Toroidal Choke Enclosure with Insulation Web for EMC Filters

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Solution Overview

Problem

Existing choke arrangements for EMC filters, particularly those using nanocrystalline toroidal cores, face challenges with mechanical robustness, insulation, and secure fixation on control boards, especially under high voltage and current conditions, leading to potential voltage flashover and increased production costs due to adhesive use.

Innovation Solution

A two-part enclosure made of synthetic material is used to securely house a toroidal core, with an integrated insulation web that extends beyond the core's outer diameter, providing enhanced mechanical stability and insulation, and a receptacle with a U-shaped retainer for secure mounting on a control board, reducing assembly time and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If adhesive is used to fix the choke arrangement on the control board, then the mechanical stability is improved, but the production cost and assembly complexity increase

Engineering Contradiction:

Improvemechanical stabilityVSAvoidassembly complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces the chemical bonding system (adhesive) with a mechanical fastening system (press fit connection between the receptacle and control board, and snap-fit retention of the toroidal core in the receptacle). This substitution eliminates the need for adhesive application while maintaining mechanical stability through precise geometric interlocking features.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The receptacle is designed with self-retaining features where the toroidal core is automatically held in position through the form-closed connection with the receptacle's housing. The core's own geometry serves as the retention mechanism, eliminating the need for additional fastening elements or adhesive application processes.

Inventive Principle:

Principle #25Self-service

2Reliability

If additional assembly means are used to secure the choke arrangement, then the fixation reliability is improved, but the assembly time and production costs increase

Engineering Contradiction:

Improvefixation reliabilityVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent merges multiple functions into the receptacle component: it serves as the mounting structure for the control board, the retention housing for the toroidal core, and the insulation barrier. This integration eliminates the need for separate assembly steps and additional fastening components, reducing assembly time while maintaining fixation reliability through the unified design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The receptacle is pre-formed with integrated retention features and mounting structures during its manufacturing process. The form-closed connection geometry is built into the receptacle itself, allowing the toroidal core to be retained and mounted without requiring additional assembly operations or separate fastening components.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If the insulation web extends beyond the core's outer diameter, then the insulation performance is improved, but the device complexity increases

Engineering Contradiction:

Improveinsulation performanceVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The receptacle's housing serves multiple functions simultaneously: it provides the form-closed connection for the toroidal core, acts as the insulation web extending beyond the core's diameter, and serves as the mounting structure for the control board. This multi-functionality achieves superior insulation performance without increasing structural complexity, as the same geometric features fulfill multiple protective and structural roles.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enhances mechanical robustness, insulation, and vibration protection of the choke arrangement, improving electromagnetic compatibility while simplifying production and reducing assembly time and costs by ensuring precise and secure positioning without additional assembly means.

Implementation Method 1

For limiting currents in electric lines for the intermediate storage of energy in the form of a magnetic field, the use of chokes is known in the form of coils or inductances

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

the insulation of the windings with respect to one another has been improved on the choke arrangement according to the invention

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS11329545B2Choke arrangement and receptacle for the choke arrangement

Publication Date: 2022.05.10 HANON SYST CO LTD

AI summary

The invention, which relates to a choke arrangement (1) for application in an EMC filter, has as its objective specifying a choke arrangement (1) that is mechanically robust and that enables improved insulation of the windings (4, 5). The objective is attained by disposing about the toroidal core (10) a two-part enclosure (15) and by disposing an insulation web (19) in the two-part enclosure (15).