Current sensing inductive devices with integrated bus bar

Abstract

A low-cost and high-precision current sensing device and methods for use and manufacturing. In one embodiment, the current sensing apparatus comprises a Rogowski-type coil which is manufactured in segments so as to facilitate the manufacturing process. In an exemplary embodiment, the current sensing apparatus segments comprise a number of bobbin elements that are wound and subsequently formed into complex geometric shapes such as torus-like shapes. In an alternative embodiment, bonded windings are utilized which allow the segments to be formed without a bobbin or former. In yet another alternative embodiment, the aforementioned current sensing devices are stacked in groups of two or more. Methods of manufacturing and using the aforementioned current sensing apparatus are also disclosed.

What is claimed is: 
     
         1 .- 20 . (canceled) 
     
     
         21 . A current sensing inductive device, comprising:
 a housing having a plurality of segmented current sensing elements disposed therein, the plurality of segmented current sensing elements being disposed in a circular orientation about a center portion;   an integrated bus bar disposed through the housing such that at least a portion of the integrated bus bar is received in the center portion; and   a plurality of current sensing terminals that protrude from a bottom portion of the housing.   
     
     
         22 . The current sensing inductive device of  claim 21 , wherein the ends of the integrated bus bar are oriented in a parallel orientation with respect to the current sensing terminals. 
     
     
         23 . The current sensing inductive device of  claim 22 , wherein the integrated bus bar is physically larger than each of the plurality of current sensing terminals. 
     
     
         24 . The current sensing inductive device of  claim 23 , wherein the integrated bus bar comprises a substantially U-shaped conductor. 
     
     
         25 . The current sensing inductive device of  claim 24 , wherein each of the segmented current sensing elements comprises a plurality of turns of a conductive wire, the plurality of current sensing terminals being in signal communication with at least a portion of the plurality of turns of the conductive wire. 
     
     
         26 . The current sensing inductive device of  claim 21 , wherein at least one of the plurality of segmented current sensing elements comprises:
 a bobbin element comprising a pair of flanges with a winding spool disposed substantially there between; and   a plurality of turns of a conductive wire disposed between the pair of flanges and on the winding spool.   
     
     
         27 . The current sensing inductive device of  claim 26 , wherein the conductive wire comprises a plurality of layers of winding disposed on the winding spool. 
     
     
         28 . The current sensing inductive device of  claim 27 , wherein at least one of the plurality of layers of winding comprises a shielding layer. 
     
     
         29 . The current sensing inductive device of  claim 28 , wherein the shielding layer is operative to at least mitigate electromagnetic noise transmission during operation. 
     
     
         30 . The current sensing inductive device of  claim 28 , wherein at least one of the plurality of layers of winding comprises a current sensing layer. 
     
     
         31 . The current sensing inductive device of  claim 30 , wherein the current sensing layer and the shielding layer are manufactured from the same gauge of a conductive wire. 
     
     
         32 . The current sensing inductive device of  claim 26 , wherein the at least one of the plurality of segmented current sensing elements further comprises an end clip disposed within a wall of one of the pair of flanges. 
     
     
         33 . A current sensing inductive device, comprising:
 a housing having a plurality of bobbin elements disposed therein, the plurality of bobbin elements being disposed in a non-closed loop configuration;   an integrated bus bar disposed within the housing such that at least a portion of the integrated bus bar is received within the non-closed loop configuration; and   a plurality of current sensing terminals that protrude from a bottom portion of the housing.   
     
     
         34 . The current sensing inductive device of  claim 33 , wherein a center portion of each of the plurality of bobbin elements is disposed in a plane, the plane being substantially orthogonal with a bottom surface of the housing. 
     
     
         35 . The current sensing inductive device of  claim 34 , wherein at least one of the plurality of bobbin elements comprises a plurality of turns of a conductive wire, the plurality of turns of the conductive wire being positioned about the center portion of the at least one bobbin element. 
     
     
         36 . The current sensing inductive device of  claim 35 , wherein the plurality of turns of the conductive wire comprises a plurality of layers of winding. 
     
     
         37 . The current sensing inductive device of  claim 36 , wherein at least one of the plurality of layers of winding comprises a shielding layer and at least one other one of the plurality of layers comprises a sensing layer. 
     
     
         38 . The current sensing inductive device of  claim 37 , wherein the ends of the integrated bus bar are oriented in a parallel orientation with respect to the current sensing terminals; and
 wherein the integrated bus bar comprises a substantially U-shaped conductor.   
     
     
         39 . The current sensing inductive device of  claim 38 , wherein the integrated bus bar is physically larger than each of the plurality of current sensing terminals. 
     
     
         40 . A current sensing inductive device, comprising:
 a plurality of bobbin elements having a plurality of turns and a plurality of layers of a conductive wire disposed thereon;   a housing having the plurality of bobbin elements disposed therein, the plurality of bobbin elements collectively being disposed in a vertical orientation with respect to a bottom surface of the housing;   an integrated bus bar disposed within the housing such that at least a portion of the integrated bus bar is surrounded by the plurality of bobbin elements; and   a plurality of current sensing terminals that protrude from the bottom surface of the housing.