EMI Filter Assembly Mounting Plate Positioning
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Solution Overview
Problem
Existing electromagnetic interference (EMI) filters face challenges in precise component positioning, stress reduction, and assembly complexity, leading to reduced effectiveness and increased size.
Innovation Solution
The proposed solution involves a conductive enclosure with precisely positioned inductive cores and capacitors, using a mounting plate with locating members and securing bands to maintain component alignment without potting material, ensuring precise electrical isolation and reduced magnetostriction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If potting material is used to maintain component positioning, then components are held in position, but manufacturing precision deteriorates due to difficulty in precise positioning and magnetostriction stresses
Solution Approach 1:
The patent replaces the chemical/physical bonding mechanism of potting material with a mechanical fastening system consisting of a mounting plate, locating members, and securing bands. This mechanical system provides precise and controllable positioning without the stresses associated with potting material solidification.
Solution Approach 2:
The mounting plate serves as an intermediary component between the inductive cores and the enclosure, providing a stable platform with integrated locating members that precisely position components during assembly and maintain their positions without requiring potting material.
2Stability of the object's composition
If potting material is used to secure components, then components are fixed, but device complexity increases due to additional mechanical devices needed during manufacturing
Solution Approach 1:
The patent combines multiple functions into the mounting plate: it serves as the structural base, incorporates locating members for positioning, and provides attachment points for securing bands. This integration eliminates the need for separate positioning fixtures and reduces manufacturing steps.
Solution Approach 2:
The mounting plate with its integrated locating members and securing band attachment points enables self-positioning of components during assembly, reducing the need for complex external fixtures and manual positioning operations.
3Reliability
If traditional filter assembly methods are used, then EMI filtering is achieved, but the filter size is larger and assembly is more difficult
Solution Approach 1:
The patent arranges inductive cores and capacitors in a compact, nested configuration within the enclosure, with components positioned to maximize space utilization. The mounting plate enables this compact arrangement by providing precise locating members that accommodate tight tolerances.
Solution Approach 2:
The patent utilizes three-dimensional spatial arrangement of components, with inductive cores positioned vertically and capacitors arranged in optimized patterns on the mounting plate, effectively using available volume rather than just surface area to reduce overall filter size.
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
This configuration allows for effective EMI attenuation with reduced component stress, smaller size, and easier assembly, enhancing the filter's performance and manufacturing efficiency.
Implementation Method 1
Several ferrite inductive cores are mounted on one side of the array
Implementation Method 2
electromagnetic interference (EMI) which can both be radiated and conducted
Implementation Method 3
a plurality of generally cylindrical capacitors arranged in a generally rectangular array
Implementation Method 4
feed through bus bars are passed through these inductors
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
An assembly (10) and method for providing electromagnetic interference isolation. The assembly includes an enclosure (12) which has a first panel (20) and a second panel. Bus bars (26) extend through the first panel and the second panel. A mounting plate (30) is positioned between the first panel and the second panel. The mounting plate has locating members (32) thereon. A plurality of inductive cores (34, 38) are positioned proximate the locating members, the inductive cores having openings (48) through which the bus bars extend. The inductive cores are precisely positioned in the enclosure to facilitate the electromagnetic interference isolation. The assembly may comprise a circuit board, capacitors mounted on the circuit board, and conductive members extending between and electrically connecting the circuit board and the bus bars. The assembly may comprise tabs (32) extending from a surface of the mounting plate (30), pairs of tabs forming respective cradles into which the inductive cores (34, 38) are positioned.