A split filter assembly

Abstract

The utility model provides a kind of split type filter assembly, including first capacitor module, inductance module, second capacitor module and interface copper bar.First capacitor module is detachably fixed in the side of inductance module in first direction;Second capacitor module is detachably fixed in the other side of inductance module in first direction.The end of interface copper bar extends to and is electrically connected with first capacitor module, the other end extends to the side outside of second capacitor module away from first capacitor module, so that first capacitor module, inductance module and second capacitor module are electrically connected in turn by interface copper bar, constitute complete CLC filter structure.The split type design enables each module to be independently installed, replaced and maintained, greatly improves the flexibility and adaptability of the assembly, can be quickly adjusted according to different system layout, significantly reduces the system integration difficulty and cost, while ensuring the integrity of filter performance.

Description

Technical Field

[0001] This utility model relates to the field of electrical devices, and in particular to a split-type filter component. Background Technology

[0002] Electromagnetic interference (EMI) filtering devices are a critical component of power electronic equipment, especially in high-power applications such as motor controllers for new energy vehicles. These devices commonly employ multi-stage filtering structures composed of capacitors (C) and inductors (L), such as CLC filters. This classic structure typically connects the capacitor and inductor core via internal copper busbars or wires, then encapsulates the entire unit within a common insulating shell, forming a compact and inseparable integrated module. This integrated design provides stable filtering performance in specific applications and is currently the mainstream implementation method.

[0003] However, the existing integrated filter modules have significant limitations. Due to their fixed structure and highly integrated internal components, their overall dimensions, electrical parameters, and installation space, interface locations, and electromagnetic compatibility levels are tightly bound to specific projects. When faced with different applications, even minor adjustments to the installation interface or capacitor values ​​often require redesigning and remanufacturing the filter, resulting in a large amount of repetitive design work, significantly lengthening the development cycle and increasing unit costs. Furthermore, if a component in the module fails, it is usually difficult to repair on-site, potentially rendering the entire filter unusable, resulting in poor maintainability and reusability.

[0004] Therefore, there is currently a lack of a filter component solution in the field that can maintain filtering performance while also possessing high flexibility, strong adaptability, and excellent cost-effectiveness. Utility Model Content

[0005] In order to overcome the above-mentioned technical defects, the purpose of this utility model is to provide a split-type filter component.

[0006] This utility model discloses a split-type filter component, including a first capacitor module, an inductor module, a second capacitor module, and an interface copper busbar; The first capacitor module is detachably fixed to one side of the inductor module in the first direction; the second capacitor module is detachably fixed to the other side of the inductor module in the first direction. One end of the interface copper busbar extends to be electrically connected to the first capacitor module, and the other end extends to the side of the second capacitor module away from the first capacitor module, so that the first capacitor module, the inductor module and the second capacitor module are electrically connected in sequence through the interface copper busbar.

[0007] Preferably, the first capacitor module and the second capacitor module are composed of board capacitors.

[0008] Preferably, the split-type filter assembly further includes at least one support base; the support base is disposed on the side of the interface copper busbar away from the first capacitor module, the inductor module and the second capacitor module in the second direction, and is used to support the interface copper busbar; The second direction is perpendicular to the first direction.

[0009] Preferably, the first capacitor module, the inductor module, and the second capacitor module are fixedly connected to the interface copper busbar by screws.

[0010] Preferably, the first capacitor module, the inductor module, and the second capacitor module are electrically connected to the interface copper busbar by welding copper sheets.

[0011] Preferably, the first capacitor module, the inductor module, and the second capacitor module are arranged flush with each other in the second direction.

[0012] Preferably, the inductor module includes a housing, a potting compound, and a magnetic core; the housing forms a receiving space; the magnetic core is disposed within the receiving space; the potting compound is potted within the receiving space, thereby fixing the magnetic core and the housing relative to each other.

[0013] Preferably, the magnetic core is a nanocrystalline magnetic core.

[0014] Preferably, a thermal pad is provided on the side of the housing near the interface copper busbar in the second direction, so that the heat generated by the magnetic core is transferred to other components in sequence through the potting compound, the housing and the thermal pad.

