, the first and second magneto-sensitive elements may be formed between the compensation coil and the first to third magnetic layers in the lamination direction on the sensor substrate. With this configuration, it is possible to reduce the distance between the first to third magnetic layers and the first and second magneto-sensitive elements, and to reduce the size of the magnetic gap formed between the external magnetic member and the first magnetic layer.

In the present invention, the first to third magnetic layers may be formed between the compensation coil and the first and second magneto-sensitive elements in the lamination direction on the sensor substrate. With this configuration, it is possible to reduce the distance between the first to third magnetic layers and the first and second magneto-sensitive elements, and to reduce the distance between the compensation coil and the first to third magnetic layers, allowing a current flowing in the compensation coil to be further reduced.

In the present invention, the compensation coil may be wound over a plurality of wiring layers on the sensor substrate. With this configuration, it is possible to enhance the freedom of the layout of a conductor pattern constituting the compensation coil.

As described above, according to the present invention, it is possible to detect a magnetic field to be measured with high sensitivity through closed loop control even when the magnetic field is weak.

Preferred embodiments of the present invention will be explained below in detail with reference to the accompanying drawings.

<FIG> is a schematic plan view for explaining the structure of a magnetic sensor <NUM> according to a preferred embodiment of the present invention. <FIG> is a schematic cross-sectional view taken along line A-A in <FIG>.

As illustrated in <FIG>, the magnetic sensor <NUM> according to the present embodiment has a sensor substrate <NUM> and external magnetic members <NUM> to <NUM>. The sensor substrate <NUM> is a chip component having a substantially rectangular parallelepiped shape. On an element formation surface 20a of the sensor substrate <NUM>, magneto-sensitive elements R1 to R4, magnetic layers <NUM> to <NUM>, terminal electrodes <NUM> to <NUM>, and a compensation coil <NUM> are provided. The terminal electrodes <NUM> to <NUM> are connected to a not-shown circuit board through, e.g., a bonding wire.

In the present embodiment, the compensation coil <NUM>, the magneto-sensitive elements R1 to R4, and the magnetic layers <NUM> to <NUM> are stacked in this order on the element formation surface 20a. The compensation coil <NUM> and the magneto-sensitive elements R1 to R4 are isolated by an insulating film <NUM>, and the magneto-sensitive elements R1 to R4 and the magnetic layers <NUM> to <NUM> are isolated by an insulating film <NUM>.

The external magnetic members <NUM> to <NUM> are each a block made of a soft magnetic material having a high permeability, such as ferrite. The external magnetic member <NUM> is disposed at substantially the center of the element formation surface 20a and has a shape protruding in the z-direction. The external magnetic members <NUM> and <NUM> are disposed on both sides of the sensor substrate <NUM> in the x-direction and each have a tip end bent in an L-shape to cover the element formation surface 20a.

The first to third magnetic layers <NUM> to <NUM> are formed on the insulating film <NUM> of the sensor substrate <NUM>. The first magnetic layer <NUM> is positioned at substantially the center of the element formation surface 20a, and the second and third magnetic layers <NUM> and <NUM> are disposed on both sides of the first magnetic layer <NUM> in the x-direction. Although not particularly restricted, the magnetic layers <NUM> to <NUM> may each be a film made of a composite magnetic material obtained by dispersing magnetic filler in a resin material, may be a thin film or a foil made of a soft magnetic material such as nickel or permalloy, or may be a thin film or a bulk sheet made of ferrite.

The first magnetic layer <NUM> is positioned at the center and includes a main area M1 covered with the external magnetic member <NUM> and convergence areas S1 to S4 whose widths in the y-direction are reduced with increasing distance from the main area M1 in the x-direction. As illustrated in <FIG>, the convergence areas S1 and S3 are positioned at the negative side (left side) in the x-direction with respect to the main area M1, and the convergence areas S2 and S4 are positioned at the positive side (right side) in the x-direction with respect to the main area M1. The first magnetic layer <NUM> and the external magnetic member <NUM> may contact each other directly or through a thin insulating film or an adhesive layer.

The second magnetic layer <NUM> includes a main area M2 covered with the external magnetic member <NUM> and convergence areas S5 and S7 whose widths in the y-direction are reduced with increasing distance from the main area M2 in the x-direction (positive side). Similarly, the third magnetic layer <NUM> includes a main area M3 covered with the external magnetic member <NUM> and convergence areas S6 and S8 whose widths in the y-direction are reduced with increasing distance from the main area M3 in the x-direction (negative side).

