Laminated EMC Filter Structure for Compact Power Module Cooling
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Solution Overview
Problem
Existing EMC filters for power electronics in electric machines are bulky and require numerous interfaces, making integration into limited installation spaces difficult and complicating cooling efficiency.
Innovation Solution
A laminated conductor structure with insulated conducting layers, toroidal inductors, and integrated capacitors, minimizing interfaces and enabling efficient cooling through a thermally conductive layer or direct housing attachment, while being compact and efficient.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional EMC filter device is used, then the filtering function is provided, but the device occupies too much installation space and has too many interfaces
Solution Approach 1:
The patent combines multiple separate components (conductor layers, capacitors, inductors, terminals) into a single integrated EMC filter device. The laminated busbar structure merges multiple conducting layers with insulating films into one compact unit, eliminating the need for separate connections and reducing the number of interfaces while maintaining all necessary filtering functions.
Solution Approach 2:
The laminated busbar structure serves multiple functions simultaneously: it provides electrical conduction, electromagnetic filtering through integrated capacitors and inductors, mechanical support, and thermal management. This multi-functionality reduces the overall device complexity and installation space requirements.
2Volume of moving object
If the conductor structure is made compact with laminated layers, then installation space is reduced, but cooling efficiency may be compromised
Solution Approach 1:
The patent introduces a thermally conductive layer as an intermediary between the laminated conductor structure and the housing. This layer acts as a heat transfer mediator, conducting heat away from the compact conductor structure to the housing, thereby maintaining cooling efficiency despite the reduced device volume.
Solution Approach 2:
The insulating films between conductor layers are designed to be thin yet thermally conductive, allowing heat to pass through the laminated structure while maintaining electrical insulation. This enables effective thermal management in the compact design.
3Reliability
If multiple separate components are used for the EMC filter, then the filtering performance can be optimized, but the number of interfaces and installation complexity increases
Solution Approach 1:
The patent merges capacitors, inductors, and conductors into a single integrated EMC filter device with a laminated busbar structure. This integration maintains the filtering performance of separate components while eliminating multiple interfaces and reducing installation complexity.
Solution Approach 2:
The laminated busbar is segmented into multiple conducting layers with insulating films, allowing each layer to be optimized for specific filtering functions while maintaining a unified compact structure. This segmentation enables optimized filtering performance without increasing overall device complexity.
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 allows for easier integration into existing spaces, reduces interface complexity, and enhances cooling efficiency, resulting in a more compact and efficient EMC filter device.
Implementation Method 1
the conductor structure has at least two separate conducting layers insulated from one another
Implementation Method 2
a thermally conducting layer/thermally conductive material, for example, in the form of a 'gap pad'/mat, to be provided between the conductor structure and a region fixed to the housing
Implementation Method 3
at least one inductor interacting with the conductor structure
Data Source
AI summary
An EMC filter device for power electronics of an electric machine includes an electric conductor structure, a capacitor coupled to the conductor structure, and an inductor that cooperates with the conductor structure. The conductor structure has at least two separate conducting layers that are insulated from one another.