Integrated Dual-Input EMI Filter Choke with Segmented Magnetic Core
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Solution Overview
Problem
Conventional EMI filters with dual-input power require two independent chokes, leading to increased manufacturing costs and the risk of choke saturation and damage due to unbalanced voltage inputs, which can result in component burning or damage.
Innovation Solution
A choke with four winding coils wound around a single magnetic core assembly is used in an EMI filter, allowing both input powers to be processed through a single choke, reducing costs and preventing saturation from voltage imbalances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If two independent chokes are used to receive dual-input power and suppress noise, then the noise suppression capability is improved, but the fabricating cost increases
Solution Approach 1:
The patent combines two independent chokes into a single integrated choke structure that receives dual-input power. The choke includes a magnetic core assembly with first and second magnetic cores, where winding coils are wound around each core. This merged structure allows one choke to handle both input power lines and suppress electromagnetic noise from both sources, thereby reducing the total number of components and lowering fabricating costs while maintaining noise suppression capability.
2Object-affected harmful factors
If two independent chokes are used for dual-input power, then each choke can suppress noise in its respective filtering circuit, but the device complexity increases
Solution Approach 1:
The patent merges two separate choke structures into one integrated choke that handles dual-input power. The integrated choke contains a magnetic core assembly with multiple magnetic cores and corresponding winding coils, all within a single choke housing. This reduces device complexity by eliminating the need for two separate choke assemblies, mounting structures, and associated connections, while still providing noise suppression for both filtering circuits.
3Ease of manufacture
If a single choke is used to receive dual-input power with unbalanced voltages, then the fabricating cost is reduced, but the magnetic core assembly may saturate causing component damage
Solution Approach 1:
The patent segments the magnetic core assembly into multiple magnetic cores (first magnetic core and second magnetic core), with winding coils wound around each core separately. Each magnetic core handles the magnetic flux from its corresponding input power line. This segmentation allows each magnetic core to operate independently within its own flux saturation limits, preventing overall saturation even when input voltages are unbalanced, thereby maintaining reliability while using a single integrated choke structure.
Solution Approach 2:
The patent applies local quality by providing different magnetic core configurations optimized for each input power line. Each magnetic core and its associated winding coils are designed with specific parameters (such as turns ratio, core material, and geometry) tailored to handle the characteristics of its corresponding input. This localized optimization ensures that each segment of the choke can handle its specific load without causing saturation in other segments, even under unbalanced voltage conditions.
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 reduces manufacturing costs and minimizes the risk of choke damage by using a single choke for dual-input power filtering, maintaining balanced current flow and preventing saturation, thus enhancing the reliability of the EMI filter.
Implementation Method 1
The choke includes at least one winding coil, a magnetic core assembly, and a bobbin for winding the winding coil. The choke is an inducting element for inhibiting noise generation.
Implementation Method 2
The magnetic core assembly includes a first magnetic core and a second magnetic core. The first winding coil and the second winding coil are directly wound around the first magnetic core. The third winding coil and the fourth winding coil are directly wound around the second magnetic core.
Data Source
AI summary
A choke for an EMI filter is provided. The EMI filter includes a first filtering circuit and a second filtering circuit. The choke includes a magnetic core assembly and four winding coils. The magnetic core assembly includes a first magnetic core and a second magnetic core. The first winding coil and the second winding coil are directly wound around the first magnetic core. The third winding coil and the fourth winding coil are directly wound around the second magnetic core. The first winding coil is serially connected with a first positive path of the first filtering circuit. The second winding coil is serially connected with a second positive path of the second filtering circuit. The third winding coil is serially connected with a first negative path of the first filtering circuit. The fourth winding coil is serially connected with a second negative path of the second filtering circuit.