Bobbin for a magnetic sensor

Claim 2

A magnetometer sensor for use in a borehole survey tool, comprising: (a) a bobbin made from a non-magnetic copper alloy having a magnetic permeability not greater than 1.001 , said alloy comprised of at least 60 percent and at least 9 percent nickel; (b) a strip of magnetic metal alloy wrapped around said bobbin to form a magnetic core, said strip having two ends with one end joined to said bobbin; (c) at least one excitation winding wrapped around said core; and (d) at least one sense winding wrapped around said core and said excitation winding.

Claim 3

The magnetometer sensor of claim 1, wherein a frame made from a non-electically conductive, high temperature thermal plastic is disposed between said excitation winding and sense winding.

Claim 4

The magnetometer sensor of claim 2, wherein said thermal plastic is selected from the group consisting of polyimide, an aromatic polyester liquid crystal polymer, and polysulfone.

Claim 5

The magnetometer sensor of claim 2, wherein said thermal plastic is poly-ether-ether-petone.

Claim 6

The magnetometer sensor of claim 1, wherein said alloy is comprised of about 65 weight percent copper, about 29 percent nickel, about 1 percent manganese and less than 0.50 percent iron.

Claim 7

The magnetometer sensor of claim 1, wherein said alloy is comprised of about 60 percent copper, about 20 percent nickel, about 20 percent manganese, and less than 0.15 weight percent iron.

Claim 8

The magnetometer sensor of claim 1, wherein said magnetic core is annealed before said excitation winding and said sense winding are wrapped around said core.

Claim 9

The magnetometer sensor of claim 7, wherein said core is annealed to a temperature of 1500 degrees Fahrenheit in a hydrogen atmosphere.

Claim 10

The magnetometer sensor of claim 1, wherein said bobbin is spool-shaped and has a U-shaped cross-section into which said strip is wound.

Claim 11

The magnetometer sensor of claim 1, further including a high temperature thermal plastic housing defining an interior cavity into which said magnetic core, excitation winding and sensing winding are carried.

Claim 12

The magnetometer sensor of claim 1, wherein said strip is made of Permalloy and is spirally wrapped around said bobbin to form a plurality of layers including an outer layer with the other end of said strip being joined to said outer layer.

Claim 13

The magnetometer sensor of claim 1, wherein the thermal coefficient of expansion of said bobbin is generally equal to the thermal coefficient of expansion of said strip.

Claim 14

The magnetometer sensor of claim 1, wherein said one end of said strip is welded to said bobbin.

Claim 15

The magnetometer sensor of claim 1, wherein said bobbin is generally ring-shaped.

Claim 16

The magnetometer sensor of claim 1, wherein said bobbin is an alloy of cooper, nickel and manganese.

Claim 17

In a magnetic survey instrument for use in a borehole, a sensor assembly comprising: (a) a generally ring-shaped bobbin made from a copper-nickel alloy having a magnetic permeability not greater than 1.0001, said alloy comprised of at least 60 percent copper and at least 9 percent nickel; (b) a thin, long strip of Square Permalloy-80 spirally wrapped around said bobbin with one end of said strip welded to said bobbin, to define a toroid having a plurality of overlying layers with the other end of said strip welded to the outermost of said layers and in close proximity to said one end; (c) one electrical conductor wrapped around said strip and said bobbin generally at right angles to said strip to define a first winding; (d) a plastic frame for carrying therein the structure formed by said toroid and said first winding; (e) another electrical conductor wrapped around said frame and two opposite portions of said toroid to define a second winding, the structure formed by said frame, said toroid, and said two windings defining a coil assembly; and (f) a high temperature thermal plastic housing having an internal opening, configured to carry said coil assembly, said housing further having at least one axial channel in communication with said opening for carrying the free ends of said windings.

Claim 18

In a magnetic survey instrument for use in a borehole, a sensor assembly comprising: (a) a generally ring-shaped bobbin made from a copper-nickel alloy having a magnetic permeability not greater than 1.0001, said alloy comprised of at least 60 percent copper and at least 9 percent nickel; (b) a thin, long strip of Square Permalloy-80 spirally wrapped around said bobbin with one end of said strip welded to said bobbin, to define a toroid having a plurality of overlying layers with the other end of said strip welded to the outermost of said layers and in close proximity to said one end; (c) one electrical conductor wrapped around said strip and said bobbin generally at right angles to said strip to define a first winding; (d) a plastic frame for carrying therein the structure formed by said toroid and said first winding; (e) another electrical conductor wrapped around said frame and two opposite portions of said toroid to define a second winding, the structure formed by said frame, said toroid, and said two windings defining a coil assembly; and (f) a high temperature thermal plastic housing having an internal opening, configured to carry said coil assembly, said housing further having at least one axial channel in communication with said opening for carrying the free ends of said windings.

Claim 19

The sensor of claim 16, wherein said frame is made from a high temperature thermal plastic.

Claim 20

The sensor of claim 16, further including a third winding wrapped around said coil assembly generally at right angles to said second winding.

Claim 21

The sensor of claim 16, wherein said frame defines a tongue and said housing defines a complementary groove which is disposed adjacent said opening and which is adapted to receive said tongue.