CONDUCTOR ASSEMBLIES HAVING FILTER CORES

• US 20200136323A1
• Filed: 10/31/2018
• Published: 04/30/2020
• Est. Priority Date: 10/31/2018
• Status: Active Grant

• Current Assignee: Hamilton Sundstrand Corporation (Rtx Corporation)
• Original Assignee: Hamilton Sundstrand Corporation (Rtx Corporation)
• Inventors: Goodrich, Timothy Arn, Karlen, Eric W., Metzler, Mark W.
• Granted Patent: US 11,101,608 B2
• Time in Patent Office: Days
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 7/004 comprising at least one non-porous part
• CPC Class Codes: B22F 7/08 with one or more parts not made from powder B22F7/062 takes precedence
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: C22C 2202/02 Magnetic
• CPC Class Codes: C23C 4/06 Metallic material
• CPC Class Codes: C23C 4/134 Plasma spraying
• CPC Class Codes: H01B 7/0861 comprising one or more screens
• CPC Class Codes: H01F 17/06 with core substantially closed in itself, e.g. toroid
• CPC Class Codes: H01F 2017/065 Core mounted around conductor to absorb noise, e.g. EMI filter
• CPC Class Codes: H01F 41/02 for manufacturing cores, coils, or magnets H01F41/14 takes precedence; for dynamo-electric machines H02K15/00
• CPC Class Codes: H01R 13/646 specially adapted for high-frequency, e.g. structures providing an impedance match or phase match non-coaxed protective earth or shield arrangements H01R13/648; coaxed connectors specially adapted for high frequency H01R24/40
• CPC Class Codes: H01R 13/7193 with ferrite filters
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A conductor assembly can include one or more conductors formed by a conductive material, and one or more filter cores formed integrally on and at least partially around the one or more conductors. The one or more filter cores can be formed of a material different than the conductive material and can be configured to reduce electromagnetic emissions from the one or more conductors.

Claims

1. A conductor assembly, comprising:

one or more conductors formed by a conductive material; and

one or more filter cores formed integrally on and at least partially around the one or more conