Connector Ferrite Core Placement for EMI Suppression
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Solution Overview
Problem
Existing connectors with integrated ferrite filters lack flexibility in ferrite core placement and insufficient damping for high-current low-voltage applications, particularly in power electronic systems.
Innovation Solution
A plug connector with an insulating molded body and a ferrite core that can be selectively positioned around line elements, allowing partial enclosure and direct contact, utilizing a ferrite core with high specific resistance and relative permeability for enhanced electromagnetic compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If ferrite core encloses all line elements, then electromagnetic interference suppression is improved, but flexibility in ferrite core placement is worsened
Solution Approach 1:
The connector housing is segmented to allow selective enclosure of line elements. The ferrite core can be positioned to enclose only specific line elements (e.g., high-current lines) rather than all line elements, enabling flexible placement while maintaining EMI suppression effectiveness for critical conductors.
Solution Approach 2:
Different line elements receive different levels of ferrite core enclosure based on their specific EMI susceptibility and current characteristics. High-current low-voltage lines receive ferrite core protection, while other lines may remain uncovered or receive different levels of shielding, optimizing both EMI suppression and design flexibility.
2Object-affected harmful factors
If ferrite core encloses all line elements, then electromagnetic interference suppression is improved, but damping for high-current low-voltage applications is worsened
Solution Approach 1:
The ferrite core material properties are optimized for specific frequency ranges and current levels. The core is strategically positioned around high-current low-voltage line elements where EMI suppression is most critical, while avoiding enclosure of lines where such enclosure would degrade signal quality or damping characteristics.
Solution Approach 2:
The ferrite core's magnetic properties (permeability, loss tangent) are selected and positioned to provide appropriate damping for high-current applications. By controlling which line elements are enclosed and the core's magnetic parameters, the system achieves sufficient damping for power electronics while maintaining signal integrity for other conductors.
3Reliability
If insulating molded body encloses line elements, then electrical insulation is improved, but flexibility in ferrite core placement is worsened
Solution Approach 1:
The insulating molded body is designed with segmented or open regions that allow ferrite core placement on selected line elements. The housing provides electrical insulation where needed while leaving gaps or removable sections that enable flexible ferrite core positioning around specific conductors based on EMI requirements.
Solution Approach 2:
The insulating molded body serves as an intermediary structure that both provides electrical insulation and facilitates ferrite core placement. Strategic design of the housing includes features like slots, openings, or removable sections that allow ferrite cores to be positioned around specific line elements while maintaining overall insulation integrity.
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 solution provides flexible ferrite core placement and sufficient damping for high-current low-voltage applications, effectively suppressing electromagnetic interference in power electronic systems.
Implementation Method 1
the ferrite cores effectively suppress the common mode interference of the cable connection
Implementation Method 2
the ferrite core with high specific resistance and relative permeability for enhanced electromagnetic compatibility
Data Source
Figure 1a~1b
Figure 2a~2c
Figure 3
AI summary
The circuit has a plug-in connector (2), and a plastic molded body (30) exposing a set of contact devices of line elements (20a-20d). Adjacent sections (26a-26d) of the line elements are surrounded by a magnetic core (4) in a recess of the plastic molded body. The magnetic core is directly attached to the sections of the line elements. Another set of contact devices (22a-22d) are electrically connected with a third set of contact devices of a printed circuit board. The contact devices form a male connector or a plug-in sleeve.