Current sensor components and methods for producing same

A residual current sensor component, comprising:

• an insulating plate-shaped carrier;
• a magnetic field sensor;
• at least two current conductors having adjacently arranged sections;
• and
• a magnetic field concentrator that at least partially surrounds the adjacently arranged sections of the at least two current conductors and is configured to concentrate a magnetic field generated by currents flowing through the at least two current conductors onto the magnetic field sensor,
• wherein the insulating plate-shaped carrier carries the magnetic field sensor, the at least two current conductors and the magnetic field concentrator,
• wherein a potting material is applied to a main surface of the insulating plate-shaped carrier and covers the magnetic field sensor and at least parts of the magnetic field concentrator, and
• wherein parts of the potting material and parts of the insulating plate-shaped carrier are exposed to an outside and constitute an outer boundary of the residual current sensor component.

A current sensor component, comprising:

• a package;
• at least one magnetic field sensor chip arranged in the package and having a magnetic field sensor;
• at least one current conductor having a section arranged in the package;
• and
• a magnetic field concentrator that at least partially surrounds the section of the current conductor arranged in the package and is configured to concentrate a magnetic field generated by a current flowing through the at least one current conductor onto the magnetic field sensor,
• wherein part of the magnetic field concentrator is formed on a chip surface of the magnetic field sensor chip.

A method for producing a residual current sensor component, the method comprising:

• providing an intermediate product comprising a magnetic field sensor, at least two current conductors having adjacently arranged sections, and an insulating component in which the adjacently arranged sections of the at least two current conductors are arranged;
• providing a preform of a magnetic field concentrator;
• mounting the preform of the magnetic field concentrator on the intermediate product and bending at least one section of the preform of the magnetic field concentrator toward the magnetic field sensor;
• and
• applying a potting material so as to cover at least the magnetic field concentrator.

A method for producing a residual current sensor component, the method comprising:

• producing a package in which a magnetic field sensor and a at least two current conductors are packaged using potting material, the at least two current conductors having adjacently arranged sections arranged adjacently in the package;
• and
• applying a magnetic field concentrator to an outer surface of the potting material, the magnetic field concentrator being clamped onto the package as a clip,
• wherein the magnetic field concentrator is arranged such that the magnetic field concentrator at least partially surrounds the adjacently arranged sections of the at least two current conductors, and
• wherein the magnetic field concentrator is configured to concentrate a magnetic field generated by currents flowing through the at least two current conductors onto the magnetic field sensor.

A method for producing a residual current sensor component, the method comprising:

• producing an intermediate product comprising an insulating plate-shaped carrier having holes, a magnetic field sensor, and a magnetic field concentrator;
• inserting at least two current conductors into the holes of the insulating plate-shaped carrier such that the magnetic field concentrator at least partially surrounds adjacently arranged sections of the at least two current conductors, wherein the magnetic field concentrator is configured to concentrate a magnetic field generated by currents flowing through the at least two current conductors onto the magnetic field sensor;
• and
• applying a potting material at least above the magnetic field concentrator.