A filter, an on-board charger and a vehicle

Abstract

This invention relates to a filter, an on-board charger, and a vehicle, and relates to the field of filtering technology to solve the technical problem that the fixed mechanical structure in the prior art limits the flexibility of capacitor configuration. The filter includes: one or more capacitor components, one or more sets of connection ports, one set of the connection ports being used to couple one of the capacitor components, corresponding to filtering out electromagnetic interference of different frequency bands, the number of connection ports connected to the capacitor components in the multiple sets of connection ports being different, or, corresponding to filtering out electromagnetic interference of different frequency bands, the parameters connected to the capacitor modules in the multiple sets of connection ports being different.

Description

Technical Field

[0001] This invention relates to the field of filtering technology, specifically to a filter, an on-board charger, and a vehicle. Background Technology

[0002] With the continuous iteration of automotive technology and the large-scale innovation and industrialization of new energy vehicles, the requirements for electromagnetic compatibility of vehicles are constantly increasing, and the design of filters is becoming increasingly stringent in order to meet the high electromagnetic shielding and anti-interference requirements of the ever-increasing voltage and power platforms of vehicles.

[0003] In related technologies, after determining the application scenario or operating conditions of the filter, the parameters of the capacitors and magnetic rings in the filter are determined to filter out electromagnetic interference in the corresponding frequency band. However, due to the significant differences in the electrical operating conditions of different vehicles and onboard components, filters using fixed mechanical structures are difficult to flexibly replace capacitors according to different electrical conditions, leading to insufficient capacitor matching and substandard filtering.

[0004] Therefore, the fixed mechanical structure in related technologies limits the flexibility of capacitor configuration. Summary of the Invention

[0005] This application provides a filter, an on-board charger, and a vehicle to solve the technical problem that fixed mechanical structures in related technologies limit the flexibility of capacitor configuration.

[0006] To achieve the above objectives, the technical solution adopted in this application is as follows: In a first aspect, a filter is provided, comprising: one or more capacitor components, and one or more sets of connection ports, wherein one set of connection ports is used to couple one capacitor component, corresponding to filtering out electromagnetic interference of different frequency bands, and the number of connection ports connected to the capacitor components in the multiple sets of connection ports is different, or, corresponding to filtering out electromagnetic interference of different frequency bands, the parameters of the capacitor components connected in the multiple sets of connection ports are different.

[0007] As can be seen from the above, by providing multiple sets of connection ports that can be independently connected to capacitor components, researchers only need to select and connect an appropriate number or different parameters of capacitor components according to the specific vehicle's electrical conditions to quickly match the frequency band characteristics of electromagnetic interference, thus improving the flexibility of capacitor configuration. Furthermore, based on the filter provided in this application embodiment, the testing and verification cycle for filter electromagnetic compatibility can be reduced, the cost of frequent component replacement can be lowered, and the technical problem of insufficient capacitor combination matching under a fixed mechanical structure can be solved.

[0008] Optionally, the filter further includes a conductive metal busbar with connection ports for transmitting current.

[0009] As can be seen from the above, conductive metal busbars have stronger current-carrying capacity, better heat dissipation performance, and lower stray inductance, which can significantly reduce the interference of parasitic parameters on the filtering effect in high-current paths. This application introduces a conductive metal busbar to provide an integrated, low-impedance current transmission backbone for multiple connection ports. By directly integrating the connection ports onto the metal busbar, capacitor components can be securely connected to different ports on the metal busbar via plug-in or soldering methods, without modifying the overall wiring. Simply plugging in the appropriate number of capacitors or capacitors with different parameters onto different ports allows for flexible adjustment of the filtering frequency band and intensity.

[0010] Optionally, the capacitor assembly includes: a capacitor and a conductive metal sheet, the conductive metal sheet being coupled to the leads of the capacitor and the conductive metal sheet being connected to the leads of the capacitor by soldering.

[0011] As can be seen from the above, in this embodiment, the capacitor and conductive metal sheet are pre-welded to form a capacitor assembly. When it is necessary to adjust the filtering frequency band according to different electrical conditions, the researchers only need to quickly insert capacitor assemblies with different parameters or different numbers of capacitors into the connection ports on the metal busbar through the conductive metal sheet (using screw crimping, spring clamping, or busbar clamping, etc.), without having to repeatedly solder the capacitor leads. In addition, the conductive metal sheet serves as the conductive medium between the capacitor and the connection ports on the metal busbar. The conductive metal sheet provides a larger heat dissipation area and lower contact resistance, which is beneficial to ensuring electrical stability under high current conditions.

[0012] Optionally, the conductive metal sheet is fixedly connected to the connection port by bolts.

