Single-Piece Magnetic Core Layout for Bus Bar Noise Filtering
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Solution Overview
Problem
Existing power conversion devices face challenges in achieving both improved cooling performance and downsizing while maintaining effective noise removal due to the use of split magnetic cores that cause noise removal loss at connection portions.
Innovation Solution
A power conversion device with a magnetic core that has a through hole for the direct-current bus bar, configured as a single member with a larger inner diameter in the width direction than in the orthogonal direction, allowing for enhanced cooling and noise removal performance without the need for split cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a split magnetic core is used to achieve downsizing and improve cooling performance, then the cooling performance and compactness are improved, but noise removal loss occurs at the connection portions of the split core
Solution Approach 1:
The patent merges the split magnetic core into a single integrated magnetic core structure. This eliminates the connection portions between split cores that cause noise removal loss, while maintaining the compact design and cooling performance through optimized single-piece geometry
2Reliability
If a flat magnetic core with slit is used to prevent magnetic saturation, then magnetic saturation is prevented, but noise removal loss occurs due to the slit being a connection portion of split core
Solution Approach 1:
The patent combines the magnetic core into a single integrated piece, eliminating the slit and connection portions that cause noise removal loss. The single-piece structure prevents magnetic saturation through optimized geometry while maintaining continuous magnetic flux paths
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 achieves both improved cooling performance and downsizing while reducing noise removal loss, enhancing the overall efficiency and reliability of the power conversion device.
Implementation Method 1
a magnetic core that has a through hole into which the direct-current bus bar is inserted... The through hole is disposed in the magnetic core to have a first inner diameter along a width direction of the direct-current bus bar and a second inner diameter orthogonal to the first inner diameter
Data Source
AI summary
A power conversion device includes a direct-current bus bar that transmits a direct current, a capacitor element for filter connected to the direct-current bus bar, and a magnetic core that has a through hole into which the direct-current bus bar is inserted and is configured by a single member. The through hole is disposed in the magnetic core to have a first inner diameter along a width direction of the direct-current bus bar and a second inner diameter orthogonal to the first inner diameter, and the first inner diameter is larger than the second inner diameter.