Magnetic sensor with laminated field concentrating flux bar

A magnetic sensor fabricating method comprising:

• providing a magnetic field generating element having a major axis and a planar pole face substantially perpendicular to said major axis;
• providing a first magnetic field sensitive sensor element having a first magnetoresistive element responsive to a magnetic field, the first magnetoresistive element including a first positive leg and a first negative leg;
• providing a second magnetic field sensitive sensor element having a second magnetoresistive element responsive to a magnetic field, the second magnetoresistive element including a second positive leg and a second negative leg;
• providing a plurality of substantially planar ferrite elements;
• arranging the plurality of substantially planar ferrite elements into alternating laminations of regularly spaced-apart ferrite elements and interstitial voids;
• filling said interstitial voids with a non-magnetic material to form a laminated stack of alternating ferrite elements and non-magnetic material along a first stack axis;
• connecting said first and second positive legs and said first and second negative legs of said first and second magnetic field sensitive sensor elements to said regularly spaced-apart ferrite elements of said laminated stack in a spaced apart relation along said first stack axis as a connected assembly;
• and,
• mounting the connected assembly to the pole face of the magnetic field generating means such that said first stack axis is substantially perpendicular to said major axis.

A method of constructing a sensor comprising the steps of:

• providing an electric signal generating element for generating an electrical signal based upon a magnetic field at said element, the electric signal generating element including a positive electrical leg and a negative electrical leg;
• providing a plurality of magnetic members;
• providing a plurality of non-magnetic members;
• arranging said plurality of magnetic members and said plurality of non-magnetic members into a flux guide having alternating laminations of said magnetic members and said non-magnetic members;
• positioning said electric signal generating element on said flux guide as a first member such that each of said positive electrical leg and said negative electrical leg are aligned with at least one of said magnetic members of said flux guide;
• and,
• positioning said first member proximate a magnetic field generating element generating a magnetic field.

A magnetic sensor fabrication method comprising:

• arranging a plurality of magnetic elements and a plurality of non-magnetic elements into a laminated stack;
• providing a magnetic field sensitive element having a positive electrical leg and a negative electrical leg;
• disposing said positive electrical leg and said negative electrical leg of the magnetic field sensitive element on a first surface of said laminated stack in alignment with said plurality of magnetic elements;
• and,
• connecting a second surface of said laminated stack to a pole face of a magnetic field generating element.

A method of constructing a sensor comprising the steps of:

• providing a magnetic field generating element;
• providing a magnetic field sensing element having a first electrical leg and a second electrical leg;
• providing a laminated flux member having alternating layers of magnetic material and non-magnetic material;
• forming a first assembly by disposing said first electrical leg and said second electrical leg of the magnetic field sensing element on the laminated flux member in alignment with said alternating layers of magnetic material;
• and,
• disposing said first assembly on said magnetic field generating element.