Busbar Inductive Component With Offset Air Gaps for Lower Losses
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Solution Overview
Problem
Existing arrangements of inductive components and busbars struggle to efficiently filter high-frequency interference while minimizing losses and maintaining a homogeneous current density, often requiring increased size or cost to achieve reduced losses.
Innovation Solution
The use of an inductive component with two air gaps arranged asymmetrically on opposite sides of a copper busbar, where the air gaps are positioned at different heights to reduce losses without increasing the component's size or cost, utilizing soft magnetic cores with legs of different lengths to create an opening for the busbar, which enhances current distribution and reduces interference filtering losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If air gaps are arranged symmetrically on the inductive component, then the structure is simple and manufacturing is easy, but losses in the busbar increase and current density becomes inhomogeneous
Solution Approach 1:
The patent applies asymmetry by arranging the two air gaps at different positions along the busbar length. Specifically, one air gap is positioned closer to one end of the busbar while the other air gap is positioned closer to the opposite end, creating an asymmetric configuration that optimizes current density distribution and reduces busbar losses without requiring complex additional components
2Loss of energy
If the distance between air gaps is reduced, then the component size is reduced, but current density homogeneity deteriorates and losses increase
Solution Approach 1:
The patent applies parameter changes by optimizing the distance between air gaps as a critical design parameter. The air gaps are positioned at specific distances from each other and from the busbar ends, creating an optimal balance between component size and current density homogeneity. This parameter optimization reduces busbar losses by up to 50% while maintaining a compact component volume
3Loss of energy
If air gaps are positioned closer to the busbar ends, then the component length is reduced, but current density distribution becomes more inhomogeneous and losses increase
Solution Approach 1:
The patent applies local quality by positioning air gaps at specific locations along the busbar rather than uniformly distributing them. The asymmetric positioning creates localized magnetic field enhancements at critical positions, optimizing current density distribution in regions where it is most needed while maintaining overall current homogeneity and reducing losses
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
This configuration reduces losses in the busbar by up to 50% and achieves a more homogeneous current density, improving electromagnetic compatibility without increasing the component's size or cost, and is particularly effective in EMC filters like input filters for inverters.
Implementation Method 1
inductive component for a busbar... used in particular for filtering interference, especially high-frequency interference
Implementation Method 2
The inductive component consists of two components. Specifically, these are two cores made of a soft magnetic material, such as ferrite
Data Source
Figure 1A~1B
AI summary
The invention relates to an inductive component (1) for a bus bar (2). The inductive component (1) comprises two air gaps (11, 12) arranged on opposite sides (21, 22) of the component (1), said air gaps (11, 12) being at a distance (d) from one another in a height direction (17) of the component (1).