[0013] As can be seen from the above, in this embodiment, the capacitor and conductive metal sheet are pre-integrated into a capacitor assembly, and then a detachable and fixed connection is achieved through bolts between the conductive metal sheet and the connection port on the conductive metal busbar. Different parameters or quantities of capacitor assemblies can be replaced by unscrewing the bolts, and the electrical connection is completed by tightening the bolts; the entire process requires no high-temperature welding. Furthermore, the bolted connection provides a more stable mechanical clamping force and lower long-term contact resistance than welding or plugging, and can withstand harsh environments such as strong vibrations and high-current thermal cycling during vehicle operation, without the problems of weld fatigue cracking or loosening of connectors. Therefore, the bolted fixing connection not only retains the high flexibility of the capacitor assembly's "on-demand configuration and plug-and-play" capability, but also improves the stability of the filter in different application scenarios.

[0014] Optionally, the capacitor assembly further includes: a first housing and a resilient snap fastener, the first housing being disposed on the outside of the capacitor and the resilient snap fastener being disposed on the outside of the first housing.

[0015] As can be seen from the above embodiments, the first housing provides physical protection and insulation for the capacitor, preventing damage to the capacitor from external metal debris or vibration impacts. After the capacitor leads are welded and encapsulated with conductive metal sheets, the capacitor no longer directly bears the external force of insertion, removal, or assembly, reducing the risk of lead root breakage and improving the mechanical strength and vibration resistance of the capacitor assembly itself. Furthermore, the elastic clips located on the outside of the first housing, together with the bolt fixing, form a double positioning system of locking after locking, ensuring that the capacitor assembly can be installed in the corresponding position of the filter. The elastic clips automatically deform elastically and snap into the preset slots, achieving rapid pre-positioning. Under long-term vehicle vibration conditions, even if the bolts become slightly loose, the elastic clips can still provide continuous holding force, preventing the capacitor assembly from loosening or making poor contact. Based on the integrated capacitor assembly provided in this application embodiment, researchers can quickly adjust the combination of different capacitor parameters or quantities to match the electrical conditions of different vehicle models, significantly shortening the electromagnetic compatibility rectification and verification cycle.

[0016] Optionally, the filter further includes a second housing, which is disposed outside the conductive metal busbar and the capacitor assembly, and when the capacitor assembly is disposed inside the second housing, a resilient snap-fit ​​engages with the second housing.

[0017] As can be seen from the above, the second outer shell, as the overall protective cover of the filter, integrates the conductive metal busbar and multiple capacitor components into one unit, providing physical protection, electromagnetic shielding, and insulation isolation, as well as a reliable fastening interface for the elastic clips on the capacitor components. When the capacitor components are pushed into the second outer shell along the installation direction, the elastic clips on the outer side of the first outer shell automatically deform elastically and engage with the pre-set slots on the inner wall of the second outer shell, achieving rapid pre-positioning. In addition, the second outer shell integrates the originally separate capacitor components, conductive metal busbar, and connection ports into a single module that can be installed as a whole, while each capacitor component can still be independently disassembled and assembled. Based on the technical solution provided in the embodiments of this application, the collaborative design of the second outer shell and the elastic clips significantly improves the vibration resistance of the filter while maintaining a high degree of modularity and configurability, ensuring the stability of the filter's filtering.

[0018] Optionally, the conductive metal busbar includes: a first conductive metal busbar and a second conductive metal busbar, the first conductive metal busbar being provided with a first connection port, and the second conductive metal busbar being provided with a second connection port. The capacitor assembly includes: a first capacitor assembly, the first conductive metal sheet of the first capacitor assembly being coupled to the first connection port, and the second conductive metal sheet of the first capacitor assembly being coupled to the second connection port.

[0019] As can be seen from the above, the embodiments of this application divide the conductive metal busbar into a first metal busbar and a second metal busbar. Each metal busbar is provided with an independent connection port. The first capacitor assembly, through the conductive metal plates at both ends, is connected across the first connection port of the first metal busbar and the second connection port of the second metal busbar, respectively, thereby electrically forming an X-capacitor type filter structure between the first and second conductive metal busbars. The embodiments of this application transform the single structure of a fixed filter into a flexibly configurable integrated filter platform, perfectly adapting to the dynamic requirements of differential mode filtering performance under different models and operating conditions of new energy vehicles, shortening the electromagnetic compatibility development and rectification cycle, and reducing R&D time costs.

[0020] Optionally, the first conductive metal busbar is further provided with a third connection port, and the second conductive metal busbar is further provided with a fourth connection port. The capacitor assembly includes a second capacitor assembly and a third capacitor assembly. The first conductive metal piece of the second capacitor assembly is coupled to the third connection port, the second conductive metal piece of the second capacitor assembly is coupled to the fifth connection port, the first conductive metal piece of the third capacitor assembly is coupled to the fourth connection port, the second conductive metal piece of the third capacitor assembly is coupled to the fifth connection port, and the fifth connection port is coupled to the voltage reference terminal.

