Dielectric-Covered Bus Bar With EMC Filter for Inverter Noise
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Solution Overview
Problem
Conventional bus bars used in electric vehicle systems, particularly in EMC filter circuits, often fail to adequately reduce noise emissions from inverters and electric motor drives, leading to interference with other circuit components.
Innovation Solution
A bus bar design featuring a metal sheet with a dielectric covering, integrated with an EMC filter element, allows for reduced noise transmission by enabling flexible shaping and improved electrical properties, including short ground paths and dense circuit element mounting, while providing a cost-effective alternative to traditional printed circuit boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional PCBs with metallized conducting structures are used for power transmission, then circuit elements can be mounted on the board, but the power transfer capability is limited and noise reduction is insufficient
Solution Approach 1:
The patent inverts the conventional PCB construction by placing a metal sheet with dielectric covering instead of a dielectric core with metallized structures. This inversion enables superior power transfer capability and noise reduction while maintaining circuit element mounting functionality.
Solution Approach 2:
The bus bar combines metal sheet and dielectric material in a composite structure where the metal provides excellent electrical conductivity and power transfer, while the dielectric covering provides insulation and noise reduction, achieving both power and EMC requirements simultaneously.
2Power
If PCBs with thicker metallizations are used to increase power transfer, then power capability improves, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of increasing metallization thickness on a PCB, the patent inverts the structure to use a metal sheet as the base with dielectric covering, achieving high power capability through the inherent properties of the metal sheet rather than thick metallization layers.
Solution Approach 2:
The patent changes the fundamental structural parameters from thin metallized layers on dielectric to a metal sheet with dielectric covering, transforming the power transfer mechanism while simplifying manufacturing compared to thick PCB metallization.
3Power
If a metal sheet with dielectric covering is used instead of conventional PCB, then power transfer and noise reduction improve, but the construction is counterintuitive and may increase manufacturing complexity
Solution Approach 1:
The patent employs structural inversion, using metal sheet with dielectric covering instead of the conventional dielectric core with metallized structures. This counterintuitive approach simplifies the power transfer function while improving EMC performance.
Solution Approach 2:
The metal sheet with dielectric covering serves multiple functions simultaneously: power transmission, circuit element mounting substrate, and EMC shielding, reducing overall device complexity despite the unconventional construction.
4Object-generated harmful factors
If conventional PCBs are used for EMC filtering, then circuit elements can be mounted, but noise emissions are not adequately reduced
Solution Approach 1:
The bus bar uses a composite structure of metal sheet and dielectric material where the metal provides superior EMC shielding and noise reduction while maintaining excellent power transfer capability, outperforming conventional PCB-based EMC filters.
Solution Approach 2:
By inverting the conventional PCB construction to use metal sheet with dielectric covering, the patent achieves both superior noise reduction and power transfer capability simultaneously, resolving the trade-off present in conventional EMC filter designs.
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 bus bar effectively reduces noise emissions and enhances electrical performance by allowing for compact, high-density integration of circuit elements and efficient noise reduction, suitable for high-power applications in electric vehicle systems.
Implementation Method 1
The first rail comprises a central section with a metal sheet and a dielectric material at least partially covering the central section
Data Source
AI summary
In an embodiment a bus bar includes a first interface and a second interface, a filter element electrically connected between the first and the second interface and a first rail between the first interface and the second interface, wherein the first rail includes a central section with a metal sheet and a dielectric material at least partially covering the central section.