EMC Filter Bus Bar Structure for Core Gap Stability Under Vibration
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Solution Overview
Problem
Existing EMC filters in vehicles are vulnerable to external vibrations and shocks, leading to gap disruption in the core, which causes saturation of large currents and generates heat due to fringing fields, compromising the effectiveness of electromagnetic noise reduction.
Innovation Solution
The EMC filter design includes a U-shaped lower bobbin and core, a hexahedral upper bobbin, and a bus bar made of hard metal to maintain a gap between magnetic cores, minimizing overlap with the gap and applying a heat dissipation material to reduce temperature rise and enhance robustness against vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a plastic bobbin is used to maintain a gap inside the core, then the gap can be maintained during normal operation, but the bobbin is vulnerable to external vibration and shock causing gap disruption
Solution Approach 1:
The invention changes the material parameter of the bobbin from plastic to hard metal, which fundamentally alters the mechanical properties including hardness, strength, and resistance to deformation. This parameter change enables the bobbin to maintain the gap under external vibrations and shocks that would damage a plastic bobbin, directly resolving the contradiction between gap maintenance and robustness.
2Device complexity
If the bus bar overlaps the gap in the core, then the structure is simpler, but heat is generated by the fringing field increasing the temperature of the bus bar
Solution Approach 1:
The invention addresses the heat generation problem by changing the spatial arrangement of the bus bar relative to the gap. Instead of allowing overlap in the vertical dimension, the bus bar is positioned to bypass the gap horizontally, extending from one side to the other without intersecting the gap region. This dimensional change eliminates the fringing field exposure while maintaining structural feasibility.
3Ease of manufacture
If the bobbin is damaged by external vibration and impact, then manufacturing cost is reduced, but saturation of large current cannot be prevented
Solution Approach 1:
The invention changes the material parameter of the bobbin from plastic to hard metal, fundamentally improving the mechanical strength and damage resistance. This parameter change ensures that the bobbin can withstand external vibrations and impacts without damage, thereby maintaining the gap structure and preventing current saturation under harsh operating conditions.
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 design maintains the gap effectively even under external shocks, reduces temperature increase due to fringing fields, and improves cooling efficiency of the bus bar, while being less affected by magnetic fields, thus enhancing the EMC filter's performance and durability.
Implementation Method 1
heat is generated in the bus bar by a magnetic field (fringing field) generated in the gap inside the core
Implementation Method 2
applying a heat dissipation material to reduce temperature rise
Data Source
AI summary
Provided is an electro-magnetic compatibility (EMC) filter including a lower bobbin having a U-shaped cross-sectional shape, a lower core including a magnetic material having a U-shaped cross-sectional shape and disposed on the lower bobbin, a bus bar disposed on the lower core, an upper bobbin having a hollow inside, having a bexahedral shape with one side open, and configured to cover an upper portion of the lower bobbin, and an upper core including a magnetic material having a plate-like shape, disposed in an internal space of the upper bobbin, and disposed on the lower core (U core) to cover the bus bar with a gap maintained by the bus bar between the upper and lower cores when the lower bobbin and the upper bobbin are coupled to each other.