[0015] Compared with existing technologies, the above technical solution has the following advantages: 1. The core of the split-type filter component provided in this application lies in arranging the first capacitor module, inductor module, and second capacitor module in a detachable manner and connecting them through interface copper busbars to form a complete CLC filter structure. Its split design allows each module to be installed, replaced, and maintained independently, greatly improving the flexibility and adaptability of the component. It allows for quick adjustments based on different system layouts (such as inside a motor controller) without replacing the entire filter, thus significantly reducing system integration difficulty and cost, while ensuring the integrity and high performance of the filtering function. 2. By adopting a board-based capacitor design, the capacitor module offers high design flexibility, allowing for easy adjustment of capacitor specifications and parameters to meet diverse electromagnetic compatibility performance requirements, thus enabling rapid customization. Simultaneously, the flush arrangement of each module in the second direction creates a compact layout, significantly improving space utilization and facilitating equipment miniaturization. Furthermore, the support base, as a standard component, not only facilitates mass production to reduce costs but also provides a simple and reliable assembly and fixing method for the interface copper busbars, ensuring the stability of the overall structure under complex operating conditions. 3. Screw fastening provides robust mechanical locking and excellent electrical contact pressure, making the connection both stable and easy to disassemble, greatly simplifying on-site assembly and subsequent maintenance. Welded copper sheets further ensure low resistance and high conductivity at the connection points, effectively resisting the effects of vibration and thermal stress, and improving the long-term reliability of the electrical connection. These two methods together give the component the characteristics of easy maintenance, reliable connection, and excellent conductivity. 4. The inductor module adopts a shell-encapsulated structure, making it a self-contained unit with high mechanical strength and good environmental tolerance. This packaging form facilitates its mass production as a standard component and rapid deployment in different filter systems. Furthermore, the use of a nanocrystalline magnetic core ensures excellent filtering performance with high permeability and low loss over a wide frequency range. Simultaneously, the added thermal pad design creates an efficient thermal management path, effectively dissipating the heat generated by the magnetic core during operation, thus improving the long-term operational stability and lifespan of the inductor module and even the entire filter assembly under high-temperature and high-power conditions. Attached Figure Description

[0016] Figure 1 An exploded view of the split-type filter component provided in this application; Figure 2 A three-dimensional structural diagram of the split-type filter component provided in this application; Figure 3 This is a top view of the split-type filter component provided in this application.

[0017] Figure reference numerals: 100, split-type filter component; 1. First capacitor module; 2. Second capacitor module; 3. Inductor module; 31. Housing; 4. Interface copper busbar; 5. Support base; x, the first direction; z, the second direction. Detailed Implementation

[0018] The advantages of this utility model are further illustrated below with reference to the accompanying drawings and specific embodiments.

[0019] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numerals in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this disclosure. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this disclosure as detailed in the appended claims.

[0020] The terminology used in this disclosure is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. The singular forms “a,” “the,” and “the” as used in this disclosure and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any and all possible combinations of one or more of the associated listed items.

[0021] It should be understood that although the terms first, second, third, etc., may be used in this disclosure to describe various information, such information should not be limited to these terms. These terms are used only to distinguish information of the same type from one another. For example, without departing from the scope of this disclosure, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if," as used herein, can be interpreted as "when," "in response to determination," or "when," or "in the event of a determination." In the description of this utility model, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0022] In the description of this utility model, unless otherwise specified and limited, it should be noted that the terms "installation", "connection" and "linking" should be interpreted broadly. For example, they can refer to mechanical or electrical connections, or internal connections between two components. They can be direct connections or indirect connections through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms according to the specific circumstances.

[0023] In the following description, the use of suffixes such as "module," "part," or "unit" to denote elements is solely for the purpose of illustrating this invention and has no specific meaning in itself. Therefore, "module" and "part" can be used interchangeably.

[0024] Please see Figures 1-3 , Figure 1 An exploded view of the split-type filter component provided in this application; Figure 2 A three-dimensional structural diagram of the split-type filter component provided in this application; Figure 3 This is a top view of the split-type filter component provided in this application.

[0025] like Figures 1-3As shown, this utility model discloses a split-type filter component 100, including a first capacitor module 1, an inductor module 3, a second capacitor module 2, and an interface copper busbar 4. The first capacitor module 1 is detachably fixed to one side of the inductor module 3 in the first direction x; the second capacitor module 2 is detachably fixed to the other side of the inductor module 3 in the first direction x; one end of the interface copper busbar 4 extends to be electrically connected to the first capacitor module 1, and the other end extends to the side of the second capacitor module 2 away from the first capacitor module 1, so that the first capacitor module 1, the inductor module 3 and the second capacitor module 2 are electrically connected in sequence through the interface copper busbar 4.

[0026] Those skilled in the art will understand that the core of the split-type filter assembly 100 provided in this application lies in the detachable arrangement of the first capacitor module 1, the inductor module 3, and the second capacitor module 2, connected by an interface copper busbar 4 to form a complete CLC filter structure. Its split design allows each module to be installed, replaced, and maintained independently, greatly improving the flexibility and adaptability of the assembly. It allows for rapid adjustment according to different system layouts (such as inside a motor controller) without replacing the entire filter, thus significantly reducing system integration difficulty and cost, while ensuring the integrity and high performance of the filtering function.

