Integrated Inductor Device for Noise Filtering and Size Reduction

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Solution Overview

Problem

Power electronics in vehicle power supplies experience noise due to switching elements, which existing technologies have not effectively addressed, leading to inefficiencies and increased costs.

Innovation Solution

An inductor device and filter system utilizing multiple cores and wires to create integrated common mode (CM) and differential mode (DM) inductors, along with capacitors, to effectively remove noise, reduce package size, and lower costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If traditional separate CM and DM inductor structures are used, then noise filtering capability is achieved, but device complexity and package size increase

Engineering Contradiction:

Improvenoise filtering capabilityVSAvoidpackage size

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent combines separate common mode (CM) and differential mode (DM) inductor structures into a single integrated inductor device. Multiple windings are wound around a shared magnetic core, allowing the device to provide both CM and DM noise filtering functions simultaneously while reducing overall package size and structural complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated inductor device performs multiple functions: it provides common mode noise filtering through windings configured with opposite current directions, differential mode noise filtering through windings configured with same current directions, and magnetic flux shielding. This multi-functionality eliminates the need for separate CM and DM inductor components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Object-affected harmful factors

If multiple separate inductors are used for CM and DM noise removal, then noise filtering effectiveness is improved, but manufacturing cost increases

Engineering Contradiction:

Improvenoise filtering effectivenessVSAvoidmanufacturing cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent merges multiple inductor functions into a single manufactured component. By winding multiple windings around a shared magnetic core with a unified structure, the device can be manufactured as one integrated unit rather than assembling multiple separate inductors, thereby reducing manufacturing complexity and cost.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs a composite magnetic core structure consisting of multiple magnetic cores arranged in specific configurations. This composite structure enables the single device to achieve both CM and DM filtering capabilities while maintaining manufacturing efficiency through standardized core and winding processes.

Inventive Principle:

Principle #40Composite materials

3Device complexity

If compact integrated design is implemented, then package size is reduced, but manufacturing precision requirements increase

Engineering Contradiction:

Improvepackage sizeVSAvoidwinding precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent segments the magnetic core into multiple separate cores (first magnetic core, second magnetic core, third magnetic core) that are arranged in specific spatial configurations. This segmentation allows for modular manufacturing where each core can be processed independently, then assembled together, reducing the overall manufacturing precision requirements compared to creating a single monolithic structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different windings are configured with specific local characteristics: some windings are arranged to produce opposite magnetic fields for CM filtering, while others produce same-direction fields for DM filtering. This local differentiation of winding configurations allows each section to be optimized for its specific function while maintaining overall compact integration.

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 effectively removes CM and DM noise, increases space utilization by reducing the package size, and lowers costs by integrating noise removal capabilities within a compact design.

Implementation Method 1

first core, a portion of the first wire passing through the first core, and a portion of the second wire passing through the first core are provided as a first inductor, the second core and another portion of the first wire passing through the second core are provided as a second inductor, and the third core and another portion of the second wire passing through the third core are provided as a third inductor

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11476820B2Inductor device, filter device, and steering system

Publication Date: 2022.10.18 HL MANDO CORP

AI summary

An inductor device, a filter device, and a steering system. The inductor device includes first to third cores and first and second wires. The first core, a portion of the first wire passing through the first core, and a portion of the second wire passing through the first core are provided as a first inductor. The second core and another portion of the first wire passing through the second core are provided as a second inductor. The third core and another portion of the second wire passing through the third core are provided as a third inductor.