LOW TEMPERATURE COEFFICIENT CURRENT SENSOR
20220365112 · 2022-11-17
Inventors
- Michael D. Petersen (Elbert, CO, US)
- Kalin V. Lazarov (Colorado Springs, CO, US)
- Gregory J. Manlove (Colorado Springs, CO, US)
- Robert Chiacchia (Colorado Springs, CO, US)
Cpc classification
G01R1/203
PHYSICS
G01R15/146
PHYSICS
International classification
Abstract
A system current sensor module can accurately sense or measure system current flowing through a sense current resistor by shunting current through a gain-setting resistor and using an amplifier to measure a resulting voltage, with an output transistor controlled by the amplifier controlling current through the gain setting resistor in a manner that tends to keep the amplifier inputs at the same voltage. The resistors can be thermally coupled to maintain similar temperatures when a system current is flowing. The thermal coupling can include conducting heat from a first resistor layer carrying the current sense resistor to a thermal cage layer located beyond a second resistor layer carrying the gain-setting resistor. This preserves accuracy, including during aging.
Claims
1. (canceled)
2. A printed circuit board (PCB) apparatus providing thermally matched first and second resistors using a thermal cage, the PCB apparatus comprising: a first resistor PCB layer, including the first resistor, the first resistor PCB layer having a first side and an opposing second side; a second resistor PCB layer, including the second resistor, the second resistor PCB layer having a third side and an opposing fourth side, the second resistor PCB layer located above the second side of the first resistor PCB layer with the third side of the second resistor PCB layer facing toward the second side of the first resistor PCB layer; a thermal conduction PCB layer, having a fifth side and an opposing sixth side, the thermal conduction PCB layer located above the fourth side of the second resistor PCB layer, with the fifth side of the thermal conduction PCB layer facing toward the fourth side of the second resistor PCB layer, the thermal conduction PCB layer being more thermally conductive than the first and second resistor PCB layers; and an electrically insulating gap that divides the thermal conduction PCB layer into first and second regions to avoid electrically shorting either or both of the first resistor layer or the second resistor layer through the thermal conduction PCB layer.
3. The apparatus of claim 2, further comprising a first plurality of vias, electrically and thermally conducting connecting the first resistor PCB layer to the first region of the thermal conduction PCB layer.
4. The apparatus of claim 3, further comprising a second plurality of vias, electrically and thermally connecting the first resistor PCB layer to the second region of the thermal conduction PCB layer located across the electrically insulating gap from the first region of the thermal conduction PCB layer.
5. The apparatus of claim 4, wherein the first plurality of vias are electrically connected to a first side of the first resistor in the first resistor PCB layer, and wherein the second plurality of vias are electrically connected to an opposing second side of the first resistor in the first resistor PCB layer.
6. The apparatus of claim 5, wherein at least one of the first plurality of vias is electrically connected to a first side of the second resistor in the second resistor PCB layer.
7. The apparatus of claim 5, wherein a first end of the first resistor in the first resistor PCB layer is electrically connected to a first end of the second resistor in the second resistor PCB layer, and wherein a second end of the first resistor in the first resistor PCB layer and the second end of the second resistor in the second resistor PCB layer are electrically connected to different ones of a pair of amplifier inputs.
8. The apparatus of claim 7, wherein the second end of the second resistor in the second resistor PCB layer is electrically connected to an electrical conduction terminal of a transistor, and wherein an output of the amplifier is electrically connected to an electrical control terminal of the transistor.
9. An apparatus providing thermally matched first and second resistors using a thermal cage, the apparatus comprising: a first resistor layer, including the first resistor, the first resistor layer having a first side and an opposing second side; a second resistor layer, including the second resistor having a first terminal that is electrically coupled to a first terminal of the first resistor to form a node, the second resistor layer having a third side and an opposing fourth side, the second resistor layer located above the second side of the first resistor layer with the third side of the second resistor layer facing toward the second side of the first resistor layer; and a thermal conduction layer, having a fifth side and an opposing sixth side, the thermal conduction layer located above the fourth side of the second resistor layer, with the fifth side of the thermal conduction layer facing toward the fourth side of the second resistor layer, the thermal conduction layer being more thermally conductive than the first and second resistor layers.
