CN118199542A - Car gauge level heavy current second-level filter - Google Patents

Abstract

The application discloses a vehicle-gauge-level high-current secondary filter. The vehicle-gauge-level high-current secondary filter comprises: an inductive element and first and second capacitive components connected to the inductive element; wherein the inductance element includes: at least one annular magnetic core and at least two winding conductors, wherein the annular magnetic core is enclosed to form a central through hole therein; each of the winding conductors comprises a winding conductor part and a winding conductor part, the winding conductor part and the winding conductor part are mutually combined, a winding part encircling the annular magnetic core is formed, and the winding part penetrates through the central through hole of the annular magnetic core in the set axial direction of the annular magnetic core.

Description

Car gauge level heavy current second-level filter

Technical Field

The invention relates to the field of inductance devices, in particular to a vehicle-gauge-level high-current secondary filter.

Background

The filter is widely used as a frequency selecting device capable of filtering signals with specific frequencies, for example, the filter can be applied to new energy electric vehicles, interference noise is filtered by filtering signals with specific frequencies, and electromagnetic interference is reduced.

In recent years, with the rapid development of the new energy electric automobile industry, more and more electronic devices are equipped in automobiles, more and more complicated electronic systems, and higher requirements on EMC (Electromagnetic Magnetic Compatibility, electromagnetic compatibility) are also required. In the new energy electric vehicle, some important vehicle components, for example, a driver, a controller, a battery pack, etc. in an electric drive system need EMC processing, and for this purpose, a filter may be configured for the new energy electric vehicle.

However, some existing filters have some problems in the practical industry. For example, the inductance is insufficient.

Specifically, the filter mainly includes an inductance element P3 and a capacitance P4. As shown in fig. 1 to 3, the conventional high-current automobile filter mainly adopts a direct-passing type inductance element, and a copper bar P2 of the high-current inductance element implemented as the direct-passing type inductance element only passes through a ring structure of a magnetic core P0, and does not pass through the ring structure of the magnetic core P0 and is wound outside the magnetic core P0, thereby forming a ring-shaped winding wound around the magnetic core P0. The capacitor is assembled at the side of the magnetic core to form a first-stage filter circuit.

Such a direct-through inductive element is far from ideal inductance. However, copper bars with large cross sections are difficult to bend and difficult to turn. Thus, the characteristic that the large-section copper bar is difficult to bend and the inductance of the inductance element are increased to form a contradiction.

For a straight-through inductive element, the inductance is mainly related to the inductance of the core P0. The inductance of a single core is very limited compared to what theoretically needs to be provided, and the effect that can be played in a circuit is very limited. In the prior art, the increase of the inductance of the direct-through inductance element is mainly achieved by increasing the volume of the magnetic cores P0 or increasing the number of the magnetic cores P0; if the filtering effect is enhanced by increasing the number of filtering stages, it is also necessary to increase the number of magnetic cores while connecting a capacitor in the middle of the magnetic cores.

The above solutions all require a multiple increase in the volume and weight of the magnetic core to achieve the effect of increasing the inductance, while also increasing the cost. On the premise that new energy automobiles increasingly pursue small size, light weight and low cost, the traditional filter design scheme cannot meet the market demand.

Disclosure of Invention

The application provides a vehicle-standard large-current secondary filter, wherein the structural design scheme of the vehicle-standard large-current secondary filter can increase the inductance of an inductance element and match the inductance element with a capacitor to form the secondary filter.

The application further provides a vehicle-standard-level high-current secondary filter, wherein in the structural design of the vehicle-standard-level high-current secondary filter, the structure of an inductance element is specially designed, so that the inductance of the inductance element can be multiplied on the premise of not basically increasing the whole volume of the inductance element, the filtering level is multiplied, and the market demands of miniaturization and light weight of the volume are met; and the inductance can be increased at low cost, so that the filter is a revolution of a high-current automobile filter.

Still another advantage of the present application is to provide a vehicle-standard high-current secondary filter, wherein the structural design of the inductance element in the vehicle-standard high-current secondary filter can form a winding conductor around the annular magnetic core, so as to multiply the inductance of the inductance element.

It is still another advantage of the present application to provide a vehicle-gauge high-current secondary filter, in which each turn of the conductor is formed by combining two or more conductors (e.g., copper bars) in the structural design of the inductance element of the vehicle-gauge high-current secondary filter, so that the flexibility of the combination of the conductors (e.g., copper bars) is high, and the flexibility and the selectivity of the structural design of the conductors (e.g., copper bars) are improved.

To achieve at least one of the above or other advantages and objects, according to one aspect of the present application, there is provided a vehicle-gauge-type high-current two-stage filter including: an inductive element and first and second capacitive components connected to the inductive element; wherein the inductance element includes:

at least one annular magnetic core, the annular magnetic core enclosing a central through hole therein; and

And each winding conductor comprises a winding conductor first part and a winding conductor second part, the winding conductor first part and the winding conductor second parts are combined with each other to form a winding part encircling the annular magnetic core, and the winding part penetrates through the central through hole of the annular magnetic core in the set axial direction of the annular magnetic core.

In one embodiment of the large current two-stage vehicle-mounted filter according to the application, the two turn conductors are a first turn conductor and a second turn conductor, respectively; the first winding conductor is provided with a first primary inductance input end, a first primary inductance output end and a first secondary inductance output end, and the second winding conductor is provided with a second primary inductance input end, a second primary inductance output end and a second secondary inductance output end; the first capacitor assembly comprises a first inter-line capacitor and two first capacitors to ground; the second capacitor assembly comprises a second line-to-line capacitor and two second capacitors to ground; the first inter-line capacitor is connected between the first primary inductance output end and the second primary inductance output end; the second line-to-line capacitance is connected between the first secondary inductance output end and the second secondary inductance output end.

