Modular EMI Filter Housing With Interchangeable End Pieces
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Solution Overview
Problem
Existing EMC filter housings are inflexible, expensive, and mechanically sensitive, requiring custom dimensions and terminal adaptations, which increases production costs and complicates stock management due to the need for multiple housing sizes and terminal types.
Innovation Solution
A modular EMC filter housing design featuring a conductive cover and end pieces with interchangeable terminals, allowing easy adaptation to different filter circuit sizes and cable connections, and made from cost-effective materials like aluminum or plastic for improved stability and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rectangular housings with predefined dimensions are used, then production is simplified, but the housing dimensions must be larger than actually required and cannot be easily adapted to different filter circuit sizes
Solution Approach 1:
The housing is divided into a base structure and interchangeable end pieces that can be selectively attached. This segmentation allows the same base housing to accommodate different filter circuit sizes by simply changing the end pieces, resolving the contradiction between simplified production and adaptability to different sizes.
Solution Approach 2:
The base housing design serves multiple functions by supporting different end pieces for various filter circuit configurations. This universal base structure eliminates the need for multiple custom housing sizes while maintaining ease of manufacture through standardized production processes.
2Volume of moving object
If custom housing dimensions are manufactured to minimize filter dimensions, then space requirements are optimized, but production costs increase significantly
Solution Approach 1:
By segmenting the housing into standardized base units and interchangeable end pieces, the design allows compact filter circuits to be achieved through component selection rather than custom housing fabrication, maintaining cost-effective standardized production.
Solution Approach 2:
The effective housing volume is adjusted by changing which end pieces are attached to the base, allowing optimization of filter circuit space requirements without requiring custom housing dimensions, thus avoiding increased production costs.
3Strength
If metal rectangular housings are made with increased wall thickness to improve mechanical stability, then structural strength is enhanced, but housing price increases accordingly
Solution Approach 1:
The housing combines a metal base structure with plastic end pieces, creating a composite construction that achieves mechanical stability through the metal framework while reducing overall material costs compared to thick-walled metal housings.
Solution Approach 2:
Dividing the housing into metal base and plastic end pieces allows each component to be optimized for its specific function, achieving structural strength where needed while minimizing material costs in non-structural areas.
4Ease of operation
If housings are adapted to specific feed-through terminal types with specific opening shapes and dimensions, then terminal compatibility is ensured, but stock management becomes much more difficult when different terminal types are used
Solution Approach 1:
The terminal adaptation function is segmented into interchangeable end pieces that can be attached to the base housing. This allows a single base housing design to support multiple terminal types by simply changing the end piece module, ensuring terminal compatibility while simplifying stock management to only end piece variants.
Solution Approach 2:
The housing configuration becomes dynamic rather than static, allowing the end piece component to be changed based on the required terminal type. This dynamic adaptability ensures compatibility with different terminals without requiring multiple fixed housing designs, reducing stock management complexity.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A housing (1) has a cover (2), which forms partly at least two longitudinal sides and a top side of the housing. Two end pieces (3, 4) are provided, which form at least partially two opposite font sides of the housing. The end pieces have electrical connection elements for the closure of the electrical conductors for anti-interference electrical conductor. An independent claim is also included for an electromagnetic compatibility filter (EMV).