WO2022015685A1 - Integrated current sensor with magnetic flux concentrators - Google Patents

Integrated current sensor with magnetic flux concentrators Download PDF

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Publication number
WO2022015685A1
WO2022015685A1 PCT/US2021/041364 US2021041364W WO2022015685A1 WO 2022015685 A1 WO2022015685 A1 WO 2022015685A1 US 2021041364 W US2021041364 W US 2021041364W WO 2022015685 A1 WO2022015685 A1 WO 2022015685A1
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WO
WIPO (PCT)
Prior art keywords
hall effect
magnetic concentrator
magnetic
effect sensor
current
Prior art date
Application number
PCT/US2021/041364
Other languages
French (fr)
Inventor
Dok Won Lee
Jo Bito
Keith Ryan Green
Original Assignee
Texas Instruments Incorporated
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Texas Instruments Incorporated filed Critical Texas Instruments Incorporated
Priority to JP2023503139A priority Critical patent/JP2023534971A/en
Priority to EP21841550.3A priority patent/EP4182707A4/en
Priority to CN202180049881.4A priority patent/CN115917332A/en
Publication of WO2022015685A1 publication Critical patent/WO2022015685A1/en

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Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R15/00—Details of measuring arrangements of the types provided for in groups G01R17/00 - G01R29/00, G01R33/00 - G01R33/26 or G01R35/00
    • G01R15/14—Adaptations providing voltage or current isolation, e.g. for high-voltage or high-current networks
    • G01R15/20—Adaptations providing voltage or current isolation, e.g. for high-voltage or high-current networks using galvano-magnetic devices, e.g. Hall-effect devices, i.e. measuring a magnetic field via the interaction between a current and a magnetic field, e.g. magneto resistive or Hall effect devices
    • G01R15/207—Constructional details independent of the type of device used
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R15/00—Details of measuring arrangements of the types provided for in groups G01R17/00 - G01R29/00, G01R33/00 - G01R33/26 or G01R35/00
    • G01R15/14—Adaptations providing voltage or current isolation, e.g. for high-voltage or high-current networks
    • G01R15/20—Adaptations providing voltage or current isolation, e.g. for high-voltage or high-current networks using galvano-magnetic devices, e.g. Hall-effect devices, i.e. measuring a magnetic field via the interaction between a current and a magnetic field, e.g. magneto resistive or Hall effect devices
    • G01R15/202—Adaptations providing voltage or current isolation, e.g. for high-voltage or high-current networks using galvano-magnetic devices, e.g. Hall-effect devices, i.e. measuring a magnetic field via the interaction between a current and a magnetic field, e.g. magneto resistive or Hall effect devices using Hall-effect devices
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00—Details of semiconductor or other solid state devices
    • H01L23/48—Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor
    • H01L23/488—Arrangements for conducting electric current to or from the solid state body in operation, e.g. leads, terminal arrangements ; Selection of materials therefor consisting of soldered or bonded constructions
    • H01L23/495—Lead-frames or other flat leads
    • H01L23/49579—Lead-frames or other flat leads characterised by the materials of the lead frames or layers thereon
    • H01L23/49586—Insulating layers on lead frames
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N—ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N52/00—Hall-effect devices
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N—ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N52/00—Hall-effect devices
    • H10N52/80—Constructional details
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
    • H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
    • H01L2224/26—Layer connectors, e.g. plate connectors, solder or adhesive layers; Manufacturing methods related thereto
    • H01L2224/31—Structure, shape, material or disposition of the layer connectors after the connecting process
    • H01L2224/32—Structure, shape, material or disposition of the layer connectors after the connecting process of an individual layer connector
    • H01L2224/321—Disposition
    • H01L2224/32151—Disposition the layer connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive
    • H01L2224/32221—Disposition the layer connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked
    • H01L2224/32245—Disposition the layer connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being metallic
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
    • H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
    • H01L2224/42—Wire connectors; Manufacturing methods related thereto
    • H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
    • H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
    • H01L2224/4805—Shape
    • H01L2224/4809—Loop shape
    • H01L2224/48091—Arched
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
    • H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
    • H01L2224/42—Wire connectors; Manufacturing methods related thereto
    • H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
    • H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
    • H01L2224/481—Disposition
    • H01L2224/48151—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive
    • H01L2224/48221—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked
    • H01L2224/48245—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being metallic
    • H01L2224/48247—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being metallic connecting the wire to a bond pad of the item
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
    • H01L2224/73—Means for bonding being of different types provided for in two or more of groups H01L2224/10, H01L2224/18, H01L2224/26, H01L2224/34, H01L2224/42, H01L2224/50, H01L2224/63, H01L2224/71
    • H01L2224/732—Location after the connecting process
    • H01L2224/73251—Location after the connecting process on different surfaces
    • H01L2224/73265—Layer and wire connectors
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10B—ELECTRONIC MEMORY DEVICES
    • H10B61/00—Magnetic memory devices, e.g. magnetoresistive RAM [MRAM] devices
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N—ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N59/00—Integrated devices, or assemblies of multiple devices, comprising at least one galvanomagnetic or Hall-effect element covered by groups H10N50/00 - H10N52/00

Definitions

  • Open-loop current sensing provides a cost- effective solution in which a magnetic field generated by the flow of current through an electrical conductor is concentrated inside a magnetic core, and a magnetic sensor measures the field and provides an output signal used for estimating the current flow.