In an embodiment of the large current two-stage vehicle-mounted filter according to the present application, the first primary inductor output end and the second primary inductor output end are located on the same side of the annular magnetic core; the first secondary inductance output end and the second secondary inductance output end are positioned on the same side of the annular magnetic core.

In an embodiment of the vehicle-mounted high-current two-stage filter according to the present application, the first primary inductor input and the first secondary inductor output are located on different sides of the toroidal core; the second primary inductor input end and the second secondary inductor output end are located on different sides of the annular magnetic core.

In an embodiment of the vehicle-mounted high-current two-stage filter according to the application, one end of a turn conductor of the first turn conductor forms a first two-stage inductance output of the inductance element, and one end of a turn conductor of the first turn conductor forms a first one-stage inductance input of the inductance element; one end of the second turn conductor forms a second secondary inductive output of the inductive element, and one end of the first turn conductor of the second turn conductor forms a second primary inductive input of the inductive element.

In an embodiment of the vehicle-gauge high-current two-stage filter according to the application, two of the turn conductors are arranged centrally symmetrically with respect to a center point of the central through hole.

In an embodiment of the vehicle-mounted high-current two-stage filter according to the present application, the inductance element includes a first one-stage inductance output pin, a first two-stage inductance output pin, a second one-stage inductance output pin, and a second two-stage inductance output pin; the first primary inductance output pin is connected to the first primary inductance output end, and the first secondary inductance output pin is connected to the first secondary inductance output end; the second-stage inductance output pin is connected to the second-stage inductance output end, and the second-stage inductance output pin is connected to the second-stage inductance output end.

In an embodiment of the vehicle-mounted high-current two-stage filter according to the present application, the first primary inductance output pin is disposed at and protrudes from a second portion of the first turn conductor, and the first secondary inductance output pin is disposed at and protrudes from a first portion of the first turn conductor; the second-stage inductance output pin is arranged on and protrudes out of one part of the second winding conductor, and the second-stage inductance output pin is arranged on and protrudes out of the second part of the second winding conductor.

In an embodiment of the vehicle-mounted high-current two-stage filter according to the present application, the first primary inductor output pin, the first secondary inductor output pin, the second primary inductor output pin, and the second secondary inductor output pin are located on the same side of the toroidal core.

In an embodiment of the vehicle-specific high-current secondary filter according to the present application, the vehicle-specific high-current secondary filter further includes a circuit board, and the first capacitor assembly, the second capacitor assembly and the inductance element are connected to the circuit board.

Further objects and advantages of the present application will become fully apparent from the following description and the accompanying drawings.

These and other objects, features and advantages of the present application will become more fully apparent from the following detailed description, the accompanying drawings and the appended claims.

Drawings

The invention is explained below on the basis of embodiments shown in the drawings, wherein similar or identical elements have the same reference numerals.

Fig. 1 illustrates a perspective view of a conventional high-current car filter.

Fig. 2 illustrates a disassembled schematic view of a conventional high current car filter.

Fig. 3 illustrates a circuit schematic of a conventional high current car filter.

Fig. 4 illustrates a schematic perspective view of an implementation of a vehicle gauge high current two-stage filter according to an embodiment of the present application.

Fig. 5 illustrates a partial perspective view of the implementation of the vehicle gauge high current two-stage filter illustrated in fig. 4 according to an embodiment of the present application.

Fig. 6 illustrates one of the schematic diagrams of the manufacturing process of the implementation of the vehicle-gauge high-current two-stage filter illustrated in fig. 4 according to the embodiment of the present application.

Fig. 7 illustrates a second schematic diagram of the manufacturing process of the implementation of the vehicle-gauge high-current two-stage filter illustrated in fig. 4 according to an embodiment of the present application.

Fig. 8 illustrates a third schematic diagram of the manufacturing process of the implementation of the vehicle-gauge high-current two-stage filter illustrated in fig. 4 according to an embodiment of the present application.

Fig. 9 illustrates a fourth schematic diagram of a manufacturing process of the implementation of the vehicle-gauge high-current two-stage filter illustrated in fig. 4 according to the embodiment of the present application.

Fig. 10 illustrates a fifth schematic diagram of a manufacturing process of the implementation of the vehicle-gauge high-current two-stage filter illustrated in fig. 4 according to the embodiment of the present application.

Fig. 11 illustrates a sixth schematic diagram of a manufacturing process of the implementation of the vehicle-gauge high-current two-stage filter illustrated in fig. 4 according to the embodiment of the present application.

Fig. 12 illustrates a circuit diagram of an implementation of the vehicle-specific high-current two-stage filter illustrated in fig. 4 according to an embodiment of the present application.

Fig. 13 illustrates a flow chart of a method of manufacturing a vehicle gauge high current two-stage filter according to an embodiment of the present application.

Detailed Description

The terms and words used in the following description and claims are not limited to literal meanings, but are used only by the inventors to enable a clear and consistent understanding of the application. It will be apparent to those skilled in the art, therefore, that the following description of the various embodiments of the application is provided for illustration only and not for the purpose of limiting the application as defined by the appended claims and their equivalents.

It will be understood that the terms "a" and "an" should be interpreted as referring to "at least one" or "one or more," i.e., in one embodiment, the number of elements may be one, while in another embodiment, the number of elements may be plural, and the term "a" should not be interpreted as limiting the number.

Although ordinal numbers such as "first," "second," etc., will be used to describe various components, those components are not limited herein. The term is used merely to distinguish one component from another. For example, a first component may be referred to as a second component, and likewise, a second component may be referred to as a first component, without departing from the teachings of the present inventive concept. The term "and/or" as used herein includes any and all combinations of one or more of the associated listed items.

The terminology used herein is for the purpose of describing various embodiments only and is not intended to be limiting. As used herein, the singular is intended to include the plural as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, or groups thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, or groups thereof.

