Emc filter for electromagnetic regulation of converter and manufacturing method thereof

Patent metadata

Field	Value
Publication number	US-2022166310-A1
Application number	US-202117530756-A
Country	US
Kind code	A1
Filing date	Nov 19, 2021
Priority date	Nov 20, 2020
Publication date	May 26, 2022
Grant date	—

Abstract

Provided is an electro-magnetic compatibility (EMC) filter including a lower bobbin having a U-shaped cross-sectional shape, a lower core including a magnetic material having a U-shaped cross-sectional shape and disposed on the lower bobbin, a bus bar disposed on the lower core, an upper bobbin having a hollow inside, having a hexahedral shape with one side open, and configured to cover an upper portion of the lower bobbin, and an upper core including a magnetic material having a plate-like shape, disposed in an internal space of the upper bobbin, and disposed on the lower core (U core) to cover the bus bar with a gap maintained by the bus bar between the upper and lower cores when the lower bobbin and the upper bobbin are coupled to each other.

First claim

What is claimed is:

1 . An electro-magnetic compatibility (EMC) filter includes:
a lower bobbin having a U-shaped cross-sectional shape; a lower core including a magnetic material having a U-shaped cross-sectional shape and disposed on the lower bobbin; a bus bar disposed on the lower core; an upper bobbin having a hollow inside, having a hexahedral shape with one side open, and configured to cover an upper portion of the lower bobbin; and an upper core including a magnetic material having a plate-like shape, disposed in an internal space of the upper bobbin, and disposed on the lower core to cover the bus bar with a gap maintained by the bus bar between the upper and lower cores when the lower bobbin and the upper bobbin are coupled to each other.

2 . The EMC filter of claim 1 , wherein the bus bar is configured to extend to bypass the gap so as not to overlap the gap.

3 . The EMC filter of claim 1 , wherein
the bus bar includes:
a first bus bar configured to extend below a height level of the gap so as not to overlap the gap; and
second and third bus bars configured to extend from respective upper end surfaces of two ends of the first bus bar in opposite directions.

4 . The EMC filter of claim 3 , wherein a height of the lower core is a thickness of the second bus bar or the third bus bar.

5 . The EMC filter of claim 3 , wherein a height of the lower core is designed by a following equation:
(the height of the lower core=2×a thickness of the first bus bar−the gap).

6 . The EMC filter of claim 1 , further comprising:
a heat dissipation material applied to a portion of the bus bar and a portion of the lower core not covered by the bus bar and exposed upwardly.

7 . The EMC filter of claim 1 , wherein
the bus bar includes:
a first bus bar extending below a height level of the gap so as not to overlap the gap; and
second and third bus bars extending from respective upper end surfaces of two ends of the first bus bar in opposite directions,
wherein the EMC filter further includes a heat dissipation material applied to a portion of the lower core not covered by the bus bar and exposed upwardly and a portion of the first bus bar.

8 . A method of manufacturing an electro-magnetic compatibility (EMC) filter, the method comprising:
attaching a lower core having a U-shaped cross-sectional shape to a lower bobbin having a U-shaped cross-sectional shape; attaching a bus bar to the lower core; applying a heat dissipation material to a portion of the bus bar and a portion of the lower core exposed upwardly and not covered by the bus bar; attaching an upper core to a lower surface of an internal space of the upper bobbin; and coupling the lower bobbin and the upper bobbin such that the lower core and the upper core encase the bus bar with a gap between the lower core and the upper core maintained by the bus bar.

9 . The method of claim 8 , wherein
the bus bar includes: a first bus bar configured to extend below a height level of the gap so as not to overlap the gap; and second and third bus bars configured to extend from respective upper end surfaces of two ends of the first bus bar in opposite directions, wherein, in the applying a heat dissipation material, the portion of the bus bar is a surface of the first bus bar.

10 . The method of claim 8 , wherein the attaching a bus bar to the lower core includes attaching the bus bar, extending to bypass the gap so as not to overlap the gap, to the lower core.

11 . The method of claim 8 , wherein the gap is constantly maintained even with external vibration and impact as the gap is maintained by the bus bar having a metal material.

12 . The method of claim 8 , wherein
the bus bar includes:
a first bus bar configured to extend below a height level of the gap so as not to overlap the gap; and
second and third bus bars configured to extend from respective upper end surfaces of two ends of the first bus bar in opposite directions,
wherein the method further comprising: manufacturing the lower core, wherein, in the manufacturing the lower core, a height of the lower core is a thickness of the second bus bar or the third bus bar, or is manufactured by a following equation:
the height of the lower core=2×a thickness of the first bus bar−the gap.

13 . An electro-magnetic compatibility (EMC) filter comprising:
a lower bobbin having a U-shaped cross-sectional shape; a lower core having a magnetic material, having a U-shaped cross-sectional shape, and disposed on the lower bobbin; a bus bar disposed on the lower core; an upper bobbin having a plate-like shape and configured to cover an upper portion of the lower bobbin; and an upper core having a magnetic material, having a plate-like shape, disposed on a lower surface of the upper bobbin, and disposed on the lower core with a gap maintained by the bus bar when the lower bobbin and the upper bobbin are coupled to each other.

14 . The EMC filter of claim 13 , wherein the bus bar is configured to extend to bypass the gap so as not to overlap the gap.

15 . The EMC filter of claim 13 , wherein a heat dissipation material is applied to a portion of the bus bar and a portion of the lower core not covered by the bus bar and exposed upwardly.

Assignees

• Hyundai Mobis Co Ltd

Inventors

• Bang Tae Ho
• Park Ji Hoon
• Shim Hyun Woo
• Kim Du Ho
• Jeon Soo Min
• Choi Deok Kwan
• Kim Won Gon
• Heo Min
• Kim Kang Min
• Lee A Ra

Classifications

• H01F27/2847

  Sheets; Strips (H01F27/2866 takes precedence) · CPC title

• H01F27/255

  made from particles (H01F27/26 takes precedence) · CPC title

• H01F27/36 Primary

  Electric or magnetic shields or screens (movable for varying inductance H01F21/10) · CPC title

• H01F41/00

  Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties · CPC title

• H01F17/04

  with magnetic core · CPC title