Connector With Integral Molded Noise Filter Core
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Solution Overview
Problem
Existing connectors with ferrite cores suffer from rattling issues and limitations in minimization, which affect noise reduction and durability, especially in vehicular applications.
Innovation Solution
A connector design featuring a magnetic noise filter core with a pair of annular division cores, integrated with a soft resin inner mold and a hard resin housing, which prevents rattling and enhances impact resistance and heat dissipation, while allowing for compact installation and improved assembly workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a ferrite core is fixed by being pinched between an inner wall surface of an inner housing receiving chamber and the inner housing, then the connector structure is simple, but the ferrite core rattles and the connector cannot be minimized
Solution Approach 1:
The patent merges the ferrite core with the inner housing by integrally molding the ferrite core into the inner housing structure. This eliminates the separate pinching mechanism and creates a unified component, resolving the contradiction by simplifying the overall structure while preventing rattling through integral formation.
Solution Approach 2:
The ferrite core is pre-formed and integrated into the inner housing during the molding process, rather than being assembled separately. This preliminary integration ensures the core is permanently fixed in position, eliminating rattling issues while maintaining structural simplicity.
2Device complexity
If a ferrite core is fixed by being pinched between an inner wall surface of an inner housing receiving chamber and the inner housing, then the connector structure is simple, but the connector cannot be minimized
Solution Approach 1:
The ferrite core is merged with the inner housing through integral molding, eliminating the need for separate receiving chambers and pinching mechanisms. This consolidation reduces the overall connector volume while maintaining structural simplicity.
Solution Approach 2:
The ferrite core is nested within the inner housing structure as an integrated component. This nesting approach allows the core to be housed within the existing housing volume without requiring additional space, enabling minimization of the connector.
3Ease of manufacture
If the ferrite core is fixed by pinching, then the manufacturing process is simple, but the impact resistance and durability during traveling are insufficient
Solution Approach 1:
The ferrite core and inner housing are merged into a single integrally molded component. This integration ensures that the core cannot detach or rattle during travel, significantly improving impact resistance and durability while maintaining manufacturing simplicity through a single molding process.
Solution Approach 2:
The ferrite core is pre-integrated into the inner housing structure during molding, creating a permanent bond that withstands vibration and impact during traveling. This preliminary integration eliminates the need for separate fastening operations while ensuring durability.
4Device complexity
If the ferrite core is exposed without coverage, then the structure is simple, but the heat of the core cannot be effectively transmitted
Solution Approach 1:
The inner mold part is merged with both the ferrite core and the housing through integral molding, creating a thermal pathway that conducts heat from the core to the housing. This integrated structure enables effective heat dissipation while maintaining structural simplicity.
Solution Approach 2:
The inner mold part acts as a thermal intermediary between the ferrite core and the housing. It conducts heat away from the core and transfers it to the housing for dissipation, improving thermal management while requiring only a single molding operation.
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 connector effectively reduces noise and enhances durability and heat dissipation, while minimizing size and stress during assembly, thereby improving performance in noisy and vibrating environments like electric vehicles.
Implementation Method 1
The noise filter part includes a core attached to the conductor and formed of a magnetic member which reduces noise of a current flowing in the conductor
Implementation Method 2
since the inner mold part is brought into close contact with the core by the integral molding, the heat of the core can be excellently transmitted to the inner mold part
Data Source
AI summary
A connector includes a conductor, a noise filter part, an inner mold part, and a housing. The conductor has a terminal at one end and the other end of the conductor is connected to a wire. The connector is to be joined with a counterpart connector so that the terminal is in conduction with a terminal of the counterpart connector. The noise filter part includes a core attached to the conductor and formed of a magnetic member which reduces noise of a current flowing in the conductor. The inner mold part is integrally molded with the noise filter part so as to cover at least a periphery of the core and formed of a soft resin material. The housing which covers a periphery of the inner mold part and is formed of a hard resin material.