Summary of the application: as described above, the conventional high-current automobile filter mainly uses the direct-passing type inductance element, and the copper bar P2 of the high-current inductance element implemented as the direct-passing type inductance element only passes through the annular structure of the magnetic core P0, and does not pass through the annular structure of the magnetic core P0 and is wound outside the magnetic core P0, thereby forming an annular winding wound around the magnetic core P0. The capacitor is assembled at the side of the magnetic core to form a first-stage filter circuit.

Such a direct-through inductive element is far from ideal inductance. However, copper bars with large cross sections are difficult to bend and difficult to turn. Thus, the characteristic that the large-section copper bar is difficult to bend and the inductance of the inductance element are increased to form a contradiction.

For a straight-through inductive element, the inductance is mainly related to the inductance of the core P0. The inductance of a single core is very limited compared to what theoretically needs to be provided, and the effect that can be played in a circuit is very limited. In the prior art, the increase of the inductance of the direct-through inductance element is mainly achieved by increasing the volume of the magnetic cores P0 or increasing the number of the magnetic cores P0; if the filtering effect is enhanced by increasing the number of filtering stages, it is also necessary to increase the number of magnetic cores while connecting a capacitor in the middle of the magnetic cores.

The above solutions all require a multiple increase in the volume and weight of the magnetic core to achieve the effect of increasing the inductance, while also increasing the cost. On the premise that new energy automobiles increasingly pursue small size, light weight and low cost, the traditional filter design scheme cannot meet the market demand.

The application provides that the winding part encircling the magnetic core can be formed by combining a plurality of copper bars. Thus, the contradiction between the characteristic that the conductor with large section (such as the copper bar) is difficult to bend and the inductance of the inductance element is increased is overcome, and the inductance of the inductance element is increased on the premise that the single conductor with large section (such as the copper bar) which is difficult to bend is not wound. That is, in the inductance element of the present application, a single large-section, non-flexible conductor (e.g., copper bar) does not need to form a turn conductor around the annular magnetic core, and the difficulty of winding the copper bar can be not increased while increasing the inductance of the inductance element. And the flexibility of the copper bar combination is higher, so that the flexibility and the selectivity of the structural design of the copper bar are improved. In addition, the structural design scheme of the inductance element does not need to increase the volume and/or the number of the annular magnetic cores, so that the inductance of the inductance element is increased on the premise of not increasing the whole volume of the inductance element basically, and the market demands of miniaturization and light weight of the volume are met; and an increase in inductance can be realized at low cost.

Furthermore, the inductance element and the capacitor can be mutually matched to form a two-stage filter, so that the filtering effect of the filter is further enhanced.

Schematic car gauge class high current two-stage filter: as shown in fig. 4 to 12, the vehicle-gauge-stage high-current two-stage filter 1 according to the embodiment of the present application is illustrated. The application provides a structural design scheme of a vehicle-gauge-level high-current secondary filter 1, which designs the structure of an inductance element 100 of the vehicle-gauge-level high-current secondary filter, and can enable conductors which are large in size and not easy to bend, for example, copper bars to surround an annular magnetic core 10 in whole circles, so that the inductance of the inductance element 100 is increased; the improved inductance elements 100 are matched with each other to form a secondary filter, and the filtering effect of the vehicle-mounted large-current secondary filter 1 is further enhanced.

Specifically, as shown in fig. 4 and 5, in the embodiment of the present application, the vehicle-gauge-stage high-current two-stage filter 1 includes an inductance element 100, a first capacitance component 60, and a second capacitance component 70. The first capacitive component 60 and the second capacitive component 70 are connected to the inductive element 100. The inductive element 100 comprises a toroidal core 10 and two turn conductors 20 forming a common mode inductive element. The toroidal core 10 encloses a central through hole 101 located therein. Each of the turn conductors 20 comprises a turn conductor one portion 21 and a turn conductor two portion 22. The first turn-conductor portion 21 and the second turn-conductor portion 22 are combined with each other to form a turn portion 2030 surrounding the toroidal core 10. The turn portion 2030 passes through the central through hole 101 of the annular magnetic core 10 in the axial direction set by the annular magnetic core 10. It should be noted that the first portion 21 of the winding conductor does not form a complete annular structure and surrounds the annular magnetic core 10 entirely, and the second portion 22 of the winding conductor does not form a complete annular structure and surrounds the annular magnetic core 10 entirely. Both the first 21 and second 22 turn conductors may be implemented as copper bars, and accordingly the first 21 turn conductor may be implemented as a first copper bar and the second 22 turn conductor may be implemented as a second copper bar. It should be understood that the first turn conductor portion 21 and the second turn conductor portion 22 may also be implemented as other conductors.

The inductance of the inductance element is expected to be large due to the increase of the inductance multiple of the geometric progression of the turn portion 2030, and the contradiction between the characteristic that the large-section conductor, for example, the copper bar, is difficult to bend and the increase of the inductance element is overcome, and the inductance of the inductance element is increased on the premise that a single large-section conductor, for example, the copper bar, is not turned. That is, in the inductance element 100 of the present application, a single large-section conductor, for example, a copper bar, does not need to form a complete turn around the turn conductor 20 of the toroidal core 10, and the difficulty of winding the copper bar can be not increased while increasing the inductance of the inductance element 100. And the flexibility of the combination of the conductors, such as the copper bars, is higher, so that the flexibility and the selectivity of the structural design of the conductors, such as the copper bars, are improved. In addition, the structural design scheme of the inductance element does not need to increase the volume and/or the number of the annular magnetic cores 10, so that the inductance of the inductance element is multiplied on the premise of not substantially increasing the whole volume of the inductance element 100, the filtering stage number is multiplied, and the market demands of volume miniaturization and weight saving are met; and the inductance can be increased at low cost, so that the filter is a revolution of a high-current automobile filter.

