Cylindrical Magnetic Core Noise Filter for Compact Inverter Design
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Solution Overview
Problem
Existing noise filters with ring-shaped ferrite cores occupy significant space on circuit substrates, limiting the density of electronic components in high-frequency power machines like inverters due to their physical structure, which hinders the achievement of high electromagnetic compatibility (EMC) and increases the size of the inverter.
Innovation Solution
A noise filter configuration featuring a cylindrical magnetic core with a fixing member that supports the core at an off-ground position using jumper cables, eliminating the need for space on the substrate and enhancing noise removal efficiency by optimizing the magnetic core's shape and the elastic fixing member's design to securely hold the cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If ring-shaped ferrite cores are used in noise filters, then electromagnetic compatibility is improved, but the area occupied on the circuit substrate increases
Solution Approach 1:
The magnetic core is changed from a ring shape (requiring planar substrate space) to a cylindrical shape that can be mounted vertically on the substrate. This dimensional change allows the noise filter to occupy less area on the circuit substrate while maintaining its electromagnetic compatibility function, as the cylindrical core can be positioned in the third dimension (height) rather than requiring extensive two-dimensional space.
2Object-affected harmful factors
If ring-shaped ferrite cores are used in noise filters, then noise removal function is achieved, but the volume of the inverter increases
Solution Approach 1:
By transitioning from a ring-shaped core to a cylindrical core with vertical mounting capability, the noise filter utilizes the vertical dimension for its structural footprint. This allows the inverter to maintain effective noise removal functionality while reducing the overall volume occupied by the filter component, thereby enabling a more compact inverter design.
3Area of stationary object
If cylindrical magnetic core with fixing member is used, then substrate space is reduced, but assembly complexity increases
Solution Approach 1:
The fixing member is integrated as an inherent component of the cylindrical magnetic core structure, combining the core and fixing elements into a single unified component. This integration eliminates the need for separate fixing operations or additional assembly steps, thereby reducing assembly complexity while maintaining the space-saving benefits of the cylindrical configuration.
Solution Approach 2:
The fixing member is designed to automatically secure the cylindrical magnetic core to the substrate through its elastic properties, eliminating the need for external fastening mechanisms or complex assembly procedures. The elastic fixing member deforms to accommodate the core and then maintains a secure holding force, enabling self-service fixation that simplifies the overall assembly process.
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 configuration allows for a more compact inverter design with improved EMC performance by reducing the substrate space required for noise filters, enabling higher component density and stable noise removal without the need for soldering or complex assembly processes.
Implementation Method 1
a magnetic core (101) having a cylindrical shape
Data Source
AI summary
A noise filter includes a magnetic core and a fixing member. The magnetic core includes a cylindrical integral body, and a wire is passed through the magnetic core. The fixing member is disposed inside the magnetic core and fixes the magnetic core to the wire.