[0021] As can be seen from the above embodiments, the first capacitor assembly is connected between the first and second conductive metal busbars as an X capacitor to suppress differential-mode interference. The second capacitor assembly is connected between the first conductive metal busbar and the voltage reference terminal as a Y capacitor to direct the common-mode interference of the first conductive metal busbar to the voltage reference terminal. The third capacitor assembly is connected between the second conductive metal busbar and the voltage reference terminal as a Y capacitor to direct the common-mode interference of the second conductive metal busbar to the voltage reference terminal. All capacitor assemblies are bolted together with corresponding connection ports on the conductive metal busbars via conductive metal sheets, supplemented by elastic clips and a second housing pre-lock. For different vehicle electrical conditions, if differential-mode interference is severe, researchers can increase the number of the first capacitor assembly or change its parameters. If common-mode interference is prominent, the number or parameters of the second and third capacitor assemblies can be adjusted independently. Furthermore, the capacitance of the first conductive metal busbar (which can be understood as the positive terminal) to ground and the second conductive metal busbar (which can be understood as the negative terminal) to ground can be asymmetrically adjusted to address unbalanced common-mode noise. Since all connection ports and capacitor components are detachable interfaces, no welding or disassembly of the entire machine is required during debugging. Simply loosen the bolts and press the clips to quickly add, remove, or replace components. This improves the flexibility and reliability of capacitor configuration, reduces R&D time costs, and adapts to the ever-evolving and differentiated filtering needs of vehicle high-voltage platforms.

[0022] Optionally, the filter further includes a magnetic ring, which is sleeved on the outside of the first conductive metal bar and the second conductive metal bar.

[0023] As can be seen from the above, in this embodiment, the magnetic ring acts as a common-mode magnetic ring, causing the common-mode currents on the two conductive metal busbars to generate unidirectional magnetic fluxes that superimpose, thus presenting a high impedance to common-mode interference. Simultaneously, the magnetic fluxes generated by the differential-mode currents cancel each other out, without affecting normal power transmission. The common-mode magnetic ring decouples the differential-mode and common-mode suppression functions; that is, common-mode interference suppression is jointly undertaken by the magnetic ring, the second capacitor assembly, and the third capacitor assembly, while differential-mode interference suppression is independently completed by the first capacitor assembly. Based on the filter provided in this embodiment, researchers can independently adjust the differential-mode filtering depth and common-mode filtering intensity without modifying the magnetic ring, simply by quickly replacing or increasing / decreasing the number and parameters of the first, second, and third capacitor assemblies, to meet different electrical operating conditions. This can cover the full-band adaptive filtering requirements from low-frequency differential mode to high-frequency common mode.

[0024] Optionally, a magnetic ring fixing structure is provided inside the second housing to fix the magnetic ring.

[0025] As can be seen from the above, the second shell integrates a dedicated magnetic ring fixing structure on the basis of the original protection and snap-fit ​​interface, so that the magnetic ring can be accurately and firmly installed in the predetermined position inside the shell, reducing the risk of inductance changes or abnormal noise caused by the loosening of the magnetic ring.

[0026] In a second aspect, an on-board charger is provided, comprising: a filter as described in the first aspect.

[0027] Thirdly, a vehicle is provided, comprising: a filter as described in the first aspect, or an on-board charger as described in the second aspect.

[0028] It should be noted that the technical effects of any of the implementation methods in the second and third aspects can be referred to the technical effects of the corresponding implementation methods in the first aspect, and will not be elaborated here.

[0029] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the structure of a vehicle as shown in an embodiment of this application; Figure 2 A schematic diagram of the structure of a filter shown in an embodiment of this application. Figure 1 ; Figure 3 A schematic diagram of the structure of a filter shown in an embodiment of this application. Figure 2 ; Figure 4 This is a schematic diagram of the structure of a capacitor assembly shown in an embodiment of this application; Figure 5This is a schematic diagram illustrating a conductive metal sheet according to an embodiment of this application; Figure 6 A schematic diagram of the structure of a filter shown in an embodiment of this application. Figure 3 .

[0031] Figure label: 1-Vehicle; 10-On-board charger; 100-Filter; 101-Magnetic ring; 102-Conductive metal busbar; 103-Capacitor assembly; 104-Connection port; 1021 - First conductive metal busbar; 1022 - Second conductive metal busbar; 1031 - First capacitor assembly; 1032 - Second capacitor assembly; 1033 - Third capacitor assembly; 201 - Conductive metal sheet; 202 - Bolt hole; 203 - First outer casing; 204 - Elastic buckle; 2011 - First conductive metal sheet; 2012 - Second conductive metal sheet; C - Capacitor; X1 - First X capacitor; X2 - Second X capacitor; Y1 - First Y capacitor; Y2 - Second Y capacitor; 1011 - Magnetic core; L - Coil; P1 - First connection port; P2 - Second connection port; P3 - Third connection port; P4 - Fourth connection port; P5 - Fifth connection port; GND - Voltage reference terminal. Detailed Implementation

[0032] The terms “first,” “second,” etc., are used for descriptive purposes only and have no sequential or technical meaning, nor should they be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated.