In an embodiment of the present application, the toroidal core 10 has a first end 110, a second end 120, and a peripheral wall 130. In the present application, a central axis passing through the first end 110 and the second end 120 of the annular magnetic core 10 is defined as a longitudinal central axis l1 of the annular magnetic core 10, and a direction in which the longitudinal central axis l1 extends is defined as an axial direction of the annular magnetic core 10. Accordingly, the extending direction of the longitudinal center axis l1 of the annular magnetic core 10 coincides with the axial direction of the annular magnetic core 10. The first end 110 of the first annular magnetic core 10 and the second end 120 of the annular magnetic core 10 are opposed in the axial direction set by the annular magnetic core 10. The peripheral wall 130 extends between the first end 110 and the second end 120 of the first toroidal core 10. The central through hole 101 penetrates the first end 110 of the annular magnetic core 10 and the second end 120 of the annular magnetic core 10 in the axial direction set by the annular magnetic core 10.

The number of the ring-shaped magnetic cores 10 is 1 or more, and the number of the ring-shaped magnetic cores 10 is not limited to the present application, and for example, the number may be 1,2,3, or more. When the number of the annular magnetic cores 10 is 2 or more, a plurality of the annular magnetic cores 10 are arranged along the set axial direction thereof. The central through holes 101 of the plurality of the ring-shaped cores 10 communicate.

The two turn conductors 20 are a first turn conductor 2040 and a second turn conductor 2050, respectively. The first turn conductor 2040 has a first inductive input and a first inductive output. The first inductance input end refers to an input end of an inductance formed by the first turn conductor 2040 and the annular magnetic ring 10. The first inductance output end refers to an output end of an inductance formed by the first turn conductor 2040 and the annular magnetic ring 10. The first turn conductor 2040 forms a primary inductance and a secondary inductance with the toroidal magnetic ring 10. A first-order inductance formed by the first turn conductor 2040 and the annular magnetic ring 10 is referred to as a first-order inductance 1001; the second inductance formed by the first turn conductor 2040 and the annular magnetic ring 10 is referred to as a first second inductance 1002.

Accordingly, the first inductor input comprises a first primary inductor input 2041 comprising a first primary inductor output 2042 and a first secondary inductor output 2043, wherein the first primary inductor output 2042 is also used as an input to the first secondary inductor 1002, i.e. the first secondary inductor input.

The second turn conductor 2050 has a second inductive input and a second inductive output. The second inductance input terminal refers to an input terminal of an inductance formed by the second winding conductor 2050 and the annular magnetic ring 10. The second inductance output end refers to an output end of an inductance formed by the second winding conductor 2050 and the annular magnetic ring 10. The second turn conductor 2050 forms a primary inductance and a secondary inductance with the annular magnetic ring 10. The first-stage inductance formed by the second winding conductor 2050 and the annular magnetic ring 10 is referred to as a second-stage inductance 1003; the secondary inductance formed by the second wound conductor 2050 and the annular magnetic ring 10 is referred to as a second secondary inductance 1004.

Accordingly, the second inductor input includes a second primary inductor input 2051, the second inductor output includes a second primary inductor output 2052 and a second secondary inductor output 2053, and the second primary inductor output 2052 is also used as an input of the second secondary inductor 1004, i.e., the second secondary inductor input.

The first capacitor assembly 60 includes a first inter-line capacitor 61 and two first ground capacitors 62; the second capacitor assembly 70 includes a second line-to-line capacitor 71 and two second ground capacitors 72; the first inter-line capacitor 61 is connected between the first inductor input stage output 2043 and the second inductor stage output 2053; the second line-to-line capacitance 71 is connected between the first secondary inductive output 2042 and the second secondary inductive output 2052.

The first primary inductor output 2043 is on the same side of the toroidal core 10 as the second primary inductor output 2053, e.g., outside the second end 120 of the toroidal core 10; the first secondary inductor output 2042 is on the same side of the toroidal core 10 as the second secondary inductor output 2052, e.g., outside of the first end 110 of the toroidal core 10. In this way, the first interline capacitor 61 is conveniently connected to the first inductor input stage output 2043 and the second inductor input stage output 2053, and the second interline capacitor 71 is conveniently connected to the first secondary inductor output 2042 and the second secondary inductor output 2052.

The first primary inductor input 2041 and the first secondary inductor output 2042 are located on different sides of the toroidal core 10, e.g., the first primary inductor input 2041 is located outside the second end 120 of the toroidal core 10, and the first secondary inductor output 2042 is located outside the first end 110 of the toroidal core 10; the second primary inductive input 2051 and the second secondary inductive output 2052 are located on different sides of the toroidal core 10, e.g., the second primary inductive input 2051 is located outside the second end 120 of the toroidal core 10 and the second secondary inductive output 2052 is located outside the first end 110 of the toroidal core 10.

The inductive element 100 includes a first inductive output pin and a second inductive output pin. The first inductive output pin includes a first primary inductive output pin 81 and a first secondary inductive output pin 83, and the second inductive output pin includes a second primary inductive output pin 82 and a second secondary inductive output pin 84. The first inductance output pin is connected to the first inductance output end; the second inductance output pin is connected to the second inductance output end. Specifically, the first primary inductor output pin 81 is connected to the first primary inductor output 2043; the first secondary inductor output pin 83 is connected to the first secondary inductor output 2042; the second stage inductor output pin 82 is connected to the second stage inductor output terminal 2053; the second inductor output pin 84 is connected to the second stage inductor output 2052.

In some embodiments of the application, two of the turn conductors 20 are arranged centrally symmetrically about the centre point of the central through hole 101. One end of the first turn conductor portion 21 of the first turn conductor 2040 forms a first secondary inductive output 2042 of the inductive element 100 and one end of the second turn conductor portion 22 of the first turn conductor 2040 forms a first primary inductive input 2041 of the inductive element 100. One end of the second turn conductor portion 22 of the second turn conductor 2050 forms a second secondary inductive output 2052 of the inductive element 100 and one end of the first turn conductor portion 21 of the second turn conductor 2050 forms a second primary inductive input 2051 of the inductive element 100.

