Coil Module Housing with Busbar Integration for EMC Flexibility

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Solution Overview

Problem

Power converters with large-sized coil devices directly mounted on circuit boards face challenges in electromagnetic compatibility and require increased flexibility in arrangement due to strict EMC regulations, leading to reduced mount region and potential performance issues.

Innovation Solution

A coil module configuration that includes a coil device housed in a case with secured busbars and a potting member, allowing the coil device to be electrically connected to a circuit board via busbars, enhancing flexibility in arrangement and reducing size constraints.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a large-sized coil device is directly mounted on a circuit board, then the coil device can be securely fixed, but the mount region is reduced and arrangement flexibility is limited

Engineering Contradiction:

Improvefixing securityVSAvoidarrangement flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The invention divides the mounting system into two independent parts: a coil device with its own housing and a separate mounting structure with engagement protrusions. This segmentation allows the coil device to be mounted in various positions and orientations on the circuit board, significantly improving arrangement flexibility while maintaining secure fixation through the engagement features.

Inventive Principle:

Principle #1Segmentation

2Reliability

If a large-sized coil device is directly mounted on a circuit board, then the coil device can be securely fixed, but the device size increases

Engineering Contradiction:

Improvefixing securityVSAvoiddevice size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The invention embeds the coil device within a housing structure that integrates mounting engagement features. The coil device is nested inside the housing, which contains engagement protrusions that interact with corresponding recesses on the circuit board. This nesting approach secures the coil device without requiring additional external mounting components, thereby maintaining compact device size while ensuring reliable fixation.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Adaptability or versatility

If the coil device is housed in a case with busbars and potting member, then arrangement flexibility is improved, but the structure becomes more complex

Engineering Contradiction:

Improvearrangement flexibilityVSAvoidstructure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention combines multiple functions into the housing structure: it serves as the protective case for the coil device, provides engagement protrusions for mounting, and houses the busbars for electrical connection. The potting member is integrated to simultaneously secure the coil device and provide environmental protection. This merging of functions reduces the number of separate components needed, simplifying the overall structure while maintaining arrangement flexibility.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11657954B2Coil module and power converter

Publication Date: 2023.05.23 DENSO CORP

AI summary

In a coil module, a coil device includes a coil unit and at least one terminal extending from the coil unit. A case is configured to house the coil device. At least one busbar is secured to the case. The at least one terminal is electrically connected to the at least one busbar. A potting member is filled in the case to fixedly retain the coil device in the case.