Integrated Filter Core Conductor Assembly for Vibration-Tolerant EMI Control

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Solution Overview

Problem

Conventional conductor assemblies with filter cores face issues such as chipping, vibration-related damage, and difficult assembly due to fixed shape and size materials, which are not tolerant to high current applications and vibrations.

Innovation Solution

The integration of filter cores made from a different material than the conductors, additively manufactured using methods like plasma or cold spraying, which are configured to surround and isolate conductors, enhancing electromagnetic emission reduction and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If conventional filter cores are glued onto bus bars, then electromagnetic emission reduction is achieved, but structural integrity deteriorates due to chipping and vibration-related damage

Engineering Contradiction:

Improveelectromagnetic emissionsVSAvoidstructural integrity

Core Design Contradiction:

Object-generated harmful factorsVSReliability

Solution Approach 1:

The filter core and bus bar are merged into a single integral structure through additive manufacturing, eliminating the separate bonding step. The filter core is built directly around the bus bar, creating a unified component that cannot chip or detach, thus resolving the contradiction between achieving EMI filtering and maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mechanical bonding system (glue/adhesive) is replaced with an additive manufacturing process that creates a metallurgical or molecular-level bond. This substitution eliminates the weak interface between filter core and bus bar, preventing vibration-related damage while maintaining the electromagnetic filtering function.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Object-generated harmful factors

If filter cores are bonded onto conductors, then electromagnetic filtering is achieved, but ease of manufacture deteriorates due to difficult assembly

Engineering Contradiction:

Improveelectromagnetic emissionsVSAvoidassembly difficulty

Core Design Contradiction:

Object-generated harmful factorsVSEase of manufacture

Solution Approach 1:

The filter core and conductor are combined into a single manufactured component through additive manufacturing. This integration eliminates the separate assembly steps of positioning and bonding the filter core to the conductor, significantly simplifying the manufacturing process while maintaining the electromagnetic filtering capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The filter core is pre-formed around the conductor during the additive manufacturing process itself, rather than being attached afterward. This preliminary formation of the complete assembly eliminates subsequent assembly operations, improving ease of manufacture while achieving the required EMI filtering.

Inventive Principle:

Principle #10Preliminary action

3Object-generated harmful factors

If fixed shape and size filter materials are used, then electromagnetic filtering is achieved, but adaptability deteriorates for different current applications

Engineering Contradiction:

Improveelectromagnetic emissionsVSAvoidapplication flexibility

Core Design Contradiction:

Object-generated harmful factorsVSAdaptability or versatility

Solution Approach 1:

The filter core geometry transitions from fixed to dynamic/customizable through additive manufacturing. The build process allows the filter core shape, size, and configuration to be adapted to match specific conductor geometries and current application requirements, providing versatility while maintaining effective electromagnetic filtering.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The filter core structure can be locally optimized for different regions through additive manufacturing. Material properties, density, and geometric features can vary at different locations within the filter core to suit specific electromagnetic filtering requirements for different current applications, enhancing adaptability.

Inventive Principle:

Principle #3Local quality

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 improved EMI filtering, increased structural strength, reduced fragility, and flexibility in design, allowing for optimized size and weight, while being more tolerant to vibrations and high-frequency noise.

Implementation Method 1

The one or more filter cores are formed of a material different than the conductive material and are configured to reduce electromagnetic emissions from the one or more conductors

Methodology Applied

Scientific EffectElectromagnetic filtering: Absorption (EM radiation)

Implementation Method 2

Additively manufacturing includes plasma spraying ferrous powder on the one or more conductors

Methodology Applied

Scientific EffectPlasma spraying: Plasma Spray

Implementation Method 3

Additively manufacturing includes cold spraying ferrous powder on the one or more conductors

Methodology Applied

Scientific EffectCold spraying: Fluid Spray

Data Source

PatentEP3671774B1Conductor assemblies having filter cores

Publication Date: 2023.11.29 HAMILTON SUNDSTRAND CORP

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AI summary

A conductor assembly (100) can include one or more conductors (101) formed by a conductive material, and one or more filter cores (103) formed integrally on and at least partially around the one or more conductors (101). The one or more filter cores (103) can be formed of a material different than the conductive material and can be configured to reduce electromagnetic emissions from the one or more conductors (101).