Ferrite Core Busbar Layout for High-Current Filter Passages
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Solution Overview
Problem
Existing busbars in power converters suffer from reduced current carrying capacity due to structural limitations, particularly in the passage area of ferrite core filters, leading to heating and inefficiencies.
Innovation Solution
The busbars are reshaped through bend forming to increase the passage cross-sectional area to match the bar cross-sectional area, guided through a feed-through opening of a ferrite core filter, and optionally enclosed by a plastic material for insulation, maintaining a compact design and reducing parasitic inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbars are guided through the feed-through opening of the ferrite core filter, then the filtering function is achieved, but the passage cross-sectional area is reduced leading to lower current carrying capacity
Solution Approach 1:
The busbar is bent in the passage area to create a folded configuration, effectively utilizing three-dimensional space. This dimensional transformation allows the busbar to pass through the limited feed-through opening while maintaining its full cross-sectional area for current conduction, resolving the contradiction between filtering function and current carrying capacity
Solution Approach 2:
The busbar is formed with curved or bent sections in the passage area rather than straight configurations. This curvature allows the busbar to navigate through the feed-through opening of the ferrite core filter while preserving its cross-sectional area, enabling both filtering and high current carrying capacity
2Quantity of substance
If the busbars are bent to increase passage cross-sectional area, then current carrying capacity is improved, but manufacturing complexity increases
Solution Approach 1:
The busbar is pre-bent or pre-formed with the required curvature in the passage area before assembly. This preliminary action ensures that the busbar can be easily inserted through the feed-through opening while maintaining its full current carrying capacity, without requiring complex on-site manipulation or additional manufacturing steps
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 approach enhances current carrying capacity without overheating and reduces parasitic inductance, allowing for efficient current distribution while minimizing structural impairments.
Implementation Method 1
the busbars being guided at least once through at least one feed-through opening of the ferrite core filter
Implementation Method 2
electromagnetic interference is necessarily created, which must be filtered
Implementation Method 3
the busbars are reshaped by bend forming
Data Source
AI summary
A power converter having a busbar device includes at least one ferrite core filter and at least two busbars, which are spaced from one another in an electrically insulated manner. The busbars may have different electric potentials, so that the busbars can carry an electric current appropriate for a bar cross-sectional area. The busbars are guided at least once through at least one feed-through opening of the ferrite core filter. The busbars are one piece in each case, and are reshaped by a bend formed in a passage area of the feed-through opening, and a passage cross-sectional area of the busbars in the passage area is at least the same size as the bar cross-sectional area, so that the busbars can carry the same electric current along the run of the busbars.