The external magnetic member <NUM> plays a role of capturing z-direction external magnetic flux. The magnetic flux captured through the external magnetic member <NUM> enters the main area M1 of the first magnetic layer <NUM> and is then distributed to the convergence areas S1 to S4 substantially evenly. The magnetic fluxes that have reached the convergence areas S1 to S4 are supplied to the convergence areas S5 to S8 respectively through their corresponding magnetic gaps G1 to G4 extending in the y-direction. The magnetic fluxes that have reached the convergence areas S5 and S7 are collected by the external magnetic member <NUM> through the main area M2. Similarly, the magnetic fluxes that have reached the convergence areas S6 and S8 are collected by the external magnetic member <NUM> through the main area M3.

As illustrated in <FIG>, the magneto-sensitive elements R1 to R4 elongated in the y-direction are disposed respectively on magnetic paths formed by the magnetic gaps G1 to G4. The magneto-sensitive elements R1 to R4 may be disposed in the magnetic gaps G1 to G4; alternatively, they may be disposed outside the magnetic gaps G1 to G4 as long as they are each positioned within the magnetic path formed by the magnetic gap. Further, the width direction of each of the magnetic gaps G1 to G4 may be the x-direction; alternatively, it may have a z-direction component as long as magnetic flux having an x-direction component can be applied to each of the magneto-sensitive elements R1 to R4.

While there is no particular restriction on the magneto-sensitive elements R1 to R4 as long as they are elements whose physical property changes depending on a magnetic flux density, they are preferably magneto-resistive elements whose electric resistance changes according to the direction of a magnetic field. In the present embodiment, the magneto-sensitive directions (fixed magnetization directions) of the magneto-sensitive elements R1 to R4 are all oriented in a direction (positive x-direction) denoted by the arrow P in <FIG>.

With the above configuration, the magnetic flux collected in the main area M1 of the first magnetic layer <NUM> through the external magnetic member <NUM> is distributed substantially evenly through the magneto-sensitive elements R1 to R4. Thus, magnetic fluxes in mutually opposite directions are given to the side of the magneto-sensitive elements R1 and R3 and the side of the magneto-sensitive elements R2 and R4. As described above, the fixed magnetization directions of the magneto-sensitive elements R1 to R4 are all oriented in the positive x-direction denoted by the arrow P, so that they have sensitivity with respect to an x-direction component of the magnetic flux.

Further, the compensation coil <NUM> is provided below the magneto-sensitive elements R1 to R4. The compensation coil <NUM> cancels the magnetic flux to be applied to the magneto-sensitive elements R1 to R4 and is used for closed loop control.

<FIG> is a schematic plan view for explaining the shape of the compensation coil <NUM>.

As illustrated in <FIG>, the compensation coil <NUM> is constituted by a conductor pattern having five turns and includes conductor patterns <NUM> and <NUM> extending in the y-direction and conductor patterns <NUM> and <NUM> extending in the x-direction. One end of the compensation coil <NUM> is connected to the terminal electrode <NUM>, and the other end thereof is connected to the terminal electrode <NUM>. The number of the turns of the compensation coil <NUM> is not limited to five.

The positional relationship between the compensation coil <NUM> and the first to third magnetic layers <NUM> to <NUM> in a plan view is as illustrated in <FIG>. That is, the first magnetic layer <NUM> is disposed at a position overlapping an inner diameter area 60a of the compensation coil <NUM> in a plan view, the second and third magnetic layers <NUM> and <NUM> are each disposed at a position overlapping the outside area of the compensation coil <NUM> in a plan view. The magnetic gaps G1 and G3 and the magneto-sensitive elements R1 and R3 are each disposed at a position overlapping the conductor pattern <NUM> of the compensation coil <NUM> in a plan view, and the magnetic gaps G2 and G4 and the magneto-sensitive elements R2 and R4 are each disposed at a position overlapping the conductor pattern <NUM> of the compensation coil <NUM> in a plan view.

<FIG> is a circuit diagram for explaining the connection relationship between the terminal electrodes <NUM> to <NUM>, the magneto-sensitive elements R1 to R4, and the compensation coil <NUM>.

As illustrated in <FIG>, the magneto-sensitive element R1 is connected between the terminal electrodes <NUM> and <NUM>, the magneto-sensitive element R2 is connected between the terminal electrodes <NUM> and <NUM>, the magneto-sensitive element R3 is connected between the terminal electrodes <NUM> and <NUM>, and the magneto-sensitive element R4 is connected between the terminal electrodes <NUM> and <NUM>. The terminal electrode <NUM> is applied with a power source potential Vcc, and the terminal electrode <NUM> is applied with a ground potential GND. Since the magneto-sensitive elements R1 to R4 have the same fixed magnetization direction, a difference is generated between a resistance variation of the magneto-sensitive elements R1 and R3 positioned on one side as viewed from the external magnetic member <NUM> and a resistance variation of the magneto-sensitive elements R2 and R4 positioned on the other side as viewed from the external magnetic member <NUM>. As a result, the magneto-sensitive elements R1 to R4 constitute a differential bridge circuit, and a change in electric resistance of the magneto-sensitive elements R1 to R4 according to a magnetic flux density appears in the terminal electrodes <NUM> and <NUM>.