[0027] The above is a brief description of the basic concept of this application. The following will describe the possible specific structure of this application.

[0028] First of all, it should be noted that there are no restrictions on the specific implementation of the first capacitor module 1 and the second capacitor module 2.

[0029] like Figures 1-3 As shown, in one possible implementation, the first capacitor module 1 and the second capacitor module 2 are composed of board capacitors.

[0030] As will be understood by those skilled in the art, a board capacitor refers to a modular capacitor assembly, the core of which lies in fixing and electrically connecting discrete capacitor components onto a dedicated printed circuit board (PCB) by soldering or mounting. This PCB not only provides mechanical support and electrical interconnection for the capacitor components but also integrates necessary mounting holes or connection terminals (such as soldered copper strips), enabling it to be easily installed and connected as a complete, standardized module to external circuits (such as interface copper busbar 4).

[0031] Therefore, by designing the first capacitor module 1 and the second capacitor module 2 as board-type capacitors, this solution greatly improves the flexibility and adaptability of the design. The board-type capacitor structure is a standardized printed circuit board, which facilitates the flexible adjustment and replacement of the specifications and quantity of capacitors soldered on it according to different electromagnetic compatibility performance requirements or circuit capacity requirements. This modular design not only simplifies the production and assembly process, but also enables the product to be quickly adapted to various application scenarios, significantly shortening the cycle and cost of customized development.

[0032] Secondly, the structure of inductor module 3 is also not limited.

[0033] In one possible implementation, the inductor module 3 includes a housing 31, a potting compound, and a magnetic core; the housing 31 forms a receiving space; the magnetic core is disposed within the receiving space; the potting compound is potted within the receiving space and fixes the magnetic core and the housing 31 relative to each other.

[0034] The inductor module 3 adopts an integrated design of housing 31, potting compound, and magnetic core. The magnetic core is fixed within the housing 31 through a potting process, significantly improving the module's mechanical strength and environmental resistance. The potting compound effectively isolates external factors such as moisture and dust, preventing core performance degradation and extending the component's lifespan. This structure also allows the inductor module 3 to be produced as a standalone unit for standardized production and large-scale application, improving manufacturing efficiency and facilitating rapid deployment or replacement in different filtering systems.

[0035] Furthermore, the magnetic core is a nanocrystalline magnetic core.

[0036] Using a nanocrystalline magnetic core as the core material of inductor module 3 leverages its high permeability and low core loss to provide excellent filtering performance over a wide frequency range. This core material is particularly suitable for high-frequency applications, effectively suppressing electromagnetic interference while reducing energy loss. The stability and reliability of the nanocrystalline magnetic core further enhance the adaptability of the entire filtering component in harsh environments, ensuring consistent performance over long-term operation.

[0037] Furthermore, a thermal pad is provided on the side of the housing 31 near the interface copper busbar 4 in the second direction z, so that the heat generated by the magnetic core is transferred to other components in sequence through the potting compound, housing 31 and thermal pad.

[0038] By placing a thermal pad on the housing 31 of the inductor module 3, efficient heat conduction and dissipation from the magnetic core are achieved. The thermal pad transfers heat from the potting compound and housing 31 to external heat dissipation components or the environment, preventing localized overheating and thus protecting the performance and lifespan of the magnetic core and surrounding components. This heat dissipation design improves the reliability of the filter component under high-temperature or high-power conditions, allowing it to be better configured and operated as an independent unit within the overall system.

[0039] Furthermore, the split-type filter component may include more structures to achieve specific functions or further enhance performance, and this application does not impose any limitations on this.

[0040] like Figures 1-3 As shown, in one possible implementation, the split-type filter assembly 100 further includes at least one support base 5; the support base 5 is disposed on the side of the interface copper busbar 4 away from the first capacitor module 1, the inductor module 3 and the second capacitor module 2 in the second direction z, and is used to support the interface copper busbar 4. The addition of a support base 5, which supports the interface copper busbar 4 in the second direction z, effectively enhances the structural stability and vibration resistance of the entire filter assembly 100. The support base 5 can be mass-produced as a standard part, significantly reducing the unit cost. It disperses the mechanical stress borne by the interface copper busbar 4, preventing loosening or deformation of the connection due to external impact or long-term use, thereby ensuring the long-term reliability of the electrical connection. Simultaneously, this design simplifies the assembly and fixing process of the interface copper busbar 4, improving assembly efficiency and the overall structural stability.

[0041] Finally, the connection and arrangement of each module are also unrestricted.

