Shared-Core DC Converter Filter Module
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Solution Overview
Problem
Conventional DC converters face issues with current circulation and magnetic saturation in parallel applications due to unbalanced negative line currents and complex design requirements for EMI filters, leading to increased costs and reduced reliability.
Innovation Solution
A DC converter with a filter module featuring input and output inductor components sharing a common magnetic core, forming a full-port EMI filter that suppresses common mode interference and balances currents, thereby simplifying the structure and reducing component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If separate EMI filters are equipped at input and output sides of DC converters in parallel configuration, then electromagnetic interference suppression is improved, but current circulation problems and magnetic saturation risks occur
Solution Approach 1:
The patent combines separate input and output EMI filters into a single integrated filter module with a shared magnetic core. This merging approach eliminates current circulation problems between separate filters and prevents magnetic saturation by providing a common magnetic path that balances the magnetic flux, thereby maintaining EMI suppression effectiveness while improving operational reliability in parallel configurations.
Solution Approach 2:
The integrated filter module serves multiple functions simultaneously: it provides EMI filtering at both input and output sides, balances current distribution among parallel converters, and prevents magnetic saturation through its shared magnetic core design. This multi-functionality resolves the technical contradiction by achieving EMI suppression without the reliability issues of separate filters.
2Object-affected harmful factors
If separate EMI filters are used at input and output sides, then electromagnetic interference suppression is improved, but device complexity and component count increase
Solution Approach 1:
The patent merges separate input and output EMI filters into one integrated filter module, reducing the total number of magnetic cores and components. This consolidation simplifies the filter structure while maintaining the EMI suppression functionality at both input and output sides, directly addressing the contradiction between EMI suppression performance and device complexity.
3Object-affected harmful factors
If conventional separate EMI filters are used in parallel DC converter configurations, then individual filter performance is maintained, but current circulation problems occur between modules
Solution Approach 1:
By integrating input and output filters into a single module with a shared magnetic core, the patent eliminates the independent current paths that cause circulation between separate filters. The shared magnetic core creates a unified magnetic circuit that prevents circulating currents while preserving EMI suppression capability.
Solution Approach 2:
The shared magnetic core in the integrated filter module creates equipotential magnetic flux distribution among parallel converter modules, preventing potential differences that drive current circulation. This approach maintains EMI suppression performance while eliminating the harmful current circulation effect.
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 addresses the unbalanced current issues and magnetic saturation problems, enhancing electromagnetic interference suppression while reducing the size and cost of the DC converter, and maintaining reliable operation in parallel configurations.
Implementation Method 1
the input inductor component and the output inductor component share the same magnetic core
Data Source
AI summary
The present disclosure relates to a DC converter, a DC converter group and a method of connecting the DC converter group. The DC converter includes a DC conversion circuit converting a DC input voltage into a DC output voltage, and a filter module electrically coupled to an input end and an output end of the DC conversion circuit. The filter module includes an input inductor component electrically coupled to the input end of the DC conversion circuit, and an output inductor component electrically coupled to the output end of the DC conversion circuit, wherein the input inductor component and the output inductor component share the same magnetic core.