EMC Filter Clamp Layout for Compact DC-DC Converter Assembly
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Solution Overview
Problem
Existing electromagnetic compatibility filters require significant space due to the need for tools to close clamps around pins, which increases the overall size of the filter.
Innovation Solution
The proposed electromagnetic compatibility filter adjusts the orientation of its components so that the pin of the first capacitor is situated higher than the pin of the second capacitor, allowing the elongated body to start at an angle and move away from the third conductor's clamp, thus reducing the space requirement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the elongated body passes at a distance from the clamp to allow tool access, then the clamp can be closed by conventional tools, but the overall space requirement of the filter increases
Solution Approach 1:
The patent repositions the first capacitor's pin higher than the second capacitor's pin, creating a vertical offset that changes the spatial arrangement from a horizontal layout to a three-dimensional configuration. This dimensional change allows the elongated body to route around the clamp in the vertical dimension, providing tool access space without increasing the horizontal footprint of the filter.
Solution Approach 2:
The clamps are designed with pre-positioned openings that anticipate the tool's approach path. The first and second clamps of the third conductor are configured with openings facing upward or sideways before assembly, allowing the closing tool to access them without requiring the elongated body to be routed far away. This preliminary configuration of the clamp geometry enables compact tool access.
2Volume of stationary object
If the pin of the first capacitor is positioned higher than the pin of the second capacitor, then the oblique axis and vertical axis form an angle of less than 80 degrees, but this requires precise orientation during manufacturing
Solution Approach 1:
The patent applies different spatial orientations to different capacitors within the same filter assembly. The first capacitor is positioned with its pin higher and oriented along an oblique axis, while the second capacitor is positioned lower with its pin oriented differently. This local differentiation of orientation and position allows the overall compact configuration while maintaining manufacturability, as each capacitor's specific orientation is optimized for its local spatial constraints rather than requiring all capacitors to follow the same orientation pattern.
Data Source
AI summary
A filter includes first, second and third conductors; a first capacitor connected between the first conductor and the third conductor; a second capacitor connected between the second conductor and the third conductor; and a third capacitor connected between the first conductor and the second conductor. A pin of the first capacitor is situated higher, in relation to a vertical axis along which a clamp of the second conductor projects upwards, than a pin of the second capacitor, such that an oblique axis along which a first clamp and a second clamp of the third conductor project in opposing directions and the vertical axis form an angle between them of less than 80°, preferably less than 70°, for example 65°.