Noise Reduction Unit Sealing for Heat Dissipation

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Solution Overview

Problem

Conventional noise reduction units for electric wires face challenges in heat dissipation due to incomplete sealing, which can lead to overheating, and lack resistance to external impacts due to air gaps between the ring-shaped core and the housing.

Innovation Solution

Intentionally forming gaps between the ring-shaped core and the housing's inner surfaces, filling them with a sealing material that contacts both the core and the housing surfaces to enhance heat dissipation and using inclined recess surfaces and tapered support portions to ensure effective sealing and impact absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the ring-shaped core and conductor are sealed in the housing using a sealing material, then protection and fixing are improved, but heat release from the ring-shaped core is obstructed due to air layers remaining in gaps

Engineering Contradiction:

Improveprotection and fixingVSAvoidheat release

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent applies preliminary action by intentionally forming gaps between the ring-shaped core and housing inner wall surfaces before sealing, and by designing the sealing material application process to ensure complete filling of these gaps. This preliminary preparation prevents air layer formation that would otherwise obstruct heat release, while still achieving complete sealing for protection and fixing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sealing material serves as an intermediary that performs dual functions: it provides protection and fixing by sealing the housing, and simultaneously enables heat release by being positioned in direct contact with both the ring-shaped core and housing inner wall surfaces. The sealing material acts as a thermal conduction medium that bridges the core and housing.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If gaps between the ring-shaped core and housing are not filled completely, then heat release is improved, but the structure becomes vulnerable to external impacts due to remaining interstices

Engineering Contradiction:

Improveheat releaseVSAvoidresistance to external impact

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent applies beforehand cushioning by using the sealing material to fill gaps between the ring-shaped core and housing, creating a cushioning layer that absorbs external impacts before they reach the core. This prevents direct transmission of impact forces to the ring-shaped core, thereby improving impact resistance while maintaining structural integrity.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Temperature

If the sealing material is charged to fill gaps, then heat release and impact resistance are improved, but the sealing process becomes more complex

Engineering Contradiction:

Improveheat releaseVSAvoidsealing process

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent applies local quality by forming gaps only in specific locations between the ring-shaped core and housing inner wall surfaces, rather than attempting to seal all surfaces uniformly. The gaps are strategically positioned to enable heat release paths while maintaining sealing effectiveness in critical areas. This localized approach simplifies the sealing process compared to complete universal sealing.

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 noise reduction unit achieves improved heat release and increased resistance to external impacts by utilizing the sealing material to transmit heat and absorb external forces, while minimizing the need for complex waterproof structures.

Implementation Method 1

heat generated by the ring-shaped core in reducing noise is transmitted to the housing via the sealing material and released to the outside of the housing

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

high-frequency noise is reduced by converting it into heat utilizing magnetic loss in the ring-shaped core (magnetic body)

Methodology Applied

Scientific EffectMagnetic loss: Magnetic Hysteresis

Implementation Method 3

external impact can be absorbed by the sealing material

Methodology Applied

Scientific EffectImpact absorption: Damping

Data Source

PatentEP3422375B1Noise reduction unit

Publication Date: 2020.02.19 YAZAKI CORP

Figure 1
Figure 2A~2B
Figure 3

AI summary

A noise reduction unit (100) is equipped with a noise filter (10), a housing (80) which houses the noise filter, and a sealing material (90) which is charged in the housing. The noise filter is equipped with conductors (20) having respective winding portions (21) and a ring-shaped core (30) which is made of a magnetic material and is inserted through the winding portions of the conductors. In the housing, a mounting portion (83) for the ring-shaped core has recesses (84) that are recessed in a direction going away from the ring-shaped core and support portions (83b) that support the ring-shaped core so that gaps (S) are formed between the ring-shaped core and the bottom surfaces of the respective recesses. The sealing material goes into the gaps and comes into contact with both of the ring-shaped core and the bottom surfaces of the recesses in the mounting portion.