Sensor coil and method of manufacturing same

Abstract

An electronic component in accordance with the invention includes a body, such as a base, having a high magnetic permeability material applied to an external surface thereof and a wire winding wound about at least a portion of the high magnetic permeability material. In a preferred form, the body is made of a non-conducting material, such as ceramic or plastic, and the high magnetic permeability material is made of a magnetic material such as ferrite or a metallic glass alloy (i.e., an amorphous metal). The component further includes a spacer for separating the wire winding from the high magnetic permeability material in order to prevent the amorphous metal from damaging the wire winding. The resulting electronic component is capable of sensing magnetic fields and may be used in a variety of circuits such as compasses and magnetometers.

1 . An electronic component for sensing magnetic fields comprising: 
 a body having first and second ends with an elongated portion extending therebetween;    an amorphous metal connected to an external surface of the elongated portion of the body;    a wire winding wrapped about at least a portion of the amorphous metal; and    a spacer for separating the wire from the amorphous metal in order to prevent the amorphous metal from damaging the wire.    
   
   
       2 . An electronic component according to  claim 1  wherein the spacer comprises a coating extending over an external surface of the amorphous metal for isolating the amorphous metal from the wire.  
   
   
       3 . An electronic component according to  claim 2  wherein the coating is a high temperature and flexible urethane.  
   
   
       4 . An electronic component according to  claim 2  wherein the coating is connected to the external surface of the amorphous metal via an adhesive.  
   
   
       5 . An electronic component according to  claim 2  further comprising an overnolding covering at least a portion of the wire winding and providing a generally flat surface to assist in positioning of the component on a printed circuit board (PCB).  
   
   
       6 . An electronic component according to  claim 5  wherein the overmolding comprises at least one of a high temperature urethane and an adhesive film.  
   
   
       7 . An electronic component according to  claim 1  wherein the body comprises at least one of a ceramic and a plastic.  
   
   
       8 . An electronic component according to  claim 2  wherein the ends of the body extend downward from the elongated portion and have metalized pads connected to a portion thereof for electrically and mechanically attaching the component to a PCB.  
   
   
       9 . An electronic component according to  claim 7  wherein the elongated portion and ends of the body form an external upper surface and the coating extends over at least a portion of the external upper surface and down external side portions of the ends.  
   
   
       10 . An electronic component according to  claim 2  wherein the ends of the body define generally rectangular recesses wherein the elongated portion and the recesses form a generally planar surface upon which the amorphous metal is positioned.  
   
   
       11 . An electronic component according to  claim 10  wherein the ends of the body further define a second set of recesses to which metalized pads are connected for electrically and mechanically attaching the component to a PCB.  
   
   
       12 . An electronic component according to  claim 11  wherein metalized pads are in the form of clips capable of frictionally engaging at least a portion of the second set of recesses defined by the ends of the body.  
   
   
       13 . An electronic component according to  claim 1  wherein the spacer comprises a pair of wall members extending from the elongated portion of the body for supporting at least a portion of the wire winding and creating an air gap between the amorphous metal and the wire winding.  
   
   
       14 . An electronic component according to  claim 13  wherein the ends of the body define generally rectangular recesses wherein the elongated portion located between the pair of wall members and the recesses form a generally planar surface upon which the amorphous metal is positioned.  
   
   
       15 . An electronic component according to  claim 14  wherein the ends of the body further define a second set of recesses to which metalized pads are connected for electrically and mechanically attaching the component to a PCB.  
   
   
       16 . An electronic component according to  claim 15  wherein metalized pads are in the form of clips capable of frictionally engaging at least a portion of the second set of recesses defined by the ends of the body.  
   
   
       17 . A method of manufacturing an electronic component comprising the steps of: 
 providing a base, an amorphous metal, and a wire;    applying the amorphous metal to an external surface of the base;    wrapping the wire about at least a portion of the amorphous metal; and    isolating the amorphous metal from the wire in order to prevent the amorphous metal from damaging the wire.    
   
   
       18 . A magnetic sensor comprising: 
 sensing circuitry for detecting magnetic fields and providing sensor data associated therewith, the sensing circuitry having a sensing coil comprising 
 a body having first and second ends with an elongated portion extending therebetween;  
 an amorphous metal connected to an external surface of the elongated portion of the body;  
 a wire winding wrapped about at least a portion of the amorphous metal; and  
 a spacer for separating the wire from the amorphous metal in order to prevent the amorphous metal from damaging the wire;  
   a controller connected to the sensing circuitry and capable of operating the sensing circuitry and processing the sensor data received therefrom and being further capable of outputting controller data corresponding to the processed data; and    a display connected to the controller for providing visual data corresponding to the controller data received therefrom.