10. The apparatus of claim 9, further comprising an electrically insulating gap that divides the thermal conduction layer into electrically separate first and second regions.
11. The apparatus of claim 9, further comprising: a first plurality of vias, electrically and thermally conducting connecting the first resistor layer to the first region of the thermal conduction layer; and a second plurality of vias, electrically and thermally connecting the first resistor layer to the second region of the thermal conduction layer located across the electrically insulating gap from the first region of the thermal conduction layer.
12. The apparatus of claim 11, wherein the first plurality of vias are electrically connected to a first side of the first resistor in the first resistor layer, and wherein the second plurality of vias are electrically connected to an opposing second side of the first resistor in the first resistor layer.
13. The apparatus of claim 11, wherein at least one of the first plurality of vias is electrically connected to a first side of the second resistor in the second resistor layer.
14. The apparatus of claim 9, wherein a first end of the first resistor in the first resistor layer is electrically connected to a first end of the second resistor in the second resistor layer, and wherein a second end of the first resistor in the first resistor layer and the second end of the second resistor in the second resistor layer are electrically connected to different ones of a pair of amplifier inputs.
15. The apparatus of claim 14, wherein the second end of the second resistor in the second resistor layer is electrically connected to an electrical conduction terminal of a transistor, and wherein an output of the amplifier is electrically connected to an electrical control terminal of the transistor.
16. An apparatus providing thermally matched first and second resistors using a thermal cage, the apparatus comprising: a first resistor layer, including the first resistor, the first resistor layer having a first side and an opposing second side, a periphery of the first resistor defining a first resistor footprint area; a second resistor layer, including the second resistor, the second resistor layer having a third side and an opposing fourth side, a periphery of the second resistor defining a second resistor footprint area, the second resistor layer located above the second side of the first resistor layer with the third side of the second resistor layer facing toward the second side of the first resistor layer; and a thermal conduction layer, having a fifth side and an opposing sixth side, the thermal conduction layer located above the fourth side of the second resistor layer, with the fifth side of the thermal conduction layer facing toward the fourth side of the second resistor layer, the thermal conduction layer being more thermally conductive than the first and second resistor layers, the thermal conduction layer defining a third footprint area that at least equals the first resistor footprint area and the second resistor footprint area.
17. The apparatus of claim 16, further comprising an electrically insulating gap that divides the thermal conduction layer into electrically separated first and second regions.
18. The apparatus of claim 16, wherein the third footprint area at least partially overlies the second resistor footprint area, and wherein the second resistor footprint area at least partially overlies the first resistor footprint area.
19. The apparatus of claim 16, wherein the third footprint area is approximately equal to the second resistor footprint area and also approximately equal to the first resistor footprint area.
20. The apparatus of claim 16, wherein the first resistor layer, the second resistor layer, and the thermal conduction layer are Printed Circuit Board (PCB) layers.
21. The apparatus of claim 16, further comprising: a first plurality of vias, electrically and thermally conducting connecting the first resistor layer to the first region of the thermal conduction layer; and a second plurality of vias, electrically and thermally connecting the first resistor layer to the second region of the thermal conduction layer located across the electrically insulating gap from the first region of the thermal conduction layer.
22. The apparatus of claim 21, wherein: the first plurality of vias are electrically connected to a first side of the first resistor in the first resistor layer; the second plurality of vias are electrically connected to an opposing second side of the first resistor in the first resistor layer; and at least one of the first plurality of vias is electrically connected to a first side of the second resistor in the second resistor layer.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.
[0009] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
[0010]
[0011]
[0012]
[0013]
[0014]
[0015]
[0016]
[0017]
DETAILED DESCRIPTION
Current Sensing Circuit Architecture
[0018] The present approach can help overcome the problems explained above.
[0019] If both the current sense resistor 100 and the gain-setting resistor 102 are constructed from the same material (e.g., copper, on a laminate substrate), and are at the same temperature, the temperature coefficient of resistance (TCR) of either of the current sense resistor 100 or the gain-setting resistor 102 does not matter in terms of the impact on the scaled sensed current I.sub.OUT. The ratio of the resistance values of the current sense resistor 100 and the gain-setting resistor 102 remains the same (e.g., “n”) regardless of changes in their absolute resistance values due to temperature and their respective TCRs.
