Power Line Filter Housing with Opposite Receptacles
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Solution Overview
Problem
Conventional power line filters face issues with interference between inductor elements due to close proximity and inadequate insulation, leading to safety hazards from spark generation during power on/off cycles due to magnetic field variations.
Innovation Solution
A power line filter design with a housing featuring opposite-oriented receptacles for filter and ground inductors, eliminating the need for insulating tape by using a connecting element and insulating materials for the housing, division plate, and side plate to ensure electrical isolation and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the filter inductor and ground inductor are both disposed in the receptacle of the housing, then the device structure is compact, but the distance between them is quite short causing interference
Solution Approach 1:
The housing is divided into a first receptacle for filter elements and a second receptacle for the ground inductor, physically separating the filter inductor from the ground inductor to increase distance and reduce interference while maintaining compact overall structure
Solution Approach 2:
An insulating plate is introduced as an intermediary component between the filter inductor and ground inductor to provide electrical isolation and prevent interference, allowing both inductors to be housed in the same receptacle while maintaining safe distance
2Device complexity
If the ground inductor is wrapped by insulating tape only, then the structure is simple, but the insulating efficacy is limited and sparks may be generated
Solution Approach 1:
Multiple insulation layers are applied to the ground inductor: insulating tape as the base layer, followed by heat shrink tube for additional protection, and insulating paint as the outermost layer, creating a composite insulation structure that significantly enhances reliability
Solution Approach 2:
The ground inductor is pre-coated with insulating paint before assembly, providing inherent insulation protection from the outset, and additional insulating tape and heat shrink tube are applied in advance to prevent spark generation during operation
3Volume of moving object
If the filter inductor and ground inductor are disposed close to each other, then the device size is reduced, but magnetic field variations induce high voltage difference causing sparks
Solution Approach 1:
An insulating plate is placed between the filter inductor and ground inductor to act as a mediator that blocks electromagnetic interference and prevents high voltage difference from causing sparks, allowing close proximity while maintaining safety
Solution Approach 2:
The ground inductor is coated with multiple insulating layers (insulating paint, insulating tape, heat shrink tube) to withstand magnetic field variations and prevent spark generation even when disposed close to the filter inductor
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 design reduces size and material usage while enhancing safety by preventing interference and spark generation, improving filtering performance and manufacturing efficiency.
Implementation Method 1
a high voltage difference, which is occasionally induced between the filter inductor and the ground inductor by a significant variation of magnetic fields at the moment of being powered on or off
Data Source
AI summary
A power line filter including a socket, a housing, a plurality of filter elements and a ground inductor is disclosed. The socket includes at least one power pin and a ground pin. The housing is assembled with the socket, and includes a first receptacle and a second receptacle. The opening direction of the first receptacle is opposite to the opening direction of the second receptacle. The plurality of filter elements is disposed in the first receptacle. At least one of the filter elements is electrically connected to the power pin. The ground inductor is disposed in the second receptacle and electrically connected to the ground pin.