Hall-effect current detector
A current detector comprising a current-path conductor assembly and a Hall generator assembly. The current-path conductor assembly includes a sheet-metal current-path conductor and a plastic conductor holder molded in one piece therewith. The Hall generator assembly includes a Hall generator in the form of a semiconductor chip mounted to a metal-made mounting plate, a set of leads electrically connected to the Hall generator, and a plastic encapsulation enveloping the Hall generator and parts of the leads. The Hall generator assembly and the current-path conductor assembly are combined by bonding together the encapsulation of the Hall generator assembly and the conductor holder of the current-path conductor assembly. The conductor holder and the encapsulation are shaped in interfitting relationship to each other, so that when they are united, the Hall generator is positioned to generate a Hall voltage in response to a magnetic field due to the current flowing through the current-path conductor.
1. A current detector utilizing the Hall-effect for detection or measurement of electric current, comprising:
(A) a current-path conductor assembly comprising:
(a) a current-path conductor for carrying the current to be detected or measured; and
(b) a conductor holder of electrically insulating material integrally enveloping part of the current-path conductor, the conductor holder having a positioning recess;
(B) a Hall generator assembly comprising:
(a) a Hall generator for generating a Hall voltage proportional to the strength of an applied magnetic field;
(b) a plurality of leads electrically connected to the Hall generator; and
(c) an encapsulation of electrically insulating material integrally enveloping the Hall generator and parts of the leads, the encapsulation having a size which can be put into the positioning recess; and
(C) the current-path conductor assembly and the Hall generator assembly being combined by joining together the conductor holder of the current-path conductor assembly and the encapsulation of the Hall generator assembly, with the current-path conductor disposed adjacent the Hall generator in order to cause the Hall generator to generate the Hall voltage in response to a magnetic field due to the current flowing through the current-path conductor, the encapsulation being put into the positioning recess of the conductor holder.
2. The current detector of claim 1 wherein the conductor holder of the current-path conductor assembly has formed therein an additional set of positioning recesses for receiving the leads of the Hall generator assembly.
3. The current detector of claim 1 wherein the current-path conductor of the current-path conductor assembly is partly exposed through the positioning recess in the conductor holder.
4. The current detector of claim 1 wherein the current-path conductor of the current-path conductor assembly is a piece of sheet metal having a slit formed therein to provide a U-shaped current path, and wherein the positional relationship is such that the Hall generator is contained in the slit as seen in a direction normal to the plane of the sheet-metal current-path conductor.
5. The current detector of claim 4 wherein the current-path conductor of the current-path conductor assembly has additional slits formed therein to constrict the current path toward the Hall generator.
6. The current detector of claim 1 wherein the Hall generator assembly further comprises a metal-made mounting plate to which the Hall generator is mounted, the mounting plate being enveloped by the encapsulation.
7. The current detector of claim 6 wherein the mounting plate has a surface held opposite the current-path conductor, and wherein the Hall generator is mounted to said surface of the mounting plate.
8. The current detector of claim 6 wherein the mounting plate has a first surface held opposite the current-path conductor, and wherein the Hall generator is mounted to a second surface, which is directed away from the current-path conductor, of the mounting plate.
9. The current detector of claim 1 wherein the current-path conductor is formed to include a pair of terminal portions projecting from the casing for connection to an external circuit, the terminal portions being out of register with the leads.
10. The current detector of claim 9 wherein the pair of terminal portions of the current-path conductor project in the same direction from the casing.
11. The current detector of claim 9 wherein the pair of terminal portions of the current-path conductor project in opposite directions from the casing.
12. The current detector of claim 1 wherein the encapsulation of the Hall generator assembly and the conductor holder of the current-path conductor assembly are bonded together via a sheet of electrically insulating material.
13. A method for the manufacture of a current detector utilizing the Hall-effect for detection or measurement of electric current, comprising:
(A) providing a current-path conductor assembly comprising:
(a) a current-path conductor for carrying the current to be detected or measured; and
(b) a conductor holder of electrically insulating material integrally enveloping part of the current-path conductor, the conductor holder having a positioning recess;
(B) providing a Hall generator assembly comprising:
(a) a Hall generator for generating a Hall voltage proportional to the strength of an applied magnetic field;
(b) a plurality of leads electrically connected to the Hall generator; and
(c) an encapsulation of electrically insulating material integrally enveloping the Hall generator and parts of the leads, the encapsulation having a size which can be put in to the positioning recess; and
(C) putting the encapsulation into the positioning recess, and bonding the encapsulation with the conductor holder.