  • Open-loop approaches typically consume little power, and can use low sensitivity sensors for measuring high currents.
  • a packaged current sensor in a current sensor that provides high voltage isolation and immunity from stray magnetic fields, includes a lead frame, an integrated circuit, an isolation spacer, a first magnetic concentrator, and a second magnetic concentrator.
  • the lead frame includes a conductor.
  • the isolation spacer is between the lead frame and the integrated circuit.
  • the first magnetic concentrator is aligned with the conductor.
  • the second magnetic concentrator is aligned with the conductor.
  • a current sensor in another example, includes a lead frame, an integrated circuit, an isolation spacer, a first magnetic concentrator, and a second magnetic concentrator.
  • the lead frame includes a conductor.
  • the conductor includes a current input segment, and a current output segment.
  • the integrated circuit includes a Hall effect sensor.
  • the isolation spacer is between the lead frame and the integrated circuit.
  • the first magnetic concentrator is aligned with the current input segment and overlaps the Hall effect sensor.
  • the second magnetic concentrator is aligned with the current output segment.
  • a current sensor includes a lead frame, a first magnetic concentrator, a second magnetic concentrator, an integrated circuit, and an isolation spacer.
  • the lead frame includes a conductor.
  • the conductor includes a current input segment, and a current output segment.
  • the integrated circuit includes a first Hall effect sensor, a second Hall effect sensor, a third Hall effect sensor, and a fourth Hall effect sensor.
  • the isolation spacer is between the lead frame and the integrated circuit.
  • the first magnetic concentrator is formed as a metal layer on the integrated circuit, and overlaps the current input segment, the first Hall effect sensor, and the second Hall effect sensor.
  • the second magnetic concentrator is formed as a metal layer on the integrated circuit, and overlaps the current output segment, the third Hall effect sensor, and the fourth Hall effect sensor.
  • FIG. 1 shows a side view of a current sensor that includes a Hall effect sensor overlapping two magnetic concentrators.
  • FIG. 2 shows a top view of a current sensor that includes a Hall effect sensor overlapping two magnetic concentrators.
  • FIG. 3 shows a side view of a current sensor that includes four Hall effect sensors overlapping two magnetic concentrators.
  • FIG. 4 shows a top view of a current sensor that includes four Hall effect sensors overlapping two magnetic concentrators.
  • FIG. 5 shows magnetic fields in the magnetic concentrators of FIG. 3 with no stray magnetic field.
  • FIG. 6 shows magnetic fields in the magnetic concentrators of FIG. 3 with a stray magnetic field.
  • FIG. 7 shows a flow diagram for a method for fabricating a current sensor in accordance with this description.
  • the shortcomings of packaged current sensing circuits include limited voltage isolation between an integrated circuit (including a Hall effect sensor and/or other circuitry) and a current carrying conductor, and susceptibility to errors caused by a stray magnetic field.
  • the current sensors described herein include high-voltage isolation that protects the integrated circuit.
  • Some implementations of the current sensors also include an arrangement of magnetic concentrators and Hall effect sensors that provide immunity from errors due to stray magnetic fields.
  • FIG. 1 shows a side view of a current sensor 100 in accordance with this description.
  • the current sensor 100 includes a lead frame 102, an isolation spacer 104, an integrated circuit 106, a magnetic concentrator 108, and a magnetic concentrator 110.
  • the lead frame 102 includes a conductor 103 that carries a current to be measured.
  • the conductor 103 includes a current input leg/segment 103A through which current flows in to the current sensor 100 and a current output leg/segment 103B through which current flows out of the current sensor 100.
  • the isolation spacer 104 is disposed between the lead frame 102 and the integrated circuit 106 to isolate the integrated circuit 106 from high voltages that may be present on the conductor 103.
  • the isolation spacer 104 is formed of material having high dielectric strength, such as glass dielectric materials, polymer- based dielectric materials, or silicon-based dielectric materials. In some implementations of the current sensor 100, the isolation spacer 104 has a thickness of about 100-150 micrometers (um).
  • the integrated circuit 106 is a silicon die that includes a Hall effect sensor 112 formed thereon. The Hall effect sensor 112 is a horizontal Hall effect sensor. The integrated circuit 106 is disposed between the isolation spacer 104 and the magnetic concentrator 108 and magnetic concentrator 110. In some implementations, the integrated circuit 106 has a thickness of about 150- 250 um.
  • the integrated circuit 106 is coupled to the lead frame 102 by bond wires 114 for transfer of electrical signals between the lead frame 102 and the integrated circuit 106.
  • the magnetic concentrator 108 is aligned with and overlaps the current output leg/segment 103B to concentrate magnetic flux produced by current flow in the current output leg/segment 103B.
  • the magnetic concentrator 110 is aligned with and overlaps the current input leg/segment 103 A to concentrate magnetic flux produced by current flow in the current input leg/segment 103 A.
