Modular Filter Device with Toroidal Core Holders
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Solution Overview
Problem
Conventional mains filters are cumbersome due to their encapsulated construction, which increases weight and size, reduces performance, and makes them difficult to assemble and repair, as well as impossible to replace defective components.
Innovation Solution
A modular filter device with toroidal core holders and ferrite rings, using insulated cables and circuit boards with detachable connections, allowing for efficient assembly and component replacement without encapsulation, thus reducing weight and size while enabling quick assembly and repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mains filters are completely encapsulated for electrical insulation, then electrical insulation is improved, but weight and size increase
Solution Approach 1:
The filter device is divided into modular components (filter modules with circuit boards, chokes, capacitors) that can be independently assembled and connected without requiring complete encapsulation. This segmentation allows electrical insulation to be achieved through individual component design rather than bulk encapsulation, reducing overall weight and size.
Solution Approach 2:
Insulating materials and structures are used as intermediaries between conductive components to achieve electrical insulation locally where needed, rather than encapsulating the entire filter. This targeted approach provides sufficient insulation while minimizing the amount of insulating material required, thus reducing weight.
2Reliability
If conventional mains filters are completely encapsulated for electrical insulation, then electrical insulation is improved, but device size increases
Solution Approach 1:
The filter is constructed from discrete modular components that can be compactly arranged and connected. This modular architecture eliminates the need for large encapsulating structures, allowing the filter to achieve its insulation requirements through compact component placement and interconnections, thereby reducing overall device size.
Solution Approach 2:
The filter components are arranged in a three-dimensional modular configuration on compact circuit boards, utilizing vertical and lateral space efficiently. This dimensional optimization allows the filter to achieve full electrical insulation functionality within a smaller footprint compared to conventional encapsulated designs.
3Ease of manufacture
If conventional mains filters use flying contact construction, then assembly is simplified, but component replacement becomes impossible
Solution Approach 1:
The filter is designed as a modular system where individual components (circuit boards, chokes, capacitors) are segregated into separate replaceable units. This segmentation maintains assembly simplicity through standardized connections while enabling easy replacement of defective components without requiring complex disassembly or soldering operations.
Solution Approach 2:
The connection system transitions from fixed flying contacts to dynamic, reversible connections that allow components to be easily inserted and removed. This dynamic connection approach maintains manufacturing simplicity while providing the flexibility needed for component replacement and repair operations.
4Reliability
If conventional mains filters are completely encapsulated, then electrical insulation is improved, but assembly time increases
Solution Approach 1:
The filter device is constructed from pre-assembled modular components that can be quickly integrated without time-consuming encapsulation processes. This modular approach maintains electrical insulation through designed component interfaces while dramatically reducing assembly time compared to conventional encapsulated filters that require molding or potting operations.
Solution Approach 2:
Individual filter components (circuit boards, chokes, capacitors) are pre-assembled and tested as complete modules before final integration. This preliminary assembly of modular units eliminates the need for time-consuming encapsulation during final assembly, as each module already contains its necessary insulation and protection features.
5Reliability
If conventional mains filters are completely encapsulated, then electrical insulation is improved, but performance class is reduced
Solution Approach 1:
The modular component architecture allows each filter element to be optimized for its specific function without the performance limitations imposed by encapsulation. Individual components can be selected and configured for high-performance applications, maintaining or enhancing the overall filter performance class while achieving necessary electrical insulation through modular design.
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 modular design allows for efficient assembly and repair of the filter device, reducing weight and size while maintaining performance, enabling quick replacement of faulty components and simplifying the assembly process.
Implementation Method 1
INSulated AC cables for different AC phases L and a neutral conductor N are wound multiple times around the first toroidal core holder 3 to form a current-compensated choke of the filter device 1
Implementation Method 2
contain a first number of ferrite rings
Data Source
Figure 1
Figure 2
Figure 3~6
AI summary
Filter device (1) for reducing electromagnetic interference with a modular assembly design, wherein the filter device (1) has a filter plate (2) for receiving first toroidal core holders (3) which are inserted into guide rails of the filter plate (2) and contain a first number of ferrite rings, wherein insulated AC cables (4-L) for AC phases (L) and a neutral conductor (4-N) or insulated DC cables (4-DC) for DC currents (DC) are wound multiple times around the first toroidal core holders (3) to form a current-compensated choke of the filter device (1), wherein the AC cables (4-L) and the neutral conductor (4-N) or the DC cables (4-DC) are connected on one side to connection contacts (5) of the filter device (1) and on the other side are passed through second toroidal core holders (6) which are mounted on the filter plate (2) of the filter device (1) and contain a second number of ferrite rings.