PCB-Integrated Busbar Filter for Vibration Resistance
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Solution Overview
Problem
Existing electromagnetic noise filters in vehicle electrical systems fail to meet the requirements of vibration resistance, simplicity in production, low weight, small space, and flexibility for different power applications, often requiring complex cabling and direct mounting on busbars.
Innovation Solution
A filter design utilizing a printed circuit board with conductor tracks to connect electrical components, including capacitors and magnetic elements, which allows for robust and automated assembly, eliminating the need for complex cabling and direct mounting, and featuring a metallic housing for a secure ground connection without additional cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electrical components are connected to busbars via cables or direct mounting, then electrical connection is achieved, but device complexity and production complexity increase
Solution Approach 1:
The patent combines the busbar and printed circuit board into a single integrated structure where the busbar is directly mounted on the PCB. This merging eliminates the need for separate cabling connections between the busbar and PCB, reducing device complexity while maintaining electrical connectivity. The busbar serves dual purposes as both a conductor and a mounting element for electrical components.
Solution Approach 2:
The busbar is designed to perform multiple functions: it serves as an electrical conductor, a structural support element, and a mounting base for electrical components. This multi-functionality reduces the number of separate components needed, simplifying both the device structure and manufacturing process while maintaining all necessary electrical connections.
2Reliability
If sufficient distances or insulations are provided for electrical insulation, then insulation between electrical components is achieved, but device volume increases
Solution Approach 1:
The printed circuit board serves as an intermediary insulating element between the busbar and other electrical components. The PCB's substrate material provides electrical insulation while maintaining a compact structure, eliminating the need for additional insulation materials or increased spacing. This allows close positioning of components without compromising electrical insulation reliability.
3Reliability
If complex cabling and direct mounting are used, then electrical connections are achieved, but production complexity and time increase
Solution Approach 1:
The busbar is pre-mounted on the printed circuit board during PCB manufacturing, establishing electrical connections and mechanical support structures before final assembly. This preliminary action eliminates the need for separate cabling and mounting operations during production, increasing manufacturing speed while ensuring reliable connections from the outset.
4Reliability
If conventional filter designs are used, then filtering function is achieved, but weight and space requirements increase
Solution Approach 1:
The patent merges multiple functional elements into a compact integrated structure: the busbar, printed circuit board, and electrical components are combined into a single filter assembly. This integration eliminates redundant structural elements and reduces overall filter volume and weight while maintaining all necessary filtering functions through the coordinated arrangement of inductances and capacitors.
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 provides a compact, lightweight, and vibration-resistant filter with reliable electrical connections, suitable for a wide range of power applications, while reducing production complexity and weight.
Implementation Method 1
The printed circuit board (5) has a first side and a second side opposite the first side and comprises electrical components, in particular a first busbar (1), a second busbar (2), at least one capacitor and at least one magnetic element, wherein the first busbar (1) and the second busbar (2) are electrically insulated from one another by the printed circuit board (5)
Implementation Method 2
the magnetic elements around the busbars for realizing current-compensated inductors or current transformers
Data Source
AI summary
A filter for electromagnetic noise comprising: a printed circuit board (5) having conductor tracks, having a first side and having a second side opposite the first side; a first busbar (1), which is secured on the first side of the printed circuit board (5) and is electrically connected to at least one of the conductor tracks; and a second busbar (2), which is secured on the second side of the printed circuit board (5) and is electrically connected to at least one of the conductor tracks. The printed circuit board (5) is arranged between the first busbar (1) and the second busbar (2) for the insulation thereof.