Preassembled EMC Filter Housing for Vibration-Robust Power Converters
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Solution Overview
Problem
Existing EMC filter assemblies for power converters in electric vehicles face challenges in manufacturing complexity due to variety of parts and are susceptible to vibration, leading to mechanical instability.
Innovation Solution
A preassembled EMC filter assembly with inductors, capacitors, and capacitors housed in a single molded plastic enclosure, using nanocrystalline cores and resin potting for mechanical protection, allowing easy installation and robustness against vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional EMC filter assemblies use multiple separate housings for different inverters, then different EMC filter assemblies can be provided for different applications, but manufacture becomes difficult due to the large variety of parts
Solution Approach 1:
The patent applies universality by designing a single standardized housing that can accommodate multiple different EMC filter assemblies with varying numbers and types of inductivities and capacitors. The housing serves multiple functions: structural support, mechanical protection, vibration damping, and electrical insulation. This allows the same housing design to be used across different inverter applications, reducing manufacturing complexity while maintaining adaptability to different filter configurations
Solution Approach 2:
The patent applies segmentation by dividing the EMC filter assembly into two independent parts: a standardized housing and configurable filter components (inductivities and capacitors). The housing is manufactured separately as a universal component, while the filter components can be selected and assembled in different combinations based on application requirements. This segmentation allows for simplified manufacturing of the housing while maintaining flexibility in filter configuration
2Ease of manufacture
If conventional EMC filter assemblies are assembled from separate components, then individual components can be optimized separately, but the assemblies are susceptible to vibration and mechanically unstable
Solution Approach 1:
The patent applies merging by integrating all filter components (inductivities and capacitors) and the housing into a single preassembled unit. The housing contains all components in a fixed arrangement, creating a mechanically robust assembly that resists vibration. The preassembly process ensures proper mechanical coupling and electrical connections, eliminating the mechanical instability associated with separately assembled components while maintaining the ability to optimize individual components during the design phase
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 provides a mechanically robust and vibration-resistant EMC filter assembly with simplified manufacturing and enhanced stability, ensuring effective electromagnetic compatibility.
Implementation Method 1
at least one first inductivity, which is part of the first electrical connection, at least one second inductivity, which is part of the second electrical connection
Implementation Method 2
the at least first inductivity, the at least one first class Y capacitor, the at least second inductivity, the at least one second class Y capacitor and the at least one class X capacitor are glued and/or potted with resin in the housing
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
EMC filter assembly (1, 23, 27) for a power converter, comprising a first electrical connection which is adapted to connect a first output terminal of a battery with a first electrical supply terminal of a power converter, at least one first inductivity (7), which is part of the first electrical connection, at least one first class Y capacitor (11, 12, 34, 35), connected between the first electrical connection and ground, a second electrical connection which is adapted to connect a second output terminal of a battery with a second electrical supply terminal of the power converter, at least one second inductivity (10), which is part of the second electrical connection, at least one second class Y capacitor (13, 14, 36, 37), connected between the second electrical connection and ground, at least one class X capacitor (15, 33), connected between the first electrical connection and the second electrical connection, wherein the at least first inductivity (7), the at least one first class Y capacitor (11, 12, 34, 35), the at least second inductivity (10), the at least one second class Y capacitor (13, 14, 36, 37) and the at least one class X capacitor (15, 33) are received and preassembled in a housing (17, 24, 30).