Annular Noise Filter Coil Layout for Compact Power Conversion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power conversion apparatuses, such as on-board chargers, face challenges in reducing the size of noise filters due to the need for space to accommodate plural-phase plural-wire type coils and their associated wiring, which complicates the layout and increases the overall size.
Innovation Solution
A noise filter design featuring a flat, thermally conductive cooling plate with an annular coil perpendicular to the principal face, aligned winding starts and ends, and optimized wiring layout to minimize space usage and reduce crossings, combined with capacitors and heat dissipation plates to enhance thermal management and reduce complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plural-phase plural-wire type coil is used in the noise filter, then noise filtration performance is improved, but the device size increases due to space requirements for wiring lines and windings
Solution Approach 1:
The patent applies dimensional change by arranging the coil windings in a planar configuration where the start and end of windings are positioned at opposite ends of the same plane. This allows wiring lines to be routed in a straight line across the plane rather than requiring three-dimensional routing around the coil, thereby reducing the space required for wiring and minimizing the overall noise filter size while maintaining plural-phase noise filtration capability.
2Reliability
If a plural-phase plural-wire type coil is used in the noise filter, then noise filtration performance is improved, but wiring complexity increases
Solution Approach 1:
The patent segments the coil into multiple independent windings, each corresponding to a different phase. By positioning the start and end of each winding at opposite ends of the same plane, the wiring for each phase can be routed independently and simply across the plane, avoiding complex three-dimensional routing and reducing overall wiring complexity while maintaining effective plural-phase noise filtration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves a compact noise filter configuration that minimizes space requirements, reduces wiring complexity, and maintains effective noise filtration performance while optimizing thermal management and manufacturing ease.
Implementation Method 1
The cooling plate has thermal conductivity, and is formed in a flat plate shape. The coil is thermally connected to the first principal face of the cooling plate.
Data Source
AI summary
A noise filter includes a cooling plate, a coil of a type of a plurality of wires of a plurality of phases, a plurality of wiring lines, and a plurality of capacitors. The cooling plate has thermal conductivity, and is formed in a flat plate shape. The coil is formed in an annular shape, and is fixed to a first principal face of the cooling plate. The plurality of wiring lines are electrically connected to leads that extend from windings of the plurality of phases. The plurality of capacitors are electrically connected to the plurality of wiring lines. The coil is thermally connected to the first principal face of the cooling plate, and an axis direction of the annular shape extends along the first principal face, in a state where the coil is fixed to the first principal face.