Power Converter Inductor Mounting to Simplify Cable Assembly
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Solution Overview
Problem
Current power converters require lengthy installation times and high manufacturing costs due to complex cable arrangements and the need for manual bundling and fastening of inductor cables.
Innovation Solution
A power converter design that includes a housing with a through-hole for the inductor apparatus, a connection piece extending from the circuit board to physically and electrically connect the inductor apparatus to the housing, eliminating the need for external cables and simplifying the assembly process by using a positioning piece with a locking mechanism to pre-position cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cables are led out from the inductor apparatus to the housing in bundles, then electrical connection between the inductor and power device is achieved, but the cable arrangement becomes complex and requires manual bundling and fastening
Solution Approach 1:
The patent merges the cable arrangement with the inductor apparatus housing by providing a housing that receives and organizes the cables internally. The housing integrates cable routing channels and fastening structures, combining multiple functions (protection, organization, connection) into a single component, thereby simplifying the overall cable management system while maintaining reliable electrical connections.
Solution Approach 2:
The patent introduces a cable management housing as an intermediary component between the inductor apparatus and the power device. This housing serves as a mediator that receives cables from the inductor, organizes them through internal channels, and provides structured exit points to the power device, eliminating the need for external manual bundling and fastening.
2Reliability
If manual arrangement and fastening of cables is performed, then proper cable organization and connection is achieved, but installation time increases and assembly efficiency decreases
Solution Approach 1:
The patent implements preliminary action by pre-integrating cable routing channels, fastening structures, and organizational features directly into the housing design. The housing is manufactured with built-in cable management capabilities before assembly, so that during final assembly, cables are automatically guided and secured without requiring manual arrangement or fastening operations, thereby maintaining connection quality while dramatically improving assembly efficiency.
3Reliability
If external inductor apparatus with cables is used, then electrical connection is achieved, but manufacturing costs increase due to complex cable management requirements
Solution Approach 1:
The patent merges the cable management function with the housing structure, eliminating the need for separate external cable management components. By integrating cable routing channels, fastening features, and organizational structures directly into the housing, the design reduces the total number of parts, simplifies the bill of materials, and lowers manufacturing costs while maintaining reliable electrical connections.
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 design reduces installation time, improves assembly efficiency, and lowers labor and material costs by eliminating the need for manual cable bundling and simplifying the connection process.
Implementation Method 1
The connection piece extends from the circuit board in the housing to the inductor apparatus and passes through a surface of the housing, to physically connect the inductor apparatus to the housing and electrically connect the power device to the inductor apparatus at the same time
Implementation Method 2
a heat dissipation structure is further provided on an outer side of a surface of the housing, and the heat dissipation structure partially or completely surrounds the inductor apparatus, and is thermally connected to the power device, to dissipate heat for the power device
Data Source
AI summary
A power converter includes a housing, a power device, a circuit board, a connection piece, and an inductor apparatus. The power device is installed on the circuit board, and an accommodation cavity is formed in the housing and is configured to accommodate the circuit board and the power device. A through-hole is provided on a surface that is of the housing and that faces the circuit board. The inductor apparatus is completely exposed or partially exposed outside the housing and covers the through-hole. The connection piece extends from the circuit board in the housing to the inductor apparatus, and passes through a surface of the housing to physically connect the inductor apparatus to the housing and electrically connect the power device to the inductor apparatus at the same time.