Inverter Bus Bar Ferrite Core Integration
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Solution Overview
Problem
The integration of wiring and ferrite cores by mold forming in on-vehicle electronic devices leads to stress on the ferrite core due to resin material shrinkage, reducing its impedance and electromagnetic noise reduction capability.
Innovation Solution
The ferrite core is partially exposed during mold forming with a resin material, allowing it to absorb electromagnetic noise while reducing stress and maintaining impedance, using a thermoplastic resin to integrate the wiring and ferrite core in a motor-driven compressor's inverter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If wiring and ferrite core are integrated by mold forming using resin material, then the wiring and ferrite core are fixed in relative position and vibration resistance is improved, but the ferrite core is subject to stress from resin shrinkage which reduces its impedance and electromagnetic noise reduction capability
Solution Approach 1:
The resin material is divided into two distinct portions: a first resin material that fills the space around the wiring without contacting the ferrite core, and a second resin material that covers the ferrite core. This segmentation prevents the shrinkage stress from being transmitted to the ferrite core while still achieving integration and vibration resistance.
Solution Approach 2:
The first resin material acts as an intermediary substance between the wiring and the ferrite core. It provides mechanical support and fixation to the wiring while isolating the ferrite core from shrinkage stresses, thereby preserving the ferrite core's electromagnetic properties.
2Ease of manufacture
If ferrite core is completely covered by resin material in mold forming, then integration is improved, but heat dissipation from the ferrite core is reduced
Solution Approach 1:
The ferrite core has different surface treatments applied to different regions: one surface is covered with resin material for integration and protection, while another surface is left exposed to maintain heat dissipation capability. This local differentiation allows the same component to serve multiple functions simultaneously.
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 suppresses the reduction in electromagnetic noise reduction capability, enhances heat dissipation, and minimizes the impact of vibrations on the ferrite core, ensuring effective noise absorption and stable motor control in on-vehicle electronic devices.
Implementation Method 1
a ferrite core that covers the wiring to absorb electromagnetic noise from the wiring
Implementation Method 2
the ferrite core is subject to stress by the resin material shrinking with solidification of the resin material. An inverse magnetostrictive effect is thereby produced to reduce the impedance of the ferrite core.
Data Source
AI summary
An inverter includes a bus bar as a wiring and a ferrite core that covers the bus bar to absorb electromagnetic noise from the bus bar. The bus bar and ferrite core are integrated by mold forming using a resin material in a state of exposing a part of the ferrite core.