Differential signals output from the terminal electrodes <NUM> and <NUM> are input to a differential amplifier <NUM> provided on a mounting substrate on which the magnetic sensor <NUM> according to the present embodiment is mounted. An output signal from the differential amplifier <NUM> is fed back to the terminal electrode <NUM>. As illustrated in <FIG>, the compensation coil <NUM> is connected between the terminal electrodes <NUM> and <NUM> and thus generates a canceling magnetic field according to the output signal from the differential amplifier <NUM>. Thus, when a change in electric resistance of the magneto-sensitive elements R1 to R4 according to the magnetic flux density of the external magnetic flux appears in the terminal electrodes <NUM> and <NUM>, a current corresponding to the electric resistance change flows in the compensation coil <NUM> to generate magnetic flux in the opposite direction, whereby the external magnetic flux is canceled. Then, by converting the current output from the differential amplifier <NUM> into voltage using a detection circuit <NUM>, the strength of the external magnetic flux can be detected.

<FIG> is a schematic view for explaining the relationship between the external magnetic flux and the cancelling magnetic flux.

In the example of <FIG>, an external magnetic flux φ1 in the z-direction is captured in the external magnetic member <NUM> and is then distributed to the left and right sides through the magnetic layer <NUM>. A magnetic flux φ2 distributed to the left side flows in the second magnetic layer <NUM> through the magnetic gaps G1 and G3, and a magnetic flux φ3 distributed to the right side flows in the third magnetic layer <NUM> through the magnetic gaps G2 and G4. At this time, a part of the magnetic flux φ2 that flows through the magnetic gaps G1 and G3 is applied to the magneto-sensitive elements R1 and R3, and a part of the magnetic flux φ3 that flows through the magnetic gaps G2 and G4 is applied to the magneto-sensitive elements R2 and R4. Thus, as described using <FIG>, a potential difference appears between the terminal electrodes <NUM> and <NUM> by the differential bridge circuit constituted by the magneto-sensitive elements R1 to R4.

The potential difference between the terminal electrodes <NUM> and <NUM> is fed back to the terminal electrode <NUM>, whereby a current flows in the compensation coil <NUM>. In the example of <FIG>, a cancelling magnetic flux φ4 rotating clockwise around the conductor pattern <NUM> of the compensation coil <NUM> and a cancelling magnetic flux φ5 rotating counterclockwise around the conductor pattern <NUM> of the compensation coil <NUM> are generated. The cancelling magnetic flux φ4 flows from the second magnetic layer <NUM> to the first magnetic layer <NUM> through the magnetic gaps G1 and G3 to cancel the external magnetic flux φ2. The cancelling magnetic flux φ5 flows from the third magnetic layer <NUM> to the first magnetic layer <NUM> through the magnetic gaps G2 and G4 to cancel the external magnetic flux φ3.

Since the external magnetic flux φ1 captured in the external magnetic member <NUM> is canceled through such closed loop control, it is possible to detect the strength of the external magnetic flux φ1 by monitoring a current flowing in the compensation coil <NUM>, i.e., a voltage appearing in the detection circuit <NUM>.

In the present embodiment, the compensation coil <NUM>, magneto-sensitive elements R1 to R4, and the magnetic layers <NUM> to <NUM> are stacked in this order on the sensor substrate <NUM>, so that it is possible to reduce the distance between the magnetic layers <NUM> to <NUM> and the magneto-sensitive elements R1 to R4 in the z-direction. This allows the magnetic fluxes passing through the magnetic gaps G1 to G4 to be applied efficiently to the magneto-sensitive elements R1 to R4, thereby achieving high detection sensitivity. In addition, the size of the magnetic gap formed between the external magnetic member <NUM> and the first magnetic layer <NUM> can be reduced, thereby allowing the external magnetic flux φ1 captured in the external magnetic member <NUM> to be supplied efficiently to the first magnetic layer <NUM>.

As described above, in the magnetic sensor <NUM> according to the present embodiment, the magneto-sensitive elements R1 to R4 are disposed respectively on the magnetic paths formed by the magnetic gaps G1 to G4, so that even a magnetic field to be measured is weak, it can be detected with high sensitivity. In addition, not only the magneto-sensitive elements R1 to R4 and magnetic layers <NUM> to <NUM>, but also the compensation coil <NUM> is provided on the sensor substrate <NUM>, so that it is possible to constitute a magnetic sensor having high detection sensitivity simply by disposing the external magnetic member <NUM> on the sensor substrate <NUM>.

