Divided Active EMI Filter Module With Fault Detection

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Solution Overview

Problem

Existing electromagnetic interference (EMI) filters face challenges such as increased size and cost due to the use of discrete elements, difficulty in identifying malfunctions in active circuit units, and thermal runaway issues with bipolar junction transistors (BJTs), along with susceptibility to environmental degradation.

Innovation Solution

The development of an integrated active current compensation device within a one-chip IC, incorporating a sensing unit, amplification unit, and malfunction detection unit, along with an encapsulation structure to reduce volume and enhance durability, and a power conversion unit to stabilize voltage supply.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If discrete elements are used to construct EMI filters, then the filter can be assembled and manufactured, but the size and cost increase

Engineering Contradiction:

Improveassembly capabilityVSAvoidfilter size

Core Design Contradiction:

Ease of manufactureVSVolume of stationary object

Solution Approach 1:

The patent integrates multiple discrete EMI filter elements (inductors, capacitors, resistors) into a single integrated circuit chip. This merging of components eliminates the need for separate discrete elements, thereby reducing the overall filter size while maintaining manufacturability through standard IC fabrication processes

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent embeds multiple functional elements within a hierarchical structure where smaller components are nested within larger integrated structures. The sensing unit, amplification unit, and compensation elements are nested within the IC chip substrate, creating a compact nested arrangement that minimizes space occupation

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If active circuit units are used for EMI filtering, then noise reduction performance improves, but malfunction detection becomes difficult

Engineering Contradiction:

Improvenoise reduction performanceVSAvoidmalfunction detection

Core Design Contradiction:

ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent incorporates a malfunction detection unit that continuously monitors the operational status of the active circuit elements. This feedback mechanism detects abnormalities in the sensing unit, amplification unit, and compensation elements, enabling real-time identification of malfunctions while maintaining the active noise reduction performance

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The integrated circuit performs self-diagnosis through the malfunction detection unit, which automatically monitors its own operational components. This self-service capability enables the system to detect and report malfunctions without external intervention, maintaining reliability while solving the detection difficulty

Inventive Principle:

Principle #25Self-service

3Power

If bipolar junction transistors are used in active circuits, then amplification function is achieved, but thermal runaway occurs

Engineering Contradiction:

Improveamplification capabilityVSAvoidthermal stability

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The patent implements thermal monitoring and feedback control mechanisms that detect temperature changes in the BJT-based amplification circuits. When thermal runaway conditions are detected, the feedback system adjusts operating parameters or shuts down affected components, maintaining amplification capability while preventing thermal instability

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent incorporates preventive thermal management measures including heat dissipation structures and thermal protection circuits designed beforehand. These cushioning measures are built into the IC design to prevent thermal runaway before it occurs, ensuring reliable operation of the amplification unit

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Volume of stationary object

If integrated IC structure is used, then volume is reduced and durability enhanced, but assembly and disassembly becomes easier

Engineering Contradiction:

Improvemodule sizeVSAvoidassembly ease

Core Design Contradiction:

Volume of stationary objectVSEase of operation

Solution Approach 1:

The patent designs the integrated EMI filter as a modular IC chip that can be easily replaced as a single unit. This segmentation of the filter function into a discrete replaceable module maintains ease of assembly and disassembly while achieving volume reduction through integration of all filter elements within the chip

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12470189B2Divided active electromagnetic interference filter module and manufacturing method thereof

Publication Date: 2025.11.11 EM CORETECH

AI summary

This application relates to an independent active electromagnetic interference filter module. In one aspect, the filter module includes a first element group including a noise sensing unit provided to sense electromagnetic noise, and a second element group including a compensating unit provided to generate a compensation signal for the electromagnetic noise. The first group and the second group may be respectively mounted on different substrates. According to some embodiments, the filter module can reduce a volume of each element constituting an electromagnetic interference filter module, implement a single modularization of a compact structure. The filter module can also improve electromagnetic interference noise reduction performance and a manufacturing method thereof.