Voltage Converter Layout for Low-Parasitic EMI Filtering

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Solution Overview

Problem

Existing voltage converters in motor vehicles suffer from parasitic capacitance and electromagnetic interference due to the distance between capacitor blocks and power electronic units, leading to increased cost and size, and existing solutions like ceramic capacitors or electrical connectors are either expensive or difficult to integrate.

Innovation Solution

A voltage converter design with power electronic units and filtering blocks connected via switching arms, maintaining identical distances between them to minimize parasitic capacitance and electromagnetic interference, using a heat sink for efficient cooling and simplified manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the capacitor block is integrated within the remote voltage converter, then the capacitors can stabilize electrical voltage and reduce electromagnetic disturbances, but the distance between the capacitor block and power electronic units induces parasitic capacitance

Engineering Contradiction:

Improvevoltage stabilization and electromagnetic disturbance reductionVSAvoidparasitic capacitance

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent merges the capacitor block with the power electronic units by integrating capacitors directly into the power electronic assembly. This consolidation eliminates the physical separation between capacitors and power electronics, thereby removing parasitic capacitance caused by distance while maintaining voltage stabilization and electromagnetic disturbance reduction functions.

Inventive Principle:

Principle #5Merging (Combining)

2Object-affected harmful factors

If ceramic capacitors are integrated directly within the power electronics units, then parasitic capacitance is reduced, but the cost increases and modification to the power electronics assembly process is required

Engineering Contradiction:

Improveparasitic capacitance reductionVSAvoidassembly process complexity and cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent segments the power electronic assembly into modular units, with capacitors integrated into specific modules rather than requiring complete redesign of the entire assembly process. This segmentation allows for standardized manufacturing procedures to be maintained while still achieving parasitic capacitance reduction through strategic capacitor placement within the modular architecture.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If an electrical connector is used to connect capacitors to power electronics, then the connection is flexible, but the connector is expensive and bulky with difficult integration

Engineering Contradiction:

Improveconnection flexibilityVSAvoidconnector design and integration difficulty

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the capacitor mounting structure directly with the power electronic unit housing or circuit board, eliminating the need for separate electrical connectors. The capacitors are mechanically and electrically integrated into the power electronic assembly through direct mounting techniques, thereby removing connector-related complexity, cost, and space requirements while maintaining necessary electrical connections.

Inventive Principle:

Principle #5Merging (Combining)

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

Reduces electromagnetic disturbances and optimizes compatibility while maintaining cost-effectiveness and compact size, with efficient cooling and simplified production processes.

Implementation Method 1

a filtering block (30) configured to filter the input electrical voltage of the power electronic unit

Methodology Applied

Scientific EffectElectromagnetic filtering: Filter (electronic)

Implementation Method 2

The voltage converter may also include a heat sink (50)

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

The heat sink (50) may include a cooling circuit (62) having a channel for circulating a cooling fluid

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 4

The voltage converter may also include a capacitor bank configured to stabilize an electrical voltage received by the power electronic units

Methodology Applied

Scientific EffectCapacitance: Capacitance

Data Source

PatentEP4432543B1Voltage converter for supplying power to an electric machine for a motor vehicle

Publication Date: 2025.11.26 VALEO ELECTRIFICATION

AI summary

Voltage converter (10), in particular intended to supply power to an electric machine for a motor vehicle, comprising: - at least three power electronic units (20) configured to convert an electrical voltage, each power electronic unit (20) comprising two switching arms (22), - a filter block (30) configured to filter the electrical input voltage of the power electronic unit (20), the filter block comprising at least three filtering units (32), the at least three power electronic units (20) and the filter block (30) being electrically connected via each switching arm (22) of said power electronic units (20), and the at least three power electronic units (20) being arranged side by side, the filter block (30) extending longitudinally along the direction of arrangement of the power electronic units (20),and all the filtering units of the filtering block following one another along this longitudinal axis.