<FIG> is a schematic cross-sectional view illustrating the configuration of the main part of a magnetic sensor <NUM> according to a first modification.

The magnetic sensor <NUM> illustrated in <FIG> differs from the magnetic sensor <NUM> according to the above embodiment in that the compensation coil <NUM> is wound over a plurality wiring layers. Specifically, the compensation coil <NUM> is constituted by a conductor pattern 60A of the lower layer and a conductor pattern 60B of the upper layer. The conductor pattern 60A in the lower layer is covered with an insulating film <NUM>, the conductor pattern 60B in the upper layer is covered with an insulating film <NUM>, and the magneto-sensitive elements R1 to R4 are covered with an insulating film <NUM>. With this configuration, it is possible to enhance the freedom of the layout of the conductor pattern constituting the compensation coil <NUM>. For example, as illustrated in <FIG>, when the conductor pattern 60A in the lower layer and the conductor pattern 60B in the upper layer are wound in mutually opposite directions, and the inner peripheral ends thereof are connected to each other, it is possible to easily connect both ends of the compensation coil <NUM> to the terminal electrodes <NUM> and <NUM>, respectively. In the example illustrated in <FIG>, when a current is made to flow from the terminal electrode <NUM> to the terminal electrode <NUM>, the current flows counterclockwise; however, as in the example illustrated in <FIG>, the compensation coil <NUM> may be wound such that a current flows clockwise.

<FIG> is a schematic cross-sectional view illustrating the configuration of the main part of a magnetic sensor <NUM> according to a second modification.

The magnetic sensor <NUM> illustrated in <FIG> differs from the magnetic sensor <NUM> according to the first modification in that the magneto-sensitive elements R1 to R4 are positioned between the conductor pattern 60A of the lower layer and the conductor pattern 60B of the upper layer. The conductor pattern 60A of the lower layer is covered with the insulating film <NUM>, the magneto-sensitive elements R1 to R4 are covered with the insulating film <NUM>, and the conductor pattern 60B of the upper layer is covered with the insulating film <NUM>. When the compensation coil <NUM> is thus wound over a plurality of wiring layers, the magneto-sensitive elements R1 to R4 may be sandwiched by the compensation coil <NUM> in the stacking direction.

<FIG> is a schematic cross-sectional view illustrating the configuration of the main part of a magnetic sensor <NUM> according to a third modification.

The magnetic sensor <NUM> illustrated in <FIG> differs from the magnetic sensor <NUM> according to the above embodiment in that the positional relationship between the magneto-sensitive elements R1 to R4 and the magnetic layers <NUM> to <NUM> is reversed. The compensation coil <NUM> is covered with the insulating film <NUM>, the magnetic layers <NUM> to <NUM> are covered with the insulating film <NUM>, and the magneto-sensitive elements R1 to R4 are covered with the insulating film <NUM>. With this configuration, the distance between the compensation coil <NUM> and the magnetic layers <NUM> to <NUM> in the z-direction can be reduced, thereby allowing a current flowing in the compensation coil <NUM> to be further reduced.

Claim 1:
A magnetic sensor (<NUM>) comprising:
first and second magnetic layers (<NUM>, <NUM>) opposed to each other through a first magnetic gap (G1);
a third magnetic layer (<NUM>) opposed to the first magnetic layer (<NUM>) through a second magnetic gap (G2);
a first magneto-sensitive element (R1) disposed on a magnetic path formed by the first magnetic gap (G1);
a second magneto-sensitive element (R2) disposed on a magnetic path formed by the second magnetic gap (G2);
an external magnetic member (<NUM>) that collects external magnetic flux to be measured in the first magnetic layer (<NUM>); and
a compensation coil (<NUM>) for canceling magnetic flux to be applied to the first and second magneto-sensitive elements (R1, R2),
characterized in that
the first magnetic layer (<NUM>) is disposed at a position overlapping an inner diameter area of the compensation coil (<NUM>) in a plan view,
the second and third magnetic layers (<NUM>, <NUM>) are disposed at a position overlapping an outside area of the compensation coil (<NUM>) in a plan view,
the first to third magnetic layers (<NUM>, <NUM>, <NUM>), the first and second magneto-sensitive elements (R1, R2), and the compensation coil (<NUM>) are all provided on a sensor substrate (<NUM>),
the first and second magneto-sensitive elements (R1, R2) are formed between the compensation coil (<NUM>) and the first to third magnetic layers (<NUM>, <NUM>, <NUM>) in a lamination direction on the sensor substrate (<NUM>), and
each of the first and second magneto-sensitive elements (R1, R2) overlaps the compensation coil (<NUM>) in a plan view.