Power Converter Busbar Shielding Using Planar Flux-Conducting Element
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Solution Overview
Problem
Power converters in vehicles face challenges in reducing magnetic alternating field radiation to ensure electromagnetic compatibility, particularly in frequency ranges below 1 kHz, due to installation space restrictions and high costs associated with using highly permeable materials or thick casings.
Innovation Solution
Incorporating a planar flux-conducting element made of a magnetically highly permeable material between the housing wall and the busbar arrangement to provide targeted shielding, which is economically viable, lightweight, and adaptable to specific installation locations with minimal electrical losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the housing is formed from a highly permeable material to reduce magnetic field radiation, then electromagnetic compatibility is improved, but the cost and weight of the power converter increase significantly
Solution Approach 1:
Instead of making the entire housing highly permeable, the invention applies flux-conducting elements only at specific locations where magnetic field radiation is most problematic. This local application reduces the overall weight and cost while maintaining electromagnetic compatibility where it matters most.
Solution Approach 2:
The housing is segmented into regions with different magnetic properties. The main housing remains made of low-permeable material, while specific areas are enhanced with highly permeable flux-conducting elements to address magnetic field radiation locally.
2Object-affected harmful factors
If thick casings are used to generate high eddy currents to limit magnetic fields, then electromagnetic compatibility is improved, but installation space requirements cannot be met due to vehicle space restrictions
Solution Approach 1:
The invention uses composite structures combining low-permeable housing material with highly permeable flux-conducting elements. This composite approach achieves effective magnetic field shielding without requiring increased overall thickness, as the highly permeable elements provide enhanced eddy current generation in a thin configuration.
3Object-affected harmful factors
If the shape of the busbar arrangement is optimized to reduce magnetic field radiation, then electromagnetic compatibility is improved, but the degrees of freedom for installation of the busbar arrangement are limited
Solution Approach 1:
The flux-conducting elements act as intermediaries between the busbar arrangement and the housing. Instead of modifying the busbar shape to control magnetic fields, these intermediate elements capture and redirect magnetic flux, allowing the busbar arrangement to maintain its standard installation-friendly geometry while still achieving electromagnetic compatibility.
4Object-affected harmful factors
If sandwich materials with ferromagnetic layers are used to form the housing, then electromagnetic compatibility is improved, but manufacturing costs increase significantly
Solution Approach 1:
Rather than using expensive sandwich materials throughout the entire housing, the invention segments the housing structure and applies highly permeable flux-conducting elements only where magnetic field radiation needs to be controlled. This reduces material costs while maintaining electromagnetic compatibility.
Solution Approach 2:
The invention replaces expensive ferromagnetic sandwich materials with more cost-effective flux-conducting elements that can be strategically positioned. These elements provide the necessary magnetic shielding function at a lower cost than comprehensive use of expensive sandwich materials.
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 effectively reduces magnetic field radiation, improving electromagnetic compatibility while maintaining low costs and weight, and allowing for flexibility in design and compliance with electromagnetic compatibility standards.
Implementation Method 1
at least one planar flux-conducting element made of a magnetically highly permeable material, which is arranged between a wall of the housing and the busbar arrangement
Implementation Method 2
the housing may be formed from a highly permeable material, which is costly, however, and results in a high weight of the power converter. An increase in the distance between the vehicle occupants and the power converter or the use of thick casings for the housing in order to generate significantly high eddy currents
Data Source
AI summary
A power converter, includes a housing and a busbar arrangement, which is arranged inside the housing, wherein the power converter is designed to guide an alternating current along the busbar arrangement, the power converter also includes at least one planar flux-conducting element made of a magnetically highly permeable material, which is arranged between a wall of the housing and the busbar arrangement.