[0042] Regarding the connection method, in one possible implementation, such as Figures 1-3 As shown, the first capacitor module 1, the inductor module 3, and the second capacitor module 2 are fixedly connected to the interface copper busbar 4 by screws.

[0043] The screw-fixed connection method ensures a secure yet easy-to-disassemble connection between the first capacitor module 1, the inductor module 3, the second capacitor module 2, and the interface copper busbar 4. This connection method is simple to operate, requiring no special tools for assembly or maintenance, significantly reducing the time and cost of on-site installation and subsequent maintenance.

[0044] Furthermore, in one possible implementation, the first capacitor module 1, the inductor module 3, and the second capacitor module 2 are electrically connected to the interface copper busbar 4 by welding copper sheets.

[0045] Electrical connections are achieved by soldering copper sheets, a solution that ensures low resistance and high conductivity while retaining the detachable nature of the components. Soldering effectively prevents loosening due to vibration or temperature changes, improving the stability and safety of the electrical connection. Furthermore, as a universal connector, the soldered copper sheet can be reused across projects, reducing the need for specialized parts, lowering material costs and inventory management complexity, while maintaining assembly process flexibility. It also saves on plastic housing material, and interface copper busbar 4 does not require soldered pins. Interface copper busbar 4 offers high space utilization and saves on material costs. Regarding the arrangement, in one possible implementation, the first capacitor module 1, the inductor module 3, and the second capacitor module 2 are arranged flush with each other in the second direction z.

[0046] It should be noted that, except for inductor module 3, none of the modules provided in this application have a housing. Furthermore, because both the first capacitor module 1 and the second capacitor module 2 use board-type capacitors, their sizes can be similar. Therefore, the first capacitor module 1, inductor module 3, and second capacitor module 2 can be designed to be essentially flush-mounted at the same height, thereby reducing the height and overall size. For example, it can be made to be less than 150mm × 70mm × 50mm, a reduction of more than 20% in total volume compared to existing technologies. This alignment method reduces the protruding parts of the components in the mounting direction, allowing the filter to be integrated more efficiently into space-constrained devices (such as compact controller enclosures). The flush design also simplifies the housing packaging requirements, reduces the complexity and weight of the overall structure, and improves the power density and aesthetics of the product.

[0047] It should be noted that the embodiments of this utility model have better implementability and are not intended to limit this utility model in any way. Any person skilled in the art may use the above-disclosed technical content to change or modify it into equivalent effective embodiments. However, any modifications or equivalent changes and modifications made to the above embodiments based on the technical essence of this utility model without departing from the content of the technical solution of this utility model shall still fall within the scope of the technical solution of this utility model.

Claims

1. A split-type filter component, characterized in that, It includes a first capacitor module, an inductor module, a second capacitor module, and an interface copper busbar; The first capacitor module is detachably fixed to one side of the inductor module in the first direction; the second capacitor module is detachably fixed to the other side of the inductor module in the first direction. One end of the interface copper busbar extends to be electrically connected to the first capacitor module, and the other end extends to the side of the second capacitor module away from the first capacitor module, so that the first capacitor module, the inductor module and the second capacitor module are electrically connected in sequence through the interface copper busbar.

2. The split-type filter component as described in claim 1, characterized in that, The first capacitor module and the second capacitor module are composed of board capacitors.

3. The split-type filter component as described in claim 1, characterized in that, The split-type filter assembly further includes at least one support base; the support base is disposed on the side of the interface copper busbar away from the first capacitor module, the inductor module and the second capacitor module in a second direction, and is used to support the interface copper busbar; The second direction is perpendicular to the first direction.

4. The split-type filter component as described in claim 1, characterized in that, The first capacitor module, the inductor module, and the second capacitor module are fixedly connected to the interface copper busbar by screws.

5. The split-type filter component as described in claim 1, characterized in that, The first capacitor module, the inductor module, and the second capacitor module are electrically connected to the interface copper busbar by welding copper sheets.

6. The split-type filter component as described in claim 1, characterized in that, The first capacitor module, the inductor module, and the second capacitor module are arranged flush with each other in the second direction.

7. The split-type filter component as described in claim 1, characterized in that, The inductor module includes a housing, a potting compound, and a magnetic core; the housing forms a receiving space; the magnetic core is disposed within the receiving space; the potting compound is potted within the receiving space, thereby fixing the magnetic core and the housing relative to each other.

8. The split-type filter component as described in claim 7, characterized in that, The magnetic core is a nanocrystalline magnetic core.

9. The split-type filter component as described in claim 7, characterized in that, A thermal pad is provided on the side of the housing near the interface copper busbar in the second direction, so that the heat generated by the magnetic core is transferred sequentially through the potting compound, the housing and the thermal pad to the external space of the split filter assembly.

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