Terminal Block Integrated Common Mode Filter for EMC
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Solution Overview
Problem
Existing voltage converters in motor vehicles face challenges with electromagnetic disturbances due to the connection of the power interface ground to the voltage converter, leading to increased costs and complexity with external common mode filters, and difficulties in integrating bulky capacitor blocks with long power traces.
Innovation Solution
A terminal block with a common mode filter integrated within, optimizing the placement of capacitors and power traces to reduce electromagnetic disturbances, with specific distance configurations between trace segments to minimize electromagnetic interference and improve compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an external common mode filter is integrated into the voltage converter, then electromagnetic disturbances are reduced, but production costs increase and device complexity increases
Solution Approach 1:
The patent merges the common mode filter functionality directly into the terminal block structure. The filtering components are integrated within the terminal block housing, combining two previously separate functions (terminal block and common mode filter) into a single unified component, thereby reducing device complexity while maintaining electromagnetic disturbance reduction
Solution Approach 2:
The terminal block is designed to serve multiple functions simultaneously: electrical connection and common mode filtering. This multi-functionality eliminates the need for separate external filtering components, reducing both device complexity and production costs while effectively addressing electromagnetic disturbances
2Object-affected harmful factors
If a capacitor block with long power traces is used for common mode filtering, then electromagnetic disturbances are reduced, but the solution becomes bulky and integration becomes difficult
Solution Approach 1:
The filtering components are nested within the terminal block housing. The compact arrangement places capacitors and power traces inside the existing terminal block structure, eliminating the need for separate bulky capacitor blocks and achieving space-efficient integration
Solution Approach 2:
The patent transitions from a three-dimensional external filter arrangement to a two-dimensional planar layout within the terminal block. Power traces are arranged on circuit boards or printed circuits within the terminal block plane, reducing the overall volume required for filtering functionality
3Object-affected harmful factors
If protection and long power traces are used for external common mode filter, then electromagnetic disturbances are reduced, but production costs increase
Solution Approach 1:
The terminal block and common mode filter are manufactured as a single integrated unit, eliminating the need for separate protection components and long external power traces. This consolidation simplifies the manufacturing process and reduces production costs while maintaining filtering effectiveness
Solution Approach 2:
The patent uses printed circuit board traces instead of long external power traces. The filtering function is replicated through standard PCB trace routing, which is more cost-effective and easier to manufacture than custom-molded resin-encased power traces
4Ease of operation
If the terminal block ground is connected to the voltage converter, then electrical connection is achieved, but electromagnetic interference is generated within the voltage converter
Solution Approach 1:
The patent extracts the ground connection path from the traditional voltage converter connection and redirects it through the integrated common mode filter within the terminal block. This separation removes the electromagnetic interference-generating path from the voltage converter while maintaining necessary electrical connections
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
This solution reduces production costs, enhances electromagnetic compatibility, and optimizes the integration of common mode filters within the voltage converter, effectively limiting electromagnetic disturbances and meeting electromagnetic compatibility standards.
Implementation Method 1
a capacitor bank configured to stabilize an electrical voltage received by the power electronic units and to reduce electromagnetic disturbances generated by the power and control electronic units
Implementation Method 2
the ground of the terminal block's power interface is connected by an electrical cable to the voltage converter
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a terminal block (10), intended for electrically connecting a voltage converter, in particular one mounted in a motor vehicle, and an electrical network, the terminal block (10) comprising: - a first filtering component (22), - a second filtering component (24), - a first power trace (26), - a second power trace (28), - a third power trace (30), in which the distance D1 along the first power trace (26), the distance D2 along the second power trace (28), the distances D3 and D4 along the third power trace (30) are configured such that the sum of the distances D1 and D3 is greater than or equal to 85% of the sum of the distances D2 and D4 and less than or equal to 115% of the sum of the distances D2 and D4.