It should be understood that the two turn conductors 20 may be arranged in other ways, for example, in a uniform arrangement; for another example, the ring-shaped magnetic cores 10 are symmetrically arranged about a longitudinal center axis l1 thereof, wherein an extending direction of the longitudinal center axis of the ring-shaped magnetic cores 10 coincides with an axial direction set by the ring-shaped magnetic cores 10.

Accordingly, the first secondary inductance output pin 83 is disposed on and protrudes from the turn conductor portion 21 of the first turn conductor 2040; the first primary inductance output pin 81 is disposed on and protrudes from the second turn conductor 22 of the first turn conductor 2040; the second stage inductor output pin 84 is disposed in and protrudes from the turn conductor two portion 22 of the second turn conductor 2050; the second stage inductor output pin 82 is disposed in and protrudes from the turn conductor portion 21 of the second turn conductor 2050.

In the embodiment of the present application, the inductance element 100 further includes a first outer case 31 and a ground pad 50 connected to the first outer case 31. The first outer casing 31 is sleeved outside the annular magnetic core 10. The first outer case 31 may protect the toroidal core 10 and the turn conductor 20, and may fix and support the turn conductor 20. The first outer case 31 is made of an insulating material.

The first outer housing 31 has a first housing one side wall 311, a first housing two side wall 312, and a first housing three side wall 326. The first housing side wall 312 is connected to the first housing side wall 311. The first housing three-side wall 326 is connected to the first housing two-side wall 312, and is opposed to the first housing one-side wall 311 in the axial direction set by the annular magnetic core 10. The first housing side wall 311 faces the first end 110 of the toroidal core 10. The first housing side walls 312 face the peripheral wall 130 of the annular magnetic core 10. The first housing three side wall 326 faces the second end 120 of the toroidal core 10.

The first outer housing 31 has two first housing first slots 313 and two first housing second slots (not shown). Two first housing-insertion slots 313 are formed in the first housing-side wall 311. The first secondary inductor output end 2042 and the second secondary inductor output end 2052 respectively correspond to the two first housing-inserting slots 313 and exceed the two first housing-inserting slots 313. Two of the first housing second slots (not shown) are formed in the first housing third side wall 326. The first primary inductor input end 2041 and the second primary inductor input end 2051 respectively correspond to two first housing second slots (not shown) and exceed two first housing second slots (not shown).

It should be noted that in some embodiments of the present application, the first capacitor assembly 60 and the second capacitor assembly 70 are at least partially housed in the first outer housing 31.

In the embodiment of the present application, the vehicle-scale high-current two-stage filter 1 further includes a circuit board 90, and the first capacitive component 60, the second capacitive component 70, and the inductive element 100 are connected to the circuit board 90. Specifically, the first inter-line capacitor 61 and the first ground capacitor 62 of the first capacitor assembly 60, the second inter-line capacitor 71 and the second ground capacitor 72 of the second capacitor assembly 70, and the first primary inductor output pin 81, the second primary inductor output pin 82, the first secondary inductor output pin 83 and the second secondary inductor output pin 84 of the inductor element 100 are connected to the circuit board 90 and are connected to each other through the circuit board 90.

The ground plate 50 has a first ground pin 51 and a second ground pin 52. The first ground pin 51 and the second ground pin 52 are connected to the circuit board. It should be noted that, alternatively, the first primary inductor output pin 81, the second primary inductor output pin 82, the first secondary inductor output pin 83, the second secondary inductor output pin 84, the first grounding pin 51 and the second grounding pin 52 are located on the same side of the toroidal core 10, for example, on the outer side of the first end 110 of the toroidal core 10, and the distribution is centralized and compact, so that the circuit board 90 may be disposed on only one side of the toroidal core 10, for example, on the outer side of the first end 110 of the toroidal core 10.

The components within the first outer housing 31 may be potted to further fix the location of the individual components within the first outer housing 31. Accordingly, in the embodiment of the present application, the vehicle-gauge-type high-current two-stage filter 1 further includes a potting 40 filled between the first outer case 31 and the toroidal core 10 and the turn conductor 20.

It should be noted that, in the present application, the shape and combination of the first portion 21 of the winding conductor and the second portion 22 of the winding conductor can be flexibly selected. In some embodiments of the application, as shown in fig. 4-12, the first turn conductor portion 21 and the second turn conductor portion 22 are cross-buckled and do not contact via a notch. Specifically, the turn conductor portion 21 has a first notch 201; the two turn conductor parts 22 are provided with second notches 202, and the first notches 201 are opposite to the second notches 202 and are buckled; the portion of the first turn conductor portion 21 where the first notch 201 is formed, i.e., the first notch forming portion 210, is inserted into the second notch 202 of the second turn conductor portion 22, and the portion of the second turn conductor portion 22 where the second notch 202 is formed, i.e., the second notch forming portion 220, is inserted into the first notch 201. The other position of the first turn-around conductor 21 is connected with the other position of the second turn-around conductor 22, and the part of the first turn-around conductor 21 connected with the other position of the second turn-around conductor 22 forms a connecting part 2020 between the first turn-around conductor 21 and the second turn-around conductor 22; the portion of the first turn conductor portion 21 located between the first notch 201 and the connection portion 2020, and the portion of the second turn conductor portion 22 located between the second notch 202 and the connection portion 2020 enclose a turn portion 2030 surrounding the toroidal core 10.