  • the magnetic flux about the magnetic concentrator 108 and the magnetic concentrator 110 is proportional to the current flowing in the current input leg/segment 103A and the current output leg/segment 103B.
  • the magnetic concentrators 108 and 110 are formed/deposited on the integrated circuit 106 by electroplating as part of wafer-level processing.
  • the magnetic concentrators 108 and 110 may be formed of soft magnetic material such as iron-nickel alloy.
  • the Hall effect sensor 112 is disposed between the magnetic concentrator 108 and the magnetic concentrator 110 and overlaps a portion of both the magnetic concentrator 108 and magnetic concentrator 110. For example, the Hall effect sensor 112 overlaps an edge 108 A of the magnetic concentrator 108 and an edge 110A of the magnetic concentrator 110.
  • the Hall effect sensor 112 detects the magnetic flux about the magnetic concentrator 108 and the magnetic concentrator 110, and based on the detected magnetic flux generates an output voltage proportional to the current flowing in the current input leg/segment 103A and the current output leg/segment 103B.
  • FIG. 2 shows a top view of the current sensor 100.
  • the conductor 103, the magnetic concentrator 108, the magnetic concentrator 110, and the Hall effect sensor 112 are shown in FIG. 2.
  • the conductor 103 is “U-shaped” or “horse-shoe-shaped.” In various implementations of the current sensor 100, the conductor 103 may have any shape.
  • the magnetic concentrator 108 overlaps the current output leg/segment 103B and the Hall effect sensor 112, and the magnetic concentrator 110 overlaps the current input leg/segment 103 A and the Hall effect sensor 112
  • FIG. 3 shows a side view of a current sensor 300 in accordance with this description.
  • the current sensor 300 includes a lead frame 302, an isolation spacer 304, an integrated circuit 306, a magnetic concentrator 308, and a magnetic concentrator 310.
  • the lead frame 302 includes a conductor 303 that carries a current to be measured.
  • the conductor 303 includes a current input leg/segment 303A through which current flows in to the current sensor 300 and a current output leg/segment 303B through which current flows out of the current sensor 300.
  • the isolation spacer 304 is disposed between the lead frame 302 and the integrated circuit 306 to isolate the integrated circuit 306 from high voltages that may be present on the conductor 303.
  • the isolation spacer 304 is formed of material having high dielectric strength, such as glass dielectric materials, polymer- based dielectric materials, or silicon-based dielectric materials. In some implementations, the isolation spacer 304 has a thickness of about 100-150 micrometers (um).
  • the integrated circuit 306 is a silicon die that includes, formed thereon, a Hall effect sensor 312, a Hall effect sensor 314, a Hall effect sensor 316, and a Hall effect sensor 318.
  • the Hall effect sensor 312, the Hall effect sensor 314, the Hall effect sensor 316, and the Hall effect sensor 318 are horizontal Hall effect sensors.
  • the integrated circuit 306 is disposed between the isolation spacer 304 and the magnetic concentrator 308 and magnetic concentrator 310. In some implementations, the integrated circuit 306 has a thickness of about 150-250 um.
  • the integrated circuit 306 is coupled to the lead frame 302 by bond wires 320 for transfer of electrical signals between the lead frame 302 and the integrated circuit 306.
  • the magnetic concentrator 308 is aligned with and overlaps the current output leg/segment 303B to concentrate magnetic flux produced by current flow in the current output leg/segment 303B.
  • the magnetic concentrator 310 is aligned with and overlaps the current input leg/segment 303 A to concentrate magnetic flux produced by current flow in the current input leg/segment 303 A.
  • the magnetic flux about the magnetic concentrator 308 and the magnetic concentrator 310 is proportional to the current flowing in the current input leg/segment 303A and the current output leg/segment 303B.
  • the magnetic concentrator 308 and the magnetic concentrator 310 may be provided in the form of a circular magnetic disk, an octagonal magnetic disk, an elliptical magnetic disk, a polygonal magnetic disk, etc. of soft magnetic material such as iron-nickel alloy.
  • the magnetic concentrators 308 and 310 are formed/deposited on the integrated circuit 306 by electroplating as part of wafer-level processing.
  • the alignment of the magnetic concentrators 308 and 310 and the Hall effect sensors 312-318 is precisely controlled.
  • the Hall effect sensor 312 is disposed to overlap an edge 308A of the magnetic concentrator 308.
  • the Hall effect sensor 314 is disposed to overlap the edge of the magnetic concentrator 308 opposite the Hall effect sensor 312.
  • the Hall effect sensor 312 and the Hall effect sensor 314 detect the magnetic flux about the magnetic concentrator 308, and based on the detected magnetic flux generate output voltages proportional to the current flowing in the current output leg/segment 303B.
  • the Hall effect sensor 316 is disposed to overlap an edge 310A of the magnetic concentrator 310.
  • the Hall effect sensor 318 is disposed to overlap the edge of the magnetic concentrator 310 opposite the Hall effect sensor 316.
  • the Hall effect sensor 316 and the Hall effect sensor 318 detect the magnetic flux about the magnetic concentrator 310, and based on the detected magnetic flux generate output voltages proportional to the current flowing in the current input leg/segment 303 A.
