Curved Ferrite Filter Assembly for Compact Voltage Conversion
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Solution Overview
Problem
Voltage converters in power electrical systems, particularly in vehicles, generate output currents with alternating voltage components that can cause malfunctions and radio interference, necessitating effective filtering while also requiring a more compact design to save space.
Innovation Solution
A filter arrangement featuring a curved current conductor enclosed by two curved ferrite bodies with recesses matching the conductor's shape, forming a single ferrite core that increases inductance and filter effectiveness within a constant installation space, including an air gap for improved saturation behavior and adjustable partial inductances via projections for capacitors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional filter arrangements with straight conductors and separate ferrite cores are used, then the filter arrangement is simple to manufacture, but the installation space required is larger and the overall inductance is lower
Solution Approach 1:
The patent applies curvature by designing the conductor, ferrite bodies, and recesses with curved shapes instead of straight or angular forms. The conductor has a curved path, the ferrite bodies are curved to match, and the recesses are curved to accommodate the conductor, enabling compact packaging while maintaining filtering performance
Solution Approach 2:
The patent merges the conductor and ferrite bodies into an integrated assembly where the curved conductor is enclosed by curved ferrite bodies with matching curved recesses. This merging allows the ferrite core to follow the conductor's curved path continuously, maximizing inductance within limited space
2Volume of moving object
If the installation space is reduced, then the filter arrangement becomes more compact, but the overall inductance decreases and filter performance deteriorates
Solution Approach 1:
The curved geometry allows the ferrite core to wrap around the conductor in a compact configuration, maintaining a long magnetic path length within a small volume. This preserves the inductance required for effective filtering while reducing the overall installation space
Solution Approach 2:
The patent transitions from a linear, one-dimensional arrangement to a curved, three-dimensional configuration. The ferrite bodies and conductor are arranged in curved profiles that utilize vertical and lateral dimensions, enabling compact packaging without sacrificing the magnetic path length needed for high inductance
3Ease of manufacture
If straight conductors and separate ferrite cores are used, then the manufacturing is simpler, but the inductance and filter effectiveness are reduced
Solution Approach 1:
The curved shapes of the conductor, ferrite bodies, and recesses are designed to match each other, creating an integrated assembly that can be manufactured as a unit or pre-assembled module. This maintains manufacturing feasibility while achieving superior inductance through the continuous curved magnetic path
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 enables a more space-saving filter design with enhanced filtering capabilities, capable of handling high useful currents in compact systems like hybrid or electric vehicles, maintaining or improving filter performance while reducing space requirements.
Implementation Method 1
The shape of the ferrite bodies, in particular the shape of the recess in them, corresponds to the shape of the conductor. The curved design of the conductor allows for a flexible design of the conductor and the two ferrite bodies, adapted to the available installation space, thus enabling a space-saving design of the filter arrangement with a constant overall inductance of the filter arrangement
Implementation Method 2
the saturation behavior of the filter assembly is handled much more effectively
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a filter assembly (FA) comprising: a conductor (SL) with a curved course for conducting a current; a first ferrite body (FK1) and a second ferrite body (FK2); a recess (AN1, AN2) in the first (FK1) and/or the second (FK2) ferrite body with a curved course, wherein the first (FK1) and the second (FK2) ferrite bodies jointly surround the conductor (SL), and the conductor (SL) extends along the recess (AN1, AN2). The invention also relates to a voltage converter having a filter assembly of this type.