More specifically, as shown in fig. 6, the turn conductor portion 21 has a first notch forming section 210, an outer edge of the first notch forming section 210 is recessed inward with respect to an outer edge of a portion adjacent to the first notch forming section 210, and the first notch 201 is formed in the recessed inward position of the outer edge of the first notch forming section 210. The turn conductor two portion 22 has a second notch forming portion 220, an outer edge of the second notch forming portion 220 is recessed inward with respect to an outer edge of a portion adjacent to the second notch forming portion 220, and an outer edge of the second notch forming portion 220 is recessed inward to form a second notch 202. When the first notch 201 and the second notch 202 are opposite, the length directions of the two notches deviate; the length direction d1 of the first notch 201 is identical to the length direction of the first portion 21 of the turn conductor, and the length direction d2 of the second notch 202 is identical to the length direction of the second portion 22 of the turn conductor. The first notch forming section 210 is inserted into the second notch 202; the second notch forming section 220 is inserted into the first notch 201 in such a manner that the first notch 201 and the second notch 202 cross each other and are not in contact. The longitudinal direction of the first notch forming section 210 is deviated from the longitudinal direction of the second notch 202, and the longitudinal direction of the second notch forming section 220 is deviated from the longitudinal direction of the first notch 201; wherein the length direction of the first notch forming section 210 is identical to the length direction of the first turn conductor section 21; the length direction of the second notch forming section 220 is identical to the length direction of the turn conductor two section 22. When the first notch 201 and the second notch 202 are opposite, the length directions of the first notch 201 and the second notch 202 may be 90 degrees, so that the first notch 201 and the second notch 202 are crisscrossed and fastened to each other without touching.

As described above, the shape and combination of the first turn-around conductor portion 21 and the second turn-around conductor portion 22 can be flexibly selected. Accordingly, the shape of the first turn conductor portion 21 and the second turn conductor portion 22 is not limiting to the present application. The structure of the first turn conductor portion 21 and the second turn conductor portion 22 is illustrated by specific examples as illustrated in fig. 4 to 12.

In one example of the present application, as shown in fig. 6, the first turn conductor portion 21 includes a first turn conductor portion extension 211 and a second turn conductor portion extension 212. The first and second extension portions 212 of the coiled conductor extend from one end of the first extension portion 211 of the coiled conductor, and the length direction of the first and second extension portions 212 of the coiled conductor is different from the length direction of the first extension portion 211 of the coiled conductor. The angle between the length direction of the first and second extension portions 212 and 211 may be 90 degrees, so that the first and second extension portions 212 and 211 may form an L-shaped structure. The first notch 201 is formed in an extension 211 of a portion of the turn conductor.

In the present application, the length direction of the one-part extending portion 211 of the turn-around conductor is taken as the extending direction of the one-part extending portion 211 of the turn-around conductor; the length direction of the first second extension 212 of the coiled conductor is taken as the extension direction of the first second extension 212 of the coiled conductor; taking the whole extension direction of the first extension 211 of the first turn conductor and the second extension 212 of the first turn conductor as the whole extension direction of the first turn conductor 21; meanwhile, the overall extending direction of the first extension 211 and the second extension 212 of the first and second coiled conductors is taken as the overall length direction of the first coiled conductor 21.

As shown in fig. 6, when the first turn conductor portion 21 of the first turn conductor 2040 is arranged, the first turn conductor portion extension 211 is at least partially located in the central through hole 101 of the toroidal core 10; the two extension portions 212 of the turn conductor extend beyond the annular magnetic core 10 in the radial direction R set by the annular magnetic core 10, and the ends thereof are located outside the annular magnetic core 10 in the radial direction R set by the annular magnetic core 10. The first notch 201 is oriented outward in the radial direction R set by the annular magnetic core 10. Outward in the radial direction R set by the annular magnetic core 10 means a direction pointing away from the central through hole 101 in the radial direction R set by the annular magnetic core 10.

It should be appreciated that the first notch 201 of the first turn conductor portion 21 may be located elsewhere in the arrangement of the turn conductor portion 21 of the first turn conductor 2040, for example, at a portion of the turn conductor portion 21 located within the central through hole 101. Accordingly, the shape of the turn conductor two 22 may be adjusted to other shapes.

Specifically, in this example, the turn-conductor-portion-extending portion 211 passes through the central through hole 101 of the annular magnetic core 10 in the axial direction set by the annular magnetic core 10, and both ends of the turn-conductor-portion-extending portion 211 respectively protrude beyond the annular magnetic core 10 in the axial direction set by the annular magnetic core 10. That is, one end of the one extension 211 of the turn conductor exceeds the first end 110 of the annular magnetic core 10 in the axial direction set by the annular magnetic core 10, and the other end of the one extension 211 of the turn conductor exceeds the second end 120 of the annular magnetic core 10 in the axial direction set by the annular magnetic core 10.

The second extension 212 of the first turn conductor 2040 extends from an end of the first extension 211 of the first turn conductor beyond the second end 120 of the toroidal core 10 and extends outside the toroidal core 10 in a radial direction R defined by the toroidal core 10.

The second turn conductor 2050 is centrally symmetric with the first turn conductor 2040 about the center point of the central through hole 101. Accordingly, the turn-conductor-portion-two extension 212 of the second turn conductor 2050 extends from an end of the turn-conductor-portion-extension 211 beyond the first end 110 of the toroidal core 10 and extends outside the toroidal core 10 in the radial direction R set by the toroidal core 10.

One end of the first extension portion 211 of the first winding conductor 2040, which is connected to the second extension portion 212 of the first winding conductor, forms a connection end of the first extension portion 211 of the first winding conductor; the other end of the one extension 211 of the one turn conductor forms the end of the one extension 211 of the one turn conductor and simultaneously forms one end of the one 21 of the turn conductor and also forms the first secondary inductor output 2042; and the end is beyond the first end 110 of the toroidal core 10 in the axial direction in which the toroidal core 10 is set.

Accordingly, as shown in fig. 7, the end of the first extension portion 211 of the second winding conductor 2050 connected to the second extension portion 212 of the winding conductor forms a connection end of the first extension portion 211 of the winding conductor; the other end of the one extension 211 of the one turn conductor forms the end of the one extension 211 of the one turn conductor, and simultaneously forms one end of the one 21 of the turn conductor, and also forms the second primary inductor input 2051; and the end is beyond the second end 120 of the toroidal core 10 in the axial direction set by the toroidal core 10.

