Insulated Dual-Core Common Mode Filter for Broadband Noise Suppression
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Solution Overview
Problem
Common mode filters made of single materials like Ni—Zn based ferrite are ineffective in suppressing low-medium frequency noise signals, and those made of composite materials suffer from poor insulation coefficients, leading to short-circuit and burnout issues during operation.
Innovation Solution
A common mode filter design featuring a first iron core with high impedance and a second iron core with low impedance, where all surfaces of the second iron core are coated with an insulating layer to enhance insulation resistance and prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If composite materials are used to suppress low-medium frequency noise signals, then the suppression effect on low-medium frequency noise is improved, but the insulation coefficient deteriorates leading to short-circuit and burnout
Solution Approach 1:
The iron core is divided into multiple segments (first iron core and second iron core) made of different materials. The first iron core uses material optimized for high-frequency suppression while the second iron core uses material optimized for low-medium frequency suppression. This segmentation allows each segment to contribute its strength without compromising the overall reliability.
Solution Approach 2:
The patent employs composite material structure by combining different ferrite materials (Ni-Zn based ferrite for high-frequency, Mn-Zn based ferrite for low-medium frequency) in a multi-segment iron core configuration. This composite approach enables simultaneous suppression of both high-frequency and low-medium frequency noise signals while maintaining system reliability through proper material selection and arrangement.
2Reliability
If Ni—Zn based ferrite is used to suppress high-frequency noise signals, then the suppression effect on high-frequency noise is improved, but the suppression effect on low-medium frequency noise deteriorates
Solution Approach 1:
Different segments of the iron core are assigned different material properties tailored to specific frequency ranges. The first iron core segment uses Ni-Zn based ferrite with properties optimized for high-frequency suppression, while the second iron core segment uses Mn-Zn based ferrite with properties optimized for low-medium frequency suppression. This local quality differentiation resolves the frequency suppression trade-off.
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 effectively suppresses both high-frequency and low-medium frequency noise signals while significantly increasing the insulation resistance of the second iron core, reducing the risk of short circuits and improving the filter's operational reliability.
Implementation Method 1
All surfaces of the second iron core are coated with an insulating layer. Therefore, in the common mode filter provided by the present disclosure, by virtue of 'all surfaces of the second iron core being coated with an insulating layer,' the insulation resistance of the second iron core can be increased to reduce a risk of short circuit
Implementation Method 2
The first iron core includes two first electrode portions and two second electrode portions. The second iron core is disposed above the first iron core, and the first iron core and the second iron core are adhered to each other. The first coil is wound around the first iron core and the second iron core. The second coil is wound around the first iron core and the second iron core.
Data Source
AI summary
A common mode filter includes a first iron core, a second iron core, a first coil, and a second coil. The first iron core includes two first electrode portions and two second electrode portions. The second iron core is disposed above the first iron core, and the first iron core and the second iron core are adhered to each other. All surfaces of the second iron core are coated with an insulating layer. The first coil is wound around the first iron core and the second iron core. The second coil is wound around the first iron core and the second iron core.