  • FIG. 4 shows a top view of the current sensor 300.
  • the conductor 303, the magnetic concentrator 308, the magnetic concentrator 310, the Hall effect sensor 312, the Hall effect sensor 314, the Hall effect sensor 316, and the Hall effect sensor 318 are shown in FIG. 4.
  • the conductor 303 is “U-shaped.”
  • the magnetic concentrator 308 overlaps the current output leg/segment 303B, the Hall effect sensor 312, and the Hall effect sensor 314.
  • the magnetic concentrator 310 overlaps the current input leg/segment 303 A, the Hall effect sensor 316, and the Hall effect sensor 318.
  • the magnetic concentrator 308 is disposed to overlap a linear section of the current output leg/segment 303B. For example, the magnetic concentrator 308 is closer to an end 402 of the current input leg/segment 303B than to an apex 404 of the conductor 303.
  • the magnetic concentrator 310 is disposed to overlay a linear section of the current input leg/segment 303 A. For example, the magnetic concentrator 310 is closer to an end 406 of the current input leg/segment 303 A than to the apex 404 of the conductor 303.
  • the positioning of the magnetic concentrator 308 and the magnetic concentrator 310 aids in cancellation of error due to stray magnetic fields.
  • FIG. 5 shows magnetic fields in the magnetic concentrators 308 and 310 with no stray magnetic field present. Given the magnetic fields, summation circuitry provided on the integrated circuit 306 sums the output of the Hall effect sensors 312-318 as: where:
  • V out is the output of the summation circuitry and is proportional to the current flowing in the current input leg/segment 303A and the current output leg/segment 303B;
  • V Hall1 is the output of the Hall effect sensor 312
  • V Hall2 is the output of the Hall effect sensor 314;
  • V Hall3 is the output of the Hall effect sensor 316; and V Hall4 is the output of the Hall effect sensor 318.
  • FIG. 6 shows magnetic fields in the magnetic concentrators 308 and 310 with a stray magnetic field present.
  • V stray is the voltage induced in the Hall effect sensors 312-318 by the stray magnetic field.
  • the current flowing in the conductor 303 generates an opposing in-plane magnetic field about the magnetic concentrator 308 and the magnetic concentrator 310.
  • the Hall effect sensors 312-318 measure the opposing magnetic fields to produce output voltages. Summation of the outputs of the Hall effect sensors 312-318 cancels the voltage due to the stray magnetic field.
  • implementations of the current sensor 300 are not subject to current measurement errors caused by stray magnetic fields.
  • FIG. 7 shows a flow diagram for a method 700 for fabricating a current sensor in accordance with this description. Though depicted sequentially as a matter of convenience, at least some of the actions shown can be performed in a different order and/or performed in parallel. Also, some implementations may perform only some of the actions shown. In the method 700, the operations of blocks 702 and 704 are performed during wafer-level processing, and the operations of blocks 706-710 are performed during package-level processing.
  • the electrical circuitry is formed on the integrated circuit 306. Accordingly, circuitry is formed on dies of a wafer, where the dies correspond to instances of the integrated circuit 106.
  • the electrical circuitry formed on the dies includes the Hall effect sensors 312-318 and summation circuitry that processes the outputs of the Hall effect sensors 312-318.
  • the magnetic concentrators 308 and 310 are formed on the integrated circuit 106. Accordingly, an instance of the magnetic concentrators 308 and 310 is formed on each instance of the integrated circuit 106 provided on the wafer.
  • the magnetic concentrators 308 and 310 are electroplated on a surface of each die as one or more layers of magnetic material. Because the location of the magnetic concentrators 308 and 310 is established via masking at the wafer-level, the alignment of the magnetic concentrators 308 and 310 with the Hall effect sensors 312-318 can be precisely controlled to improve communication of magnetic fields between the magnetic concentrators 308 and 310 and the Hall effect sensors 312-318.
  • the integrated circuit 106 is packaged in blocks 706-710.
  • the isolation spacer 304 is placed on the lead frame 302.
  • the isolation spacer 304 may be bonded to the lead frame 302 using epoxy or other adhesive.
  • the isolation spacer 300 is bonded to the wafer before, rather than after, singulation
  • the integrated circuit 306 is placed on the isolation spacer 304.
  • the integrated circuit 306 may be bonded to the isolation spacer 304 using epoxy or other adhesive.
  • the bond wires 320 are added to electrically couple the integrated circuit 306 to the lead frame 302.
  • An encapsulation compound may be applied to protect the lead frame 302 (or a portion thereof), the isolation spacer 304, and the integrated circuit 306.
  • the term “couple” may cover connections, communications, or signal paths that enable a functional relationship consistent with this description. For example, if device A generates a signal to control device B to perform an action, then: in a first example, device A is coupled to device B; or in a second example, device A is coupled to device B through intervening component C if intervening component C does not substantially alter the functional relationship between device A and device B, such that device B is controlled by device A via the control signal generated by device A.