One end of the first extension portion 212 of the first winding conductor 2040, which is connected to the first extension portion 211 of the first winding conductor, forms a connection end of the first extension portion 212 of the first winding conductor; the other end of the one-turn-conductor-portion-two extension 212 forms an end of the one-turn-conductor-portion-two extension 212, while forming the other end of the one-turn-conductor-portion 21, which extends beyond the second end 120 of the toroidal core 10 in the radial direction R set by the toroidal core 10. The first notch 201 is formed in a portion of an extension 211 of the turn conductor beyond the first end 110 of the toroidal core 10.

Accordingly, the end of the first extension 212 of the second winding conductor 2050 connected to the first extension 211 of the winding conductor forms the connection end of the first extension 212 of the winding conductor; the other end of the turn-conductor-portion-two extension 212 forms an end of the turn-conductor-portion-two extension 212, while forming the other end of the turn-conductor-portion 21, which extends beyond the first end 110 of the toroidal core 10 in the radial direction R set by the toroidal core 10.

The two-turn conductor 22 includes a two-turn conductor one extension 221, a two-turn conductor two extension 222, and a two-turn conductor three extension 223. The two-part extension 222 of the coiled conductor extends from one end of the one-part extension 221 of the coiled conductor; the turn conductor two-part three-extension 223 extends from the other end of the turn conductor two-part one-extension 221. The length direction of the two-part extension 222 of the coiled conductor is different from the length direction of the one-part extension 221 of the coiled conductor. The length direction of the two-part three-extension 223 of the turn conductor is different from the length direction of the one-part two-extension 221 of the turn conductor. The angle between the length direction of the two-part extension 222 of the winding conductor and the length direction of the one-part extension 221 of the winding conductor may be 90 degrees, and the angle between the length direction of the three-part extension 223 of the winding conductor and the length direction of the one-part extension 221 of the winding conductor may be 90 degrees, so that the two-part extension 222 of the winding conductor and the one-part extension 221 of the winding conductor may form an L-shaped structure; the turn conductor two-part three-extension 223 and the turn conductor two-part one-extension 221 may form an "L" shaped structure. The winding conductor two-part three-extension portion 223 is opposite to the winding conductor two-part two-extension portion 222, and the winding conductor two-part one-extension portion 221, the winding conductor two-part three-extension portion 223 and the winding conductor two-part two-extension portion 222 form a "U" shape structure.

When the two turn-around conductor parts 22 are arranged and combined with the one turn-around conductor part 21, the one-turn-around conductor part extension part 221 extends to the one turn-around conductor part extension part 211 in the radial direction R set by the annular magnetic core 10, is positioned outside the first end 110 of the annular magnetic core 10, and intersects with the one turn-around conductor part extension part 211.

The second notch 202 corresponds to the first notch 201, and the second notch 202 is oriented inward in the radial direction R set by the annular magnetic core 10. Inward in the radial direction R set by the annular magnetic core 10 means to point in a direction approaching the central through hole 101 in the radial direction R set by the annular magnetic core 10. The first notch 201 and the second notch 202 intersect and are buckled and do not contact at the same time that the two-part one-extension 221 of the turn conductor intersects with the one-part one-extension 211 of the turn conductor.

One end of the two-extension portion 222 connected to the one-extension portion 221 of the two-extension portion of the coiled conductor is a connection end of the two-extension portion 222 of the coiled conductor, and the other end of the two-extension portion 222 of the coiled conductor is an end of the two-extension portion 222 of the coiled conductor, which is also an end of the two-extension portion 22 of the coiled conductor.

The ends of the turn conductor first extension 212 are connected to the ends of the turn conductor second extension 222. The end of the first three extension 212 and the second two extension 222 form a connection 2020 between the first 21 and second 22 portions. The manner in which the ends of the turn conductor first extension 212 are connected to the ends of the turn conductor second extension 222 is not limiting to the application, and may be, for example, by welding. The welding process greatly reduces the connection space of the turn conductors 20, such as copper bars, and has compact structure and low cost. The portion of the first turn conductor portion 21 extending from the first notch 201 to the end of the second turn conductor portion extension 212 and the portion of the second turn conductor portion 22 extending from the second notch 202 to the end of the second turn conductor portion extension 222 together form a turn portion 2030 surrounding the toroidal core 10.

One end of the two-three extension 223 connected to the one extension 221 of the two-part winding is a connection end of the two-three extension 223 of the two-part winding, and the other end of the three-extension 223 of the two-part winding is an end of the three-extension 223 of the two-part winding, which is also the other end of the two-part 22 of the two-part winding. The ends of the first extension 212 of the first turn conductor are connected to the ends of the second extension 222 of the second turn conductor such that the ends of the first extension 212 of the first turn conductor 21 of the first turn conductor form the connection ends of the first turn conductor 21 and the ends of the first extension 211 of the first turn conductor 21 of the first turn conductor form the free ends of the first turn conductor 21; the ends of the two-turn-conductor two-extension 222 of the two-turn-conductor 22 form the connecting ends of the two-turn-conductor 22, and the ends of the three-turn-conductor two-extension 223 of the two-turn-conductor 22 form the free ends of the two-turn-conductor 22.

The two-part three-extension 223 of the turn conductor extends into the central through hole 101 of the annular magnetic core 10; and the ends of the turn conductor two-part three-extension 223 extend beyond the annular magnetic core 10 in the axial direction set by the annular magnetic core 10.

The end of the two-part three-extension 223 of the first turn conductor 2040 forms the first primary inductor input end 2041, which is located outside the second end 120 of the toroidal core 10; the ends of the turn conductor two-part three extensions 223 of the second turn conductor 2050 form the second secondary inductive output terminal 2052 outside the first end 110 of the toroidal core 10.