[0033] In the description of the embodiments of this application, unless otherwise expressly specified and limited, the terms "coupled" and "connected" refer to the flow of current or signal from one conductor to another. A connection between A and B means that current or signal can flow from A to B and vice versa. A connection between A and B includes direct electrical connection and indirect electrical connection. A direct electrical connection between A and B means that A and B are electrically connected through physical contact. An indirect electrical connection between A and B means that A and B are electrically connected through C, where C can be at least one wire or device.

[0034] In the embodiments of this application, "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0035] First, a brief introduction to the application scenarios involved in this application will be given.

[0036] As described in the background section, with the continuous improvement of vehicle electrification and intelligence, the number of electrical devices such as on-board controllers, power modules, and drive motors has increased significantly. The complex electrical environment in vehicles has led to increasingly prominent electromagnetic interference problems. Therefore, electromagnetic compatibility (EMC) filters are needed to suppress conducted and radiated interference to meet the EMC requirements of the automotive industry. At the same time, with the continuous iteration of automotive technology and the large-scale innovation and industrialization of new energy vehicles, the EMC requirements of vehicles are constantly increasing, and the design of filters is becoming increasingly stringent to meet the high electromagnetic shielding and anti-interference requirements of the ever-increasing voltage and power platforms of vehicles.

[0037] Filters can be applied to the high-voltage circuit of a vehicle, such as in an on-board charger, to suppress electromagnetic interference at the input and / or output of the on-board charger. They can also be used in motor controllers, DC-DC converters, and power modules to ensure the stable operation of various electronic components in the high-voltage circuit and to prevent control malfunctions or communication abnormalities caused by electromagnetic interference.

[0038] In some embodiments, the application of a filter to an on-board charger is used as an example for illustration, such as... Figure 1 As shown, vehicle 1 includes an on-board charger 10.

[0039] At least one filter is provided in the on-board charger 10 to suppress electromagnetic interference at the input and / or output terminals of the on-board charger 10.

[0040] In some embodiments, the filter includes at least one X capacitor and at least one set of Y capacitors and a magnetic ring.

[0041] The following is combined Figure 2 Taking a filter consisting of two X capacitors and a set of Y capacitors as an example, the working principle of the filter is introduced. Figure 2 As shown, the filter 100 includes: a first X capacitor X1, a second X capacitor X2, a first Y capacitor Y1, a second Y capacitor Y2, a magnetic ring 101, and a conductive metal busbar 102.

[0042] The conductive metal busbar 102 is usually made of copper. The conductive metal busbar 102 is divided into a first conductive metal busbar 1021 and a second conductive metal busbar 1022.

[0043] The first terminal of the first X capacitor X1 is coupled to the first conductive metal bus 1021, and the second terminal of the first X capacitor X1 is coupled to the second conductive metal bus 1022. The first terminal of the second X capacitor X2 is coupled to the first conductive metal bus 1021, and the second terminal of the second X capacitor X2 is coupled to the second conductive metal bus 1022. The first terminal of the first Y capacitor Y1 is coupled to the first conductive metal bus 1021, and the second terminal of the first Y capacitor Y1 is coupled to the voltage reference terminal GND. The first terminal of the second Y capacitor Y2 is coupled to the second conductive metal bus 1022, and the second terminal of the second Y capacitor Y2 is coupled to the voltage reference terminal GND.

[0044] The magnetic ring 101 is sleeved on the outside of the first conductive metal bar 1021 and the second conductive metal bar 1022.

[0045] In some embodiments, the coil L is wound around the outside of the magnetic core 1011 to form a magnetic ring, which is used as a common-mode magnetic ring in this application.

[0046] Differential-mode interference is an interference signal where current flows out along the positive terminal and returns along the negative terminal, forming a loop. Common-mode interference is an interference current in the same direction relative to ground appearing simultaneously on both the positive and negative transmission lines (i.e., the first conductive metal bus 1021 and the second conductive metal bus 1022). Utilizing the characteristic of capacitors to pass high frequencies and block low frequencies, differential-mode interference will preferentially pass through the low-impedance path formed by the first X capacitor X1 and / or the second X capacitor X2, and will not continue to propagate to subsequent circuits. The Y capacitor provides a stable, low-impedance path to ground for common-mode interference. The common-mode current flows to ground through the first Y capacitor Y1 and the second Y capacitor Y2, thus being bypassed and no longer propagating to the subsequent stages. At the same time, the common-mode magnetic ring exhibits high inductive reactance to the common-mode current, forming an LC filter network together with the Y capacitors, enhancing the attenuation of common-mode noise. Through the coordinated work of these three components, electromagnetic interference can be suppressed.

[0047] Since the electromagnetic interference spectrum varies in different application scenarios, it is necessary to select different parameters for the X capacitor, Y capacitor, and magnetic ring according to different application scenarios so that the filter works in the best matching state.

[0048] However, in related technologies, filters use fixed mechanical structures, which makes it inconvenient to adjust the parameters of capacitors and magnetic rings.