[0020] The two primary error sources in the architecture shown in
[0021]
[0022] In another example, adjusting or trimming the gain can be achieved such as by placing a large value shunt resistor in parallel to the gain-setting resistor 102 of resistance value n.Math.R, or a portion thereof, and then selecting a tap point on that large value shunt resistor for coupling to the inverting input to the amplifier 104. This has the effect of taking a fraction of the voltage across the gain-setting resistor 102 of resistance value n.Math.R to use as the feedback resistance value for the amplifier 104. As long as the fraction used of the large value shunt resistor remains stable with temperature and over time, the gain adjustment will remain stable.
[0023]
Thermal Stability
[0024] The present inventors have recognized, among other things, that it can be helpful to keep the two resistors (e.g., the sense resistor 100 of resistance R and the gain-setting resistor 102 of resistance n.Math.R) at the same temperature, such as to help maintain a stable gain n over temperature and to help reduce errors due to aging. Since the largest power dissipation will occur in the primary sense resistor 100 of resistance R (which can have the full, large, system current flowing through it), the gain setting resistor 102 of resistance n.Math.R can be constructed so as to be thermally coupled to the sense resistor 100, such that both of these resistors 100, 102 are at about the same temperature and experience the same temperature variations. This can include forming a “thermal cage” to help keep the sense resistor 100 and the gain-setting resistor 102 at the same temperature, such as shown in the schematic example of
[0025]
[0026] To help ensure sufficient thermal coupling between the sense resistor 100 and the gain-setting resistor 102, a thermal “cage” can be provided around the gain setting resistor 102. In
[0027]
[0028]
[0029] Because the current sense resistor 100 and the gain-setting resistor 102 can be thermally-coupled, such as using a thermal cage approach such as shown and described herein, these resistors 100, 102 will be at similar temperatures during operation, and this will be true over the usable operational life of the component as well. Therefore, any component aging effects of the resistors 100, 102 that depend upon temperature or temperature cycling will affect these resistors 100, 102 similarly. However, since the current sensing and measurement accuracy depends upon the ratio of these two resistance values of the resistors 100, 102, such temperature-dependent aging effects should affect both of these resistors 100, 102 equally or similarly, but component aging is not expected to affect the ratio of these resistance values, thereby helping preserve accuracy of the current sensing and measurement as the component or assembly ages.
[0030]
[0031]
Some Examples of Other Variations, Applications, or Uses
[0032] Since all the circuitry shown in the example of
[0033] The circuit shown in the example of
[0034] An additional resistor can optionally be included between IOUT and GND, such as can permit the circuit shown in the example of
[0035] The above description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “examples.” Such examples can include elements in addition to those shown or described. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.
[0036] In the event of inconsistent usages between this document and any documents so incorporated by reference, the usage in this document controls.
[0037] In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.
[0038] Geometric terms, such as “parallel”, “perpendicular”, “round”, or “square”, are not intended to require absolute mathematical precision, unless the context indicates otherwise. Instead, such geometric terms allow for variations due to manufacturing or equivalent functions. For example, if an element is described as “round” or “generally round,” a component that is not precisely circular (e.g., one that is slightly oblong or is a many-sided polygon) is still encompassed by this description. The term “coupled” can include both direct and indirect electrical interconnections that can be regarded as providing the described operative functional coupling.
[0039] Method examples described herein can be machine or computer-implemented at least in part. Some examples can include a computer-readable medium or machine-readable medium encoded with instructions operable to configure an electronic device to perform methods as described in the above examples. An implementation of such methods can include code, such as microcode, assembly language code, a higher-level language code, or the like. Such code can include computer readable instructions for performing various methods. The code may form portions of computer program products. Further, in an example, the code can be tangibly stored on one or more volatile, non-transitory, or non-volatile tangible computer-readable media, such as during execution or at other times. Examples of these tangible computer-readable media can include, but are not limited to, hard disks, removable magnetic disks, removable optical disks (e.g., compact disks and digital video disks), magnetic cassettes, memory cards or sticks, random access memories (RAMs), read only memories (ROMs), and the like.
[0040] The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims or aspects are hereby incorporated into the Detailed Description as examples or embodiments, with each claim or aspect standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims or aspects, along with the full scope of equivalents to which such claims or aspects are entitled.