Battery system and hybrid current sensor therefor

1 . A hybrid current sensor, comprising: a main conductor, having a first end and a second end, wherein a current flow direction of a main current in the main conductor extends between the first end and the second end; a magnetic core, disposed at least partially around a middle portion of the main conductor, the magnetic core having a C-shape at least around an outer surface, wherein the magnetic core defines a core gap region, the magnetic core comprising: a first portion having the C-shape that defines a first gap along a transverse direction; and a second portion having a U-shape that defines a second gap along the transverse direction, the second gap being greater than the first gap; and a chip assembly, disposed within the core gap region, wherein the chip assembly comprises a low current chip, and a pair of high current chips.

2 . The hybrid current sensor of claim 1 , wherein main conductor comprises a notch region, wherein the chip assembly is disposed adjacent the notch region.

3 . The hybrid current sensor of claim 1 , the low current chip and the pair of high current chips comprising a Hall sensor.

4 . The hybrid current sensor of claim 1 , wherein the pair of high current chips are disposed within a first plane in the core gap region, and wherein the low current chip is disposed within a second plane, different than the first plane, in the core gap region.

5 . The hybrid current sensor of claim 1 , the low current chip being adapted to measure the main current in a range up to five hundred amps, and the pair of high current chips being adapted to measure the main current in a range up to 2000 A.

6 . The hybrid current sensor of claim 1 , further comprising, a PCB assembly, wherein the chip assembly is mechanically affixed to a PCB of the PCB assembly via a set of pin assemblies.

7 . The hybrid current sensor of claim 6 , wherein the PCB assembly is disposed in a vertical fashion, wherein a long direction of the PCB assembly extends perpendicularly with respect to a long direction of the main conductor.

8 . The hybrid current sensor of claim 7 , further comprising a housing, disposed at least partially around the PCB assembly and the magnetic core.

9 . The hybrid current sensor of claim 1 , further comprising:

a PCB assembly, electrically coupled to the chip assembly; and

a housing, disposed at least partially around the PCB assembly and the magnetic core.

10 . The hybrid current sensor of claim 9 , wherein the housing comprises:

an outer surface comprising a C-shape, disposed adjacent a portion of the magnetic core; and

a back cover, disposed adjacent to the PCB assembly.

11 . The hybrid current sensor of claim 10 , further comprising a side cover, disposed adjacent to a side of the magnetic core and extending perpendicularly to a long direction of the main conductor.

12 . The hybrid current sensor of claim 9 , wherein the housing comprises: a front cover, disposed adjacent to a continuous portion of the magnetic core; and a back cover, disposed adjacent to the PCB assembly.

13 . A battery system, comprising;

a battery to output a main current in a vehicle;

a hybrid current sensor, coupled to measure the main current along a current flow direction, the hybrid current sensor comprising:

a busbar structure having a first end and a second end;

a magnetic core, disposed at least partially around the busbar structure, the magnetic core defining a core gap region, the magnetic core comprising: —a first portion having a C-shape that defines a first gap along a transverse direction; and —a second portion having a U-shape that defines a second gap along the transverse direction, the second gap being greater than the first gap; and

a chip assembly, disposed within the core gap region, wherein the chip assembly comprises a low current chip, and a pair of high current chips.

14 . The battery system of claim 13 , the low current chip being adapted to measure the main current in a range up to five hundred amps, and the pair of high current chips being adapted to measure the main current in a range up to 2000 A.

15 . The battery system of claim 13 , further comprising a PCB assembly, connected to the chip assembly, and disposed in a vertical fashion, wherein a long direction of the PCB assembly extends perpendicularly with respect to a long direction of the main conductor.

16 . The battery system of claim 15 , further comprising a housing, disposed at least partially around the PCB assembly and the magnetic core.

17 . The battery system of claim 16 , wherein the housing comprises: an outer surface comprising a C-shape, disposed adjacent a portion of the magnetic core; and a back cover, disposed adjacent to the PCB assembly.

18 . The battery system of claim 17 , further comprising a side cover, disposed adjacent to a side of the magnetic core and extending perpendicularly to a long direction of the busbar structure.

19 . The battery system of claim 16 , wherein the housing comprises: a front cover, disposed adjacent to a continuous portion of the magnetic core; and a back cover, disposed adjacent to the PCB assembly.

20 . The battery system of claim 13 , further comprising:

a controller, electrically coupled to receive an output from the low current chip and the pair of high current chips;

a controller area network transceiver, coupled to the controller; and

a battery management system, coupled to receive an output from the controller area network transceiver.