[0049] Due to the significant differences in electrical operating conditions among different vehicles and onboard components, traditional filters, with their fixed mechanical structures, struggle to flexibly replace capacitors according to varying electrical conditions. This leads to insufficient capacitor matching and substandard filtering. When interference exceeds limits, each capacitor must be replaced individually, requiring a complete reconfiguration of the structure. This process is time-consuming and costly. Furthermore, the welding and assembly during rework can easily cause problems such as cold solder joints and excessively long leads, increasing stray inductance, weakening the filtering effect, and potentially leading to insufficient insulation withstand voltage. Therefore, the fixed mechanical structure in related technologies limits the flexibility of capacitor configuration.

[0050] Based on this, embodiments of this application provide a filter, such as... Figure 3 As shown, the filter 100 includes: one or more capacitor components 103, one or more sets of connection ports 104, and a conductive metal busbar 102. The conductive metal busbar 102 is used to transmit current, and the conductive metal busbar 102 is provided with connection ports 104.

[0051] A set of connection ports 104 is used to couple a capacitor component 103. Corresponding to filtering electromagnetic interference of different frequency bands, the number of connection ports 104 connected to the capacitor component 103 in the multiple sets of connection ports 104 is different, or, corresponding to filtering electromagnetic interference of different frequency bands, the parameters of the capacitor components 103 connected in the multiple sets of connection ports 104 are different.

[0052] Based on the filter 100 provided in the embodiments of this application, the filter 100 is provided with a connection port. Depending on different operating conditions, different numbers and parameters of capacitor components 103 can be integrated in the filter 100 to achieve filtering of electromagnetic interference in different frequency bands.

[0053] As can be seen from the above, by providing multiple sets of connection ports 104 that can be independently connected to the capacitor assembly 103, researchers only need to select and connect an appropriate number or different parameters of capacitor assemblies 103 according to the specific vehicle's electrical conditions to quickly match the frequency band characteristics of electromagnetic interference, thus improving the flexibility of capacitor configuration. Furthermore, this reduces the testing and verification cycle of the filter 100's electromagnetic compatibility and the cost associated with frequent component replacements.

[0054] In some examples, the conductive metal bus 102 includes a first conductive metal bus 1021 and a second conductive metal bus 1022. The first conductive metal bus 1021 is provided with a first connection port P1 and a third connection port P3, and the second conductive metal bus 1022 is provided with a second connection port P2 and a fourth connection port P4. The filter 100 is also provided with a fifth connection port P5 for coupling to the voltage reference terminal GND.

[0055] Among them, the first connection port P1 and the second connection port P2 can be regarded as a group of connection ports, the third connection port P3 and the fifth connection port P5 can be regarded as a group of connection ports, and the fourth connection port P4 and the fifth connection port P5 can be regarded as a group of connection ports.

[0056] The capacitor assembly 103 includes a first capacitor assembly 1031, a second capacitor assembly 1032, and a third capacitor assembly 1033. The first capacitor assembly 1031 is coupled to a first connection port P1 and a second connection port P2. The second capacitor assembly 1032 is coupled to a third connection port P3 and a fifth connection port P5. The third capacitor assembly 1033 is coupled to a fourth connection port P4 and a fifth connection port P5.

[0057] In this embodiment, the first capacitor assembly 1031 is used to filter out differential-mode interference, and the second capacitor assembly 1032 and the third capacitor assembly 1033 are used to filter out common-mode interference.

[0058] It should be noted that the first conductive metal busbar 1021 and the second conductive metal busbar 1022 are provided with multiple connection ports 104 for connecting multiple capacitor assemblies 103.

[0059] The filter 100 also includes a magnetic ring 101, which is sleeved on the outside of the first conductive metal bar 1021 and the second conductive metal bar 1022 as a common-mode magnetic ring to further filter out common-mode interference.

[0060] Optionally, the filter 100 may use a magnetic ring with a ferrite core, or a nanocrystalline magnetic ring or other common-mode magnetic rings may be sleeved on the outside of the first conductive metal busbar 1021 and the second conductive metal busbar 1022.

[0061] In this embodiment, the magnetic ring 101 serves as a common-mode magnetic ring, causing the common-mode currents on the two conductive metal busbars to generate unidirectional magnetic fluxes that superimpose, thus presenting high impedance to common-mode interference. Simultaneously, the magnetic fluxes generated by the differential-mode currents cancel each other out, without affecting normal power transmission. The common-mode magnetic ring decouples the differential-mode and common-mode suppression functions. Based on the filter provided in this embodiment, researchers can independently adjust the differential-mode filtering depth and common-mode filtering strength under different electrical conditions without adjusting the magnetic ring 101, simply by quickly replacing or increasing / decreasing the number and parameters of the capacitor components. This can cover the full-band adaptive filtering requirements from low-frequency differential-mode to high-frequency common-mode.

[0062] Based on the filter 100 provided in this application embodiment, the filter 100 can be connected to the vehicle's electrical circuit to quickly complete the verification of current conduction, radiation interference, and noise shielding performance. There is no need to build a temporary manual filter circuit. After the test is passed, it can be directly installed as a product component in the vehicle, realizing the integration of verification and application.

