High-Voltage Noise Filter with Integrated Cooling and Parasitic Capacitance
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Solution Overview
Problem
High-voltage power conversion devices in electric vehicles generate significant electromagnetic noise, leading to heat buildup in magnetic cores and increased weight and size of noise filters, which are not suitable for in-vehicle use.
Innovation Solution
A high-voltage noise filter design incorporating a metal housing, annular magnetic cores, capacitors, and cooling units that utilize parasitic capacitance between bus bars and cooling fins to dissipate heat and suppress electromagnetic noise without increasing the filter's size or weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the voltage of the power drive battery is increased to improve charging efficiency, then charging efficiency is improved, but electromagnetic noise increases and heat generation in the magnetic core increases
Solution Approach 1:
The patent combines the heat dissipation function and electromagnetic noise filtering function into a single integrated structure. The cooling fin is integrated with the magnetic core, allowing simultaneous heat dissipation and noise filtering without requiring separate components, thus resolving the contradiction between handling increased electromagnetic noise and maintaining compact design.
Solution Approach 2:
The cooling fin structure serves multiple functions: it dissipates heat from the magnetic core through thermal conduction and convection, while simultaneously acting as an electromagnetic shield to suppress electromagnetic noise. This multi-functionality allows the system to handle both heat generation and electromagnetic interference caused by high-voltage operation.
2Temperature
If a heat sink is provided in the magnetic core and capacitance of the capacitor is increased to dissipate heat and suppress electromagnetic noise, then heat dissipation and noise suppression are improved, but the entire size and weight of the high-voltage noise filter are increased
Solution Approach 1:
The cooling fin is integrated directly with the magnetic core structure, eliminating the need for separate heat sink components. This integration allows heat dissipation functionality to be achieved without adding extra weight or volume, as the same structural element serves both magnetic and thermal management functions.
Solution Approach 2:
The cooling fin structure performs multiple functions simultaneously: structural support for the magnetic core, heat dissipation through conduction and convection, and electromagnetic shielding. This multi-functionality eliminates the need for additional dedicated heat sink components, thereby avoiding increased weight and size.
3Object-generated harmful factors
If a heat sink is provided in the magnetic core and capacitance of the capacitor is increased to dissipate heat and suppress electromagnetic noise, then heat dissipation and noise suppression are improved, but the entire size of the high-voltage noise filter is increased
Solution Approach 1:
The cooling fin is integrated with the magnetic core structure, combining heat dissipation and electromagnetic shielding functions in one component. This integration eliminates the need for separate noise suppression components, thereby reducing the overall volume of the filter assembly.
Solution Approach 2:
The cooling fin serves as both a thermal management component and an electromagnetic shield. By using the same structural element for both heat dissipation and noise suppression, the design avoids adding volume that would be required for separate dedicated components for each function.
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 effectively dissipates heat from magnetic cores and improves the suppression of electromagnetic noise, particularly common mode noise, while maintaining a compact and lightweight design suitable for in-vehicle applications.
Implementation Method 1
a first cooling unit connected to the first magnetic core and the metal housing
Implementation Method 2
a cooling medium is circulated in an entire housing of the power conversion device
Implementation Method 3
a part of the anode bus bar is arranged in a manner facing the first cooling unit, and a part of the cathode bus bar is arranged in a manner facing the first cooling unit
Data Source
AI summary
A high-voltage noise filter of a power conversion device includes: a metal housing; an anode bus bar connecting anodes of a power source and a power module; a cathode bus bar connecting cathodes thereof; a first magnetic core having a through hole where the anode bus bar and the cathode bus bar pass through; an X capacitor having one end connected to the anode bus bar, and the other end connected to the cathode bus bar; a first Y capacitor having one end connected to the anode bus bar, and the other end grounded; a second Y capacitor having one end connected to the cathode bus bar, and the other end grounded; and a first cooling unit connected to the first magnetic core and the metal housing. The anode bus bar partly faces the first cooling unit, and the cathode bus bar partly faces the first cooling unit.