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  • General Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
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Abstract

A packaged current sensor (100) includes a lead frame (102), an integrated circuit (106), an isolation spacer (104), a first magnetic concentrator (108), and a second magnetic concentrator (110). The lead frame (102) includes a conductor (103). The isolation spacer (104) is between the lead frame (102) and the integrated circuit (106). The first magnetic concentrator (108) is aligned with the conductor (103). The second magnetic concentrator (110) is aligned with the conductor (103).

Description

INTEGRATED CURRENT SENSOR WITH MAGNETIC FLUX CONCENTRATORS
BACKGROUND
[0001] Contactless current sensing is employed in a variety of applications for safely measuring current flow, particularly for high current levels. Open-loop current sensing provides a cost- effective solution in which a magnetic field generated by the flow of current through an electrical conductor is concentrated inside a magnetic core, and a magnetic sensor measures the field and provides an output signal used for estimating the current flow. Open-loop approaches typically consume little power, and can use low sensitivity sensors for measuring high currents. SUMMARY
[0002] In a current sensor that provides high voltage isolation and immunity from stray magnetic fields, a packaged current sensor includes a lead frame, an integrated circuit, an isolation spacer, a first magnetic concentrator, and a second magnetic concentrator. The lead frame includes a conductor. The isolation spacer is between the lead frame and the integrated circuit. The first magnetic concentrator is aligned with the conductor. The second magnetic concentrator is aligned with the conductor.
[0003] In another example, a current sensor includes a lead frame, an integrated circuit, an isolation spacer, a first magnetic concentrator, and a second magnetic concentrator. The lead frame includes a conductor. The conductor includes a current input segment, and a current output segment. The integrated circuit includes a Hall effect sensor. The isolation spacer is between the lead frame and the integrated circuit. The first magnetic concentrator is aligned with the current input segment and overlaps the Hall effect sensor. The second magnetic concentrator is aligned with the current output segment.
[0004] In a further example, a current sensor includes a lead frame, a first magnetic concentrator, a second magnetic concentrator, an integrated circuit, and an isolation spacer. The lead frame includes a conductor. The conductor includes a current input segment, and a current output segment. The integrated circuit includes a first Hall effect sensor, a second Hall effect sensor, a third Hall effect sensor, and a fourth Hall effect sensor. The isolation spacer is between the lead frame and the integrated circuit. The first magnetic concentrator is formed as a metal layer on the integrated circuit, and overlaps the current input segment, the first Hall effect sensor, and the second Hall effect sensor. The second magnetic concentrator is formed as a metal layer on the integrated circuit, and overlaps the current output segment, the third Hall effect sensor, and the fourth Hall effect sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 shows a side view of a current sensor that includes a Hall effect sensor overlapping two magnetic concentrators.
[0006] FIG. 2 shows a top view of a current sensor that includes a Hall effect sensor overlapping two magnetic concentrators.
[0007] FIG. 3 shows a side view of a current sensor that includes four Hall effect sensors overlapping two magnetic concentrators.
[0008] FIG. 4 shows a top view of a current sensor that includes four Hall effect sensors overlapping two magnetic concentrators.
[0009] FIG. 5 shows magnetic fields in the magnetic concentrators of FIG. 3 with no stray magnetic field.
[0010] FIG. 6 shows magnetic fields in the magnetic concentrators of FIG. 3 with a stray magnetic field.
[0011] FIG. 7 shows a flow diagram for a method for fabricating a current sensor in accordance with this description.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
[0012] The shortcomings of packaged current sensing circuits include limited voltage isolation between an integrated circuit (including a Hall effect sensor and/or other circuitry) and a current carrying conductor, and susceptibility to errors caused by a stray magnetic field. The current sensors described herein include high-voltage isolation that protects the integrated circuit. Some implementations of the current sensors also include an arrangement of magnetic concentrators and Hall effect sensors that provide immunity from errors due to stray magnetic fields.
[0013] FIG. 1 shows a side view of a current sensor 100 in accordance with this description. The current sensor 100 includes a lead frame 102, an isolation spacer 104, an integrated circuit 106, a magnetic concentrator 108, and a magnetic concentrator 110. The lead frame 102 includes a conductor 103 that carries a current to be measured. The conductor 103 includes a current input leg/segment 103A through which current flows in to the current sensor 100 and a current output leg/segment 103B through which current flows out of the current sensor 100. The isolation spacer 104 is disposed between the lead frame 102 and the integrated circuit 106 to isolate the integrated circuit 106 from high voltages that may be present on the conductor 103. The isolation spacer 104 is formed of material having high dielectric strength, such as glass dielectric materials, polymer- based dielectric materials, or silicon-based dielectric materials. In some implementations of the current sensor 100, the isolation spacer 104 has a thickness of about 100-150 micrometers (um). [0014] The integrated circuit 106 is a silicon die that includes a Hall effect sensor 112 formed thereon. The Hall effect sensor 112 is a horizontal Hall effect sensor. The integrated circuit 106 is disposed between the isolation spacer 104 and the magnetic concentrator 108 and magnetic concentrator 110. In some implementations, the integrated circuit 106 has a thickness of about 150- 250 um. The integrated circuit 106 is coupled to the lead frame 102 by bond wires 114 for transfer of electrical signals between the lead frame 102 and the integrated circuit 106.