[0063] To further explain the connection relationship between capacitor assembly 103 and conductive metal busbar 102, the structure of capacitor assembly 103 needs to be explained first.

[0064] like Figure 4 As shown, the capacitor assembly 103 includes a capacitor C and a conductive metal sheet 201. The conductive metal sheet 201 is coupled to the leads of the capacitor C.

[0065] The conductive metal sheet 201 is divided into a first conductive metal sheet 2011 and a second conductive metal sheet 2012. The two pins of the capacitor C are respectively coupled to the first conductive metal sheet 2011 and the second conductive metal sheet 2012.

[0066] The first conductive metal sheet 2011 and the second conductive metal sheet 2012 are connected to the leads of the capacitor C by welding. The conductive metal sheet 201 also has the dual function of clamping and fixing for welding installation. Specifically, the terminals of the conductive metal sheet are welded to the leads of the capacitor C, and the lead length of the capacitor C is strictly controlled to reduce stray inductance in the circuit and ensure accurate EMC test data and stable filtering performance.

[0067] In one example, the length of the capacitor lead beyond the terminal is controlled to be within 3mm to minimize stray inductance, ensure stable filtering performance, and avoid the risk of poor soldering or missing soldering caused by manual external capacitor connection in assembly process or traditional scenarios, which could affect the accuracy of EMC test results.

[0068] An exemplary schematic diagram of the conductive metal sheet 201 without welding is shown below. Figure 5 As shown.

[0069] In this embodiment, the leads of capacitor C are welded to conductive metal sheet 201 (resistance welding can be used) to ensure a stable connection between capacitor C and conductive metal sheet 201, thus meeting the vehicle vibration requirements.

[0070] The conductive metal sheet 201 is also provided with bolt holes 202, and the conductive metal sheet 201 is fixedly connected to the connection port 104 by bolts.

[0071] Combination Figure 3 , Figure 4 In such Figure 6 In the embodiment shown, the first conductive metal sheet of the first capacitor assembly 1031 is coupled to the first connection port P1, and the second conductive metal sheet of the first capacitor assembly 1031 is coupled to the second connection port P2.

[0072] The first conductive metal piece of the second capacitor assembly 1032 is coupled to the third connection port P3, the second conductive metal piece of the second capacitor assembly 1032 is coupled to the fifth connection port P5, the first conductive metal piece of the third capacitor assembly 1033 is coupled to the fourth connection port P4, the second conductive metal piece of the third capacitor assembly 1033 is coupled to the fifth connection port P5, and the fifth connection port P5 is coupled to the voltage reference terminal GND.

[0073] In this embodiment, the capacitor assembly 103 is described using the example of a first capacitor assembly 1031, a second capacitor assembly 1032, and a third capacitor assembly 1033. However, in practical applications, it may include multiple first capacitor assemblies 1031, multiple second capacitor assemblies 1032, and multiple third capacitor assemblies 1033. The parameters of each capacitor assembly 103 can be determined according to specific electrical conditions.

[0074] For example, the capacitor assembly 103 includes: eight first capacitor assemblies 1031, two second capacitor assemblies 1032 and two third capacitor assemblies 1033.

[0075] In the embodiments of this application, the first capacitor component 1031 is typically a capacitor C with capacitance parameters in the range of 1nF to 4.7μF, such as capacitors C with capacitance parameters of 4.7μF, 3.3μF, 2.2μF, 1μF, 680nF, 220nF, 33nF, 10nF, and 1nF.

[0076] The second capacitor assembly 1032 and the third capacitor assembly 1033 are typically capacitors C with capacitance parameters in the range of 100pF to 200nF, such as capacitors C with capacitance parameters of 200nF, 100nF, 33nF, 10nF, 1nF, 680pF, 470pF, 220pF, and 100pF.

[0077] It should be noted that when multiple first capacitor components 1031 are selected, the capacitance parameters of the multiple first capacitor components 1031 can be the same or different. Similarly, when multiple second capacitor components 1032 are selected, the capacitance parameters of the multiple second capacitor components 1032 can be the same or different. When multiple third capacitor components 1033 are selected, the capacitance parameters of the multiple third capacitor components 1033 can be the same or different. This application does not impose any limitations on this.

[0078] In one example, capacitor assembly 103 includes: two 4.7μF first capacitor assemblies 1031, two 2.2μF first capacitor assemblies 1031, two 10nF first capacitor assemblies 1031, one 220nF first capacitor assembly 1031, one 33nF first capacitor assembly 1031, one 100nF second capacitor assembly 1032, one 680pF second capacitor assembly 1032, and two 100nF third capacitor assemblies 1033. Based on the filter provided in this application embodiment, by applying multiple capacitor assemblies with different parameters, the conventional electromagnetic interference frequency band of 150kHz~1GHz can be covered, which can fully match the electromagnetic compatibility requirements of components such as power supplies, electronic control units, DC-DC converters, and on-board chargers in vehicles.

