Distributed Gap Inductor Filter for High Frequency Harmonic Removal
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Solution Overview
Problem
Industrial power filtering systems using standard inductors overheat due to high frequency harmonics, as these frequencies primarily travel on the outside diameter of conductors, causing increased AC resistance and overheating, especially when insulated gate bipolar transistors (IGBTs) switch at high frequencies.
Innovation Solution
A distributed gap inductor filter apparatus with a core made of powdered material, wound with multiple turns optionally wired in parallel, is used to filter and convert power, effectively removing high frequency harmonics and reducing overheating by utilizing a core that allows harmonic removal at frequencies above 10 kHz, even at high amperages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If standard inductors are used in power filtering systems, then the system can process power, but the inductors overheat due to high frequency harmonics traveling on the outside diameter of conductors causing increased AC resistance
Solution Approach 1:
The patent changes the physical parameters of the inductor by introducing a distributed air gap structure into the core, which fundamentally alters the magnetic path and reduces core losses at high frequencies. This parameter change enables the inductor to handle high frequency harmonics without excessive heating while maintaining filtering effectiveness
Solution Approach 2:
The patent employs composite core construction combining magnetic material with distributed air gaps, creating a composite structure that optimizes both magnetic flux containment and loss reduction. This composite approach allows the inductor to process high frequency power harmonics efficiently without the overheating problems of solid core inductors
2Productivity
If high frequency switching is used to improve power conversion efficiency, then energy processing efficiency improves, but high frequency harmonics cause cable overheating and increased AC resistance
Solution Approach 1:
The patent extracts and removes high frequency harmonic components from the power signal using the distributed gap inductor filter before they can propagate through the cable system. By taking out these harmful frequency components, the system maintains high frequency switching benefits while eliminating the harmful effects on cables
Solution Approach 2:
The distributed gap inductor acts as an intermediary filtering element between the high frequency switching source and the power cable system. It mediates by allowing efficient power conversion while blocking and attenuating the high frequency harmonics that would otherwise cause cable overheating
3Object-affected harmful factors
If distributed gap inductor filter is used to remove high frequency harmonics, then harmonic amplitudes are reduced by up to 99%, but the device complexity increases
Solution Approach 1:
The patent segments the core structure into multiple sections with distributed air gaps, which simplifies the manufacturing process and allows for modular construction. This segmentation approach achieves effective harmonic filtering while making the complex filtering function more manageable and manufacturable
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 distributed gap inductor filter significantly reduces high frequency harmonic amplitudes by up to 99%, preventing overheating and enhancing energy processing efficiency in high frequency power conversion systems.
Implementation Method 1
A distributed gap inductor filter apparatus with a core made of powdered material, wound with multiple turns optionally wired in parallel, is used to filter and convert power
Implementation Method 2
A distributed gap inductor filter apparatus with a core made of powdered material, wound with multiple turns optionally wired in parallel, is used to filter and convert power, effectively removing high frequency harmonics and reducing overheating
Data Source
AI summary
The invention comprises a high frequency inductor filter apparatus and method of use thereof. In one embodiment, an inductor is used to filter/convert power, where the inductor comprises a distributed gap core and/or a powdered core material. The inductor core is wound with one or more turns, where multiple turns are optionally electrically wired in parallel. In one example, the minimum carrier frequency is above that usable by an iron-steel inductor, such as greater than ten kiloHertz at fifty or more amperes. The core is optionally an annular core, solid rod core, or a core used for multiple phases, such as a ‘C’ or ‘E’ core. Optionally, the inductor is used in an inductor/converter apparatus, where output power has a carrier frequency, modulated by a fundamental frequency, and a set of harmonic frequencies, in conjunction with one or more of a silicon carbide, gallium arsenide, and/or gallium nitride based transistor.