The manufacturing method of the schematic car gauge-level high-current two-stage filter comprises the following steps: according to the structural design principle of the vehicle-gauge-stage high-current secondary filter 1 of the present application, as shown in fig. 6 to 13, the present application proposes a manufacturing method of the vehicle-gauge-stage high-current secondary filter 1, the manufacturing method of the vehicle-gauge-stage high-current secondary filter 1 comprises: s110, assembling at least one part 21 of the turn conductor on the annular magnetic core 10; s120, combining at least one second turn conductor 22 with the first turn conductor 21, wherein the second turn conductor 22, the first turn conductor 21 and the second turn conductor 22 form a turn portion 2030 surrounding the annular magnetic core 10; s130, respectively mounting pins on one part of the turn conductor and two parts of the turn conductor; s140, arranging a first capacitor assembly and a second capacitor assembly; s150, at least one outer shell is sleeved outside the annular magnetic core 10; s160, and, mounting the circuit board 90.

In some embodiments, the method for manufacturing the vehicle-gauge high-current two-stage filter further includes S170, encapsulating the device in the outer housing.

The structure and arrangement of the components of the large current vehicle-standard secondary filter 1 are described in more detail in the above-described portions describing the large current vehicle-standard secondary filter 1, for example, the structure and arrangement of the first turn conductor portion 21 and the second turn conductor portion 22, and the structure and arrangement of the outer case are not described in detail.

In summary, the vehicle-specific high-current two-stage filter 1 according to the embodiment of the present application is explained. The design scheme designs the structure of the inductance element 100, and can encircle the annular magnetic core 10 by a copper bar whole circle, so that the inductance of the inductance element 100 is increased; the improved inductance elements 100 are matched with each other to form a secondary filter, and the filtering effect of the vehicle-mounted large-current secondary filter 1 is further enhanced.

The basic principles of the present application have been described above in connection with specific embodiments, but it should be noted that the advantages, benefits, effects, etc. mentioned in the present application are merely examples and not intended to be limiting, and these advantages, benefits, effects, etc. are not to be construed as necessarily possessed by the various embodiments of the application. Furthermore, the specific details disclosed herein are for purposes of illustration and understanding only, and are not intended to limit the application to the particular details disclosed.

Claims (10)

1. A vehicle gauge-level high-current two-stage filter, comprising: an inductive element and first and second capacitive components connected to the inductive element; wherein the inductance element includes:

at least one annular magnetic core, the annular magnetic core enclosing a central through hole therein; and

And each winding conductor comprises a winding conductor first part and a winding conductor second part, the winding conductor first part and the winding conductor second parts are combined with each other to form a winding part encircling the annular magnetic core, and the winding part penetrates through the central through hole of the annular magnetic core in the set axial direction of the annular magnetic core.

2. The vehicle-mounted high-current two-stage filter according to claim 1, wherein the two turn conductors are a first turn conductor and a second turn conductor, respectively; the first winding conductor is provided with a first primary inductance input end, a first primary inductance output end and a first secondary inductance output end, and the second winding conductor is provided with a second primary inductance input end, a second primary inductance output end and a second secondary inductance output end; the first capacitor assembly comprises a first inter-line capacitor and two first capacitors to ground; the second capacitor assembly comprises a second line-to-line capacitor and two second capacitors to ground; the first inter-line capacitor is connected between the first primary inductance output end and the second primary inductance output end; the second line-to-line capacitance is connected between the first secondary inductance output end and the second secondary inductance output end.

3. The vehicle-specific high-current two-stage filter according to claim 2, wherein the first primary inductor output and the second primary inductor output are located on the same side of the toroidal core; the first secondary inductance output end and the second secondary inductance output end are positioned on the same side of the annular magnetic core.

4. The vehicle-specific high-current two-stage filter of claim 2, wherein the first primary inductor input and the first secondary inductor output are located on different sides of the toroidal core; the second primary inductor input end and the second secondary inductor output end are located on different sides of the annular magnetic core.

5. The vehicle-specific high-current two-stage filter of claim 2, wherein one end of a turn conductor portion of the first turn conductor forms a first two-stage inductive output of the inductive element and one end of a turn conductor portion of the first turn conductor forms a first one-stage inductive input of the inductive element; one end of the second turn conductor forms a second secondary inductive output of the inductive element, and one end of the first turn conductor of the second turn conductor forms a second primary inductive input of the inductive element.

6. The vehicle-mounted high-current two-stage filter according to claim 5, wherein two of the turn conductors are arranged centrally symmetrically about a center point of the central via.

7. The vehicle-specific high-current two-stage filter of claim 5, wherein the inductive element comprises a first primary inductive output pin, a first secondary inductive output pin, a second primary inductive output pin, and a second secondary inductive output pin; the first primary inductance output pin is connected to the first primary inductance output end, and the first secondary inductance output pin is connected to the first secondary inductance output end; the second-stage inductance output pin is connected to the second-stage inductance output end, and the second-stage inductance output pin is connected to the second-stage inductance output end.

8. The vehicle-mounted high-current two-stage filter of claim 7, wherein the first primary inductor output pin is disposed on and protrudes from a turn conductor portion of the first turn conductor, and the first secondary inductor output pin is disposed on and protrudes from a turn conductor portion of the first turn conductor; the second-stage inductance output pin is arranged on and protrudes out of one part of the second winding conductor, and the second-stage inductance output pin is arranged on and protrudes out of the second part of the second winding conductor.

9. The vehicle-specific high-current two-stage filter of claim 7, wherein the first primary inductor output pin, the first secondary inductor output pin, the second primary inductor output pin, and the second secondary inductor output pin are on the same side of the toroidal core.

10. The vehicle-specific high-current secondary filter of claim 1, further comprising a circuit board, the first capacitive component, the second capacitive component, and the inductive element being connected to the circuit board.