[0079] In conjunction with the above embodiments, the first capacitor assembly 1031 is connected between the first conductive metal busbar 1021 and the second conductive metal busbar 1022, serving as an X capacitor to suppress differential-mode interference. The second capacitor assembly 1032 is connected between the first conductive metal busbar 1021 and the voltage reference terminal GND, serving as a Y capacitor to direct common-mode interference from the first conductive metal busbar 1021 to the voltage reference terminal. The third capacitor assembly 1033 is connected between the second conductive metal busbar 1022 and the voltage reference terminal GND, serving as a Y capacitor to direct common-mode interference from the second conductive metal busbar 1022 to the voltage reference terminal GND. When faced with different vehicle electrical conditions, if differential-mode interference is severe, researchers can increase the number of the first capacitor assembly or change its parameters. If common-mode interference is prominent, the number or parameters of the second capacitor assembly 1032 and the third capacitor assembly 1033 can be adjusted independently. Furthermore, the capacitance between the first conductive metal busbar 1021 (which can be understood as the positive terminal) and ground, and between the second conductive metal busbar 1022 (which can be understood as the negative terminal) and ground can be asymmetrically adjusted to address unbalanced common-mode noise. Since all connection ports 104 and capacitor assemblies 103 are detachable interfaces, no soldering or disassembly of the entire unit is required during debugging. This improves the flexibility and reliability of capacitor configuration, reduces R&D time costs, and adapts to the evolving filtering needs of vehicle high-voltage platforms.

[0080] In such Figure 4 In the embodiment shown, the capacitor assembly 103 further includes a first housing 203 and an elastic buckle 204, wherein the first housing 203 is disposed on the outside of the capacitor C and the elastic buckle 204 is disposed on the outside of the first housing 203.

[0081] In one example, after the capacitor assembly 103 integrates the conductive metal sheet 201 and the capacitor C, it is covered by a first outer shell 203. The first outer shell 203 is an injection-molded shell, that is, it is formed by injection molding of an insulating plastic shell to cover part of the conductive metal sheet 201 (specifically as shown in the example). Figure 4 As shown in the figure, and reserve the position of bolt hole 202.

[0082] In conjunction with the above embodiments, the first housing 203 provides physical protection and insulation for the capacitor C, preventing damage to the capacitor from external metal debris or vibration impacts. After the capacitor C leads are welded and encapsulated to the conductive metal sheet 201, the capacitor C no longer directly bears the external force of insertion, removal, or assembly, reducing the risk of lead root breakage and improving the mechanical strength and vibration resistance of the capacitor assembly 103 itself. Furthermore, the elastic buckle 204 located on the outside of the first housing 203 forms a double positioning system with the bolt fixing, ensuring that the capacitor assembly 103 can be installed in the corresponding position of the filter 100. The elastic buckle 204 automatically deforms elastically and snaps into the preset slot, achieving rapid pre-positioning. Under long-term vehicle vibration conditions, even if the bolts become slightly loose, the elastic buckle 204 can still provide continuous holding force, preventing the capacitor assembly 103 from loosening or making poor contact. Based on the integrated capacitor assembly 103 provided in this application embodiment, researchers can quickly adjust the combination of different capacitor parameters or quantities to match the electrical conditions of different vehicle models, significantly shortening the electromagnetic compatibility rectification and verification cycle.

[0083] In some embodiments, the filter 100 further includes a second housing disposed outside the conductive metal bar 102 and the capacitor assembly 103, wherein when the capacitor assembly 103 is disposed inside the second housing, an elastic snap 204 is engaged inside the second housing.

[0084] In one example, the second outer shell is a plastic shell, injection molded from flame-retardant PA66 or higher-grade engineering plastic. Internally, it has a mounting groove for the capacitor assembly 103, a pre-reserved elastic snap-fit ​​groove, a conductive metal strip groove, and bolt fixing positions. The elastic snap-fit ​​groove serves as a support and limiting mechanism, allowing for quick engagement between the capacitor assembly 103 and the filter 100 via the elastic snap-fit ​​204.

[0085] In conjunction with the above embodiments, the elastic clips 204 are symmetrically arranged at both ends of the first housing 203. The capacitor assembly 103 is inserted into the mounting slot from top to bottom, and the elastic clips 204 snap into the reserved elastic clip slots. The conductive metal sheet 201 and the conductive metal busbar 102 are fixedly connected by bolts, which can achieve insulation protection and fixing functions, avoiding problems such as arcing, poor contact, and capacitor assembly falling off during testing. The elastic clips 204 can be installed and removed without any tools; they are simply plugged in and unplugged, making them suitable for repeated EMC testing scenarios.