[0015] The magnetic concentrator 108 is aligned with and overlaps the current output leg/segment 103B to concentrate magnetic flux produced by current flow in the current output leg/segment 103B. Similarly, the magnetic concentrator 110 is aligned with and overlaps the current input leg/segment 103 A to concentrate magnetic flux produced by current flow in the current input leg/segment 103 A. The magnetic flux about the magnetic concentrator 108 and the magnetic concentrator 110 is proportional to the current flowing in the current input leg/segment 103A and the current output leg/segment 103B. In some implementations of the 100, the magnetic concentrators 108 and 110 are formed/deposited on the integrated circuit 106 by electroplating as part of wafer-level processing. Thus, the alignment of the magnetic concentrators 108 and 110 and the Hall effect sensor 112 is precisely controlled. The magnetic concentrators 108 and 110 may be formed of soft magnetic material such as iron-nickel alloy.
[0016] The Hall effect sensor 112 is disposed between the magnetic concentrator 108 and the magnetic concentrator 110 and overlaps a portion of both the magnetic concentrator 108 and magnetic concentrator 110. For example, the Hall effect sensor 112 overlaps an edge 108 A of the magnetic concentrator 108 and an edge 110A of the magnetic concentrator 110. The Hall effect sensor 112 detects the magnetic flux about the magnetic concentrator 108 and the magnetic concentrator 110, and based on the detected magnetic flux generates an output voltage proportional to the current flowing in the current input leg/segment 103A and the current output leg/segment 103B.
[0017] FIG. 2 shows a top view of the current sensor 100. The conductor 103, the magnetic concentrator 108, the magnetic concentrator 110, and the Hall effect sensor 112 are shown in FIG. 2. As shown in FIG. 2, the conductor 103 is “U-shaped” or “horse-shoe-shaped.” In various implementations of the current sensor 100, the conductor 103 may have any shape. The magnetic concentrator 108 overlaps the current output leg/segment 103B and the Hall effect sensor 112, and the magnetic concentrator 110 overlaps the current input leg/segment 103 A and the Hall effect sensor 112
[0018] FIG. 3 shows a side view of a current sensor 300 in accordance with this description. The current sensor 300 includes a lead frame 302, an isolation spacer 304, an integrated circuit 306, a magnetic concentrator 308, and a magnetic concentrator 310. The lead frame 302 includes a conductor 303 that carries a current to be measured. The conductor 303 includes a current input leg/segment 303A through which current flows in to the current sensor 300 and a current output leg/segment 303B through which current flows out of the current sensor 300. The isolation spacer 304 is disposed between the lead frame 302 and the integrated circuit 306 to isolate the integrated circuit 306 from high voltages that may be present on the conductor 303. The isolation spacer 304 is formed of material having high dielectric strength, such as glass dielectric materials, polymer- based dielectric materials, or silicon-based dielectric materials. In some implementations, the isolation spacer 304 has a thickness of about 100-150 micrometers (um).
[0019] The integrated circuit 306 is a silicon die that includes, formed thereon, a Hall effect sensor 312, a Hall effect sensor 314, a Hall effect sensor 316, and a Hall effect sensor 318. The Hall effect sensor 312, the Hall effect sensor 314, the Hall effect sensor 316, and the Hall effect sensor 318 are horizontal Hall effect sensors. The integrated circuit 306 is disposed between the isolation spacer 304 and the magnetic concentrator 308 and magnetic concentrator 310. In some implementations, the integrated circuit 306 has a thickness of about 150-250 um. The integrated circuit 306 is coupled to the lead frame 302 by bond wires 320 for transfer of electrical signals between the lead frame 302 and the integrated circuit 306.
[0020] The magnetic concentrator 308 is aligned with and overlaps the current output leg/segment 303B to concentrate magnetic flux produced by current flow in the current output leg/segment 303B. Similarly, the magnetic concentrator 310 is aligned with and overlaps the current input leg/segment 303 A to concentrate magnetic flux produced by current flow in the current input leg/segment 303 A. The magnetic flux about the magnetic concentrator 308 and the magnetic concentrator 310 is proportional to the current flowing in the current input leg/segment 303A and the current output leg/segment 303B. The magnetic concentrator 308 and the magnetic concentrator 310 may be provided in the form of a circular magnetic disk, an octagonal magnetic disk, an elliptical magnetic disk, a polygonal magnetic disk, etc. of soft magnetic material such as iron-nickel alloy. In some implementations of the 300, the magnetic concentrators 308 and 310 are formed/deposited on the integrated circuit 306 by electroplating as part of wafer-level processing. Thus, the alignment of the magnetic concentrators 308 and 310 and the Hall effect sensors 312-318 is precisely controlled. [0021] The Hall effect sensor 312 is disposed to overlap an edge 308A of the magnetic concentrator 308. The Hall effect sensor 314 is disposed to overlap the edge of the magnetic concentrator 308 opposite the Hall effect sensor 312. The Hall effect sensor 312 and the Hall effect sensor 314 detect the magnetic flux about the magnetic concentrator 308, and based on the detected magnetic flux generate output voltages proportional to the current flowing in the current output leg/segment 303B.
[0022] The Hall effect sensor 316 is disposed to overlap an edge 310A of the magnetic concentrator 310. The Hall effect sensor 318 is disposed to overlap the edge of the magnetic concentrator 310 opposite the Hall effect sensor 316. The Hall effect sensor 316 and the Hall effect sensor 318 detect the magnetic flux about the magnetic concentrator 310, and based on the detected magnetic flux generate output voltages proportional to the current flowing in the current input leg/segment 303 A.
[0023] FIG. 4 shows a top view of the current sensor 300. The conductor 303, the magnetic concentrator 308, the magnetic concentrator 310, the Hall effect sensor 312, the Hall effect sensor 314, the Hall effect sensor 316, and the Hall effect sensor 318 are shown in FIG. 4. As shown in FIG. 4, the conductor 303 is “U-shaped.” The magnetic concentrator 308 overlaps the current output leg/segment 303B, the Hall effect sensor 312, and the Hall effect sensor 314. The magnetic concentrator 310 overlaps the current input leg/segment 303 A, the Hall effect sensor 316, and the Hall effect sensor 318.
[0024] The magnetic concentrator 308 is disposed to overlap a linear section of the current output leg/segment 303B. For example, the magnetic concentrator 308 is closer to an end 402 of the current input leg/segment 303B than to an apex 404 of the conductor 303. The magnetic concentrator 310 is disposed to overlay a linear section of the current input leg/segment 303 A. For example, the magnetic concentrator 310 is closer to an end 406 of the current input leg/segment 303 A than to the apex 404 of the conductor 303. The positioning of the magnetic concentrator 308 and the magnetic concentrator 310 aids in cancellation of error due to stray magnetic fields.
[0025] FIG. 5 shows magnetic fields in the magnetic concentrators 308 and 310 with no stray magnetic field present. Given the magnetic fields, summation circuitry provided on the integrated circuit 306 sums the output of the Hall effect sensors 312-318 as:
Figure imgf000008_0001
where:
Vout is the output of the summation circuitry and is proportional to the current flowing in the current input leg/segment 303A and the current output leg/segment 303B;
VHall1 is the output of the Hall effect sensor 312;
VHall2 is the output of the Hall effect sensor 314;
VHall3 is the output of the Hall effect sensor 316; and VHall4 is the output of the Hall effect sensor 318.
[0026] FIG. 6 shows magnetic fields in the magnetic concentrators 308 and 310 with a stray magnetic field present.
Figure imgf000008_0002
where Vstray is the voltage induced in the Hall effect sensors 312-318 by the stray magnetic field.
[0027] The current flowing in the conductor 303 generates an opposing in-plane magnetic field about the magnetic concentrator 308 and the magnetic concentrator 310. The Hall effect sensors 312-318 measure the opposing magnetic fields to produce output voltages. Summation of the outputs of the Hall effect sensors 312-318 cancels the voltage due to the stray magnetic field. Thus, implementations of the current sensor 300 are not subject to current measurement errors caused by stray magnetic fields.
[0028] FIG. 7 shows a flow diagram for a method 700 for fabricating a current sensor in accordance with this description. Though depicted sequentially as a matter of convenience, at least some of the actions shown can be performed in a different order and/or performed in parallel. Also, some implementations may perform only some of the actions shown. In the method 700, the operations of blocks 702 and 704 are performed during wafer-level processing, and the operations of blocks 706-710 are performed during package-level processing.
[0029] In block 702, the electrical circuitry is formed on the integrated circuit 306. Accordingly, circuitry is formed on dies of a wafer, where the dies correspond to instances of the integrated circuit 106. The electrical circuitry formed on the dies includes the Hall effect sensors 312-318 and summation circuitry that processes the outputs of the Hall effect sensors 312-318.
[0030] In block 704, the magnetic concentrators 308 and 310 are formed on the integrated circuit 106. Accordingly, an instance of the magnetic concentrators 308 and 310 is formed on each instance of the integrated circuit 106 provided on the wafer. The magnetic concentrators 308 and 310 are electroplated on a surface of each die as one or more layers of magnetic material. Because the location of the magnetic concentrators 308 and 310 is established via masking at the wafer-level, the alignment of the magnetic concentrators 308 and 310 with the Hall effect sensors 312-318 can be precisely controlled to improve communication of magnetic fields between the magnetic concentrators 308 and 310 and the Hall effect sensors 312-318.
[0031] After singulation, the integrated circuit 106 is packaged in blocks 706-710. In block 706, the isolation spacer 304 is placed on the lead frame 302. For example, the isolation spacer 304 may be bonded to the lead frame 302 using epoxy or other adhesive. In some implementations of the method 700, the isolation spacer 300 is bonded to the wafer before, rather than after, singulation [0032] In block 708, the integrated circuit 306 is placed on the isolation spacer 304. For example, the integrated circuit 306 may be bonded to the isolation spacer 304 using epoxy or other adhesive. [0033] In block 710, the bond wires 320 are added to electrically couple the integrated circuit 306 to the lead frame 302. An encapsulation compound may be applied to protect the lead frame 302 (or a portion thereof), the isolation spacer 304, and the integrated circuit 306.
[0034] In this description, the term “couple” may cover connections, communications, or signal paths that enable a functional relationship consistent with this description. For example, if device A generates a signal to control device B to perform an action, then: in a first example, device A is coupled to device B; or in a second example, device A is coupled to device B through intervening component C if intervening component C does not substantially alter the functional relationship between device A and device B, such that device B is controlled by device A via the control signal generated by device A.
[0035] Modifications are possible in the described embodiments, and other embodiments are possible, within the scope of the claims.

Claims

CLAIMS What is claimed is:
1. A packaged current sensor, comprising: a lead frame comprising a conductor; an integrated circuit; an isolation spacer between the lead frame and the integrated circuit; and a magnetic concentrator aligned with the conductor.
2. The packaged current sensor of claim 1 , wherein the integrated circuit comprises a Hall effect sensor aligned with the magnetic concentrator.
3. The packaged integrated circuit of claim 2, wherein: the magnetic concentrator is a first magnetic concentrator; the packaged integrated circuit comprises a second magnetic concentrator; and the Hall effect sensor is between the first magnetic concentrator and the second magnetic concentrator.
4. The packaged current sensor of claim 3, wherein the Hall effect sensor overlaps an edge of the first magnetic concentrator and an edge of the second magnetic concentrator.
5. The packaged current sensor of claim 1 wherein the integrated circuit comprises: a first Hall effect sensor aligned with an edge of the magnetic concentrator; and a second Hall effect sensor aligned with the edge of the magnetic concentrator opposite the first Hall effect sensor.
6. The packaged current sensor of claim 5, wherein: the magnetic concentrator is a first magnetic concentrator; the packaged integrated circuit comprises a second magnetic concentrator; and the integrated circuit comprises: a third Hall effect sensor aligned with an edge of the second magnetic concentrator; and a fourth Hall effect sensor aligned with the edge of the second magnetic concentrator opposite the third Hall effect sensor.
7. The packaged current sensor of claim 6, wherein: the conductor comprises: a current input leg; and a current output leg; and the first magnetic concentrator is aligned with the current input leg; and the second magnetic concentrator is aligned with the current output leg.
8. The packaged current sensor of claim 1, wherein the first magnetic concentrator and the second magnetic concentrator are electroplated onto the integrated circuit.
9. The packaged current sensor of claim 1, wherein the first magnetic concentrator and the second magnetic concentrator comprise a circular disk of soft magnetic material or a polygonal disk of soft magnetic material.
10. A current sensor, comprising: a lead frame comprising a conductor, wherein the conductor comprises: a current input segment; and a current output segment; an integrated circuit comprising a Hall effect sensor; an isolation spacer between the lead frame and the integrated circuit; a first magnetic concentrator aligned with the current input segment and overlapping the Hall effect sensor; and a second magnetic concentrator aligned with the current output segment.
11. The current sensor of claim 10, wherein the second magnetic concentrator overlaps the Hall effect sensor.
12. The current sensor of claim 10, wherein: the Hall effect sensor is a first Hall effect sensor; and the integrated circuit comprises a second Hall effect sensor overlapping an edge of the first magnetic concentrator opposite the first Hall effect sensor.
13. The current sensor of claim 12, wherein: the integrated circuit comprises a third Hall effect sensor overlapping an edge of the second magnetic concentrator.
14. The current sensor of claim 13, wherein: the integrated circuit comprises a fourth Hall effect sensor overlapping an edge of the second magnetic concentrator opposite the third Hall effect sensor.
15. The current sensor of claim 10, wherein the first magnetic concentrator and the second magnetic concentrator comprise a circular disk of soft magnetic material.
16. The current sensor of claim 10, wherein the first magnetic concentrator and the second magnetic concentrator comprise a polygonal disk of soft magnetic material.
17. A current sensor, comprising: a lead frame comprising a conductor, wherein the conductor comprises: a current input segment; and a current output segment; an integrated circuit comprising: a first Hall effect sensor; a second Hall effect sensor; a third Hall effect sensor; and a fourth Hall effect sensor; and an isolation spacer between the lead frame and the integrated circuit; and a first magnetic concentrator and a second magnetic concentrator formed as a metal layer on the integrated circuit, the first magnetic concentrator overlapping the current input segment, the first Hall effect sensor, and the second Hall effect sensor, and the second magnetic concentrator overlapping the current output segment, the third Hall effect sensor, and the fourth Hall effect sensor.
18. The current sensor of claim 17, wherein: the first Hall effect sensor overlaps an edge of the first magnetic concentrator; and the second Hall effect sensor overlaps the edge of the first magnetic concentrator opposite the first Hall effect sensor.
19. The current sensor of claim 17, wherein: the third Hall effect sensor overlaps an edge of the second magnetic concentrator; and the fourth Hall effect sensor overlaps the edge of the second magnetic concentrator opposite the first Hall effect sensor. 0 The current sensor of claim 17, wherein the first magnetic concentrator and the second magnetic concentrator comprise a circular magnetic disk or a polygonal magnetic disk.
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