[0086] Based on the capacitor assembly 103 and filter 100 provided in this application embodiment, the second housing serves as the overall protective cover for the filter 100, integrating the conductive metal busbar 102 and multiple capacitor assemblies 103 into one unit. This provides physical protection, electromagnetic shielding, and insulation isolation, and also provides a reliable fastening interface for the elastic clips 204 on the capacitor assemblies 103. When the capacitor assembly 103 is pushed into the second housing along the installation direction, the elastic clips 204 on the outer side of the first housing 203 automatically undergo elastic deformation and engage with the pre-set slots on the inner wall of the second housing, achieving rapid pre-positioning. Furthermore, the second housing integrates the originally separate capacitor assemblies, conductive metal busbars, and connection ports into a single, installable module, while each capacitor assembly 103 can still be independently disassembled and assembled. Specifically, the capacitor assemblies 103 can be disassembled and switched at any time as needed, adapting to the requirements of repeated testing and rapid troubleshooting in the EMC verification process, without damaging the structure or repeatedly welding capacitors to introduce the risk of insufficient insulation withstand voltage. Based on the technical solution provided in the embodiments of this application, the collaborative design of the second shell and the elastic buckle significantly improves the vibration resistance of the filter while maintaining a high degree of modularity and configurability, thus ensuring the stability of the filter.

[0087] The second outer casing is equipped with a magnetic ring fixing structure for fixing the magnetic ring 101.

[0088] In one example, adhesive can be used to fix the magnetic ring 101 to the second housing.

[0089] In practical applications, the conductive metal busbar 102 and magnetic ring 101 can be riveted and fixed first, and then the capacitor assembly 103 can be installed according to requirements.

[0090] As can be seen from the above, based on the filter provided in the embodiments of this application, researchers can independently adjust the differential mode filtering depth and common mode filtering intensity without modifying the magnetic ring when facing different electrical conditions, simply by quickly replacing or adding or subtracting the quantity and parameters of the first, second, and third capacitor components. This can cover the full-band adaptive filtering requirements from low-frequency differential mode to high-frequency common mode.

[0091] The above embodiments are merely preferred embodiments provided to fully illustrate the present invention, and the scope of protection of the present invention is not limited thereto. Equivalent substitutions or modifications made by those skilled in the art based on the present invention are all within the scope of protection of the present invention.

Claims

1. A filter, characterized by, include: One or more capacitor components (103); One or more sets of connection ports (104), one set of the connection ports (104) is used to couple one of the capacitor components (103), corresponding to filtering electromagnetic interference of different frequency bands. The number of connection ports (104) connected to the capacitor component (103) in the multiple sets of connection ports (104) is different, or, corresponding to filtering electromagnetic interference of different frequency bands, the parameters of the capacitor component (103) connected to the multiple sets of connection ports (104) are different.

2. The filter of claim 1, wherein, The filter also includes: A conductive metal busbar (102) is provided with the connection port (104) for transmitting current.

3. The filter of claim 2, wherein, The capacitor assembly (103) includes: Capacitor (C) A conductive metal sheet (201) is coupled to the pins of the capacitor (C); the conductive metal sheet (201) and the pins of the capacitor (C) are connected by soldering.

4. The filter of claim 3, wherein, The conductive metal sheet (201) is fixedly connected to the connection port (104) by bolts.

5. The filter according to any one of claims 2-4, characterized in that, The capacitor assembly (103) also includes: A first outer casing (203) is disposed outside the capacitor (C); An elastic buckle (204) is provided on the outside of the first housing (203).

6. The filter according to claim 5, characterized in that, The filter also includes: The second housing is disposed outside the conductive metal bar (102) and the capacitor assembly (103); When the capacitor assembly (103) is disposed inside the second housing, the elastic buckle (204) engages inside the second housing.

7. The filter of claim 6, wherein, The conductive metal bus (102) includes: A first conductive metal busbar (1021) is provided with a first connection port (P1). The second conductive metal bus (1022) is provided with a second connection port (P2). The capacitor assembly (103) includes: a first capacitor assembly (1031); a first conductive metal sheet of the first capacitor assembly (1031) is coupled to the first connection port (P1), and a second conductive metal sheet of the first capacitor assembly (1031) is coupled to the second connection port (P2).

8. The filter of claim 7, wherein, The first conductive metal busbar (1021) is also provided with a third connection port (P3); the second conductive metal busbar (1022) is also provided with a fourth connection port (P4). The capacitor assembly (103) includes: The second capacitor assembly (1032) has a first conductive metal sheet coupled to the third connection port (P3) and a second conductive metal sheet coupled to the fifth connection port (P5). The third capacitor assembly (1033) has a first conductive metal plate coupled to the fourth connection port (P4) and a second conductive metal plate coupled to the fifth connection port (P5). The fifth connection port (P5) is coupled to the voltage reference terminal.

9. The filter of claim 7, wherein, The filter also includes: A magnetic ring (101) is sleeved on the outside of the first conductive metal bar (1021) and the second conductive metal bar (1022).

10. The filter according to claim 9, characterized in that, A magnetic ring fixing structure is provided inside the second outer shell; the magnetic ring fixing structure is used to fix the magnetic ring.

11. An on-board charger, comprising: include: The filter as described in any one of claims 1-10.

12. A vehicle characterized by comprising: include: The filter as described in any one of claims 1-10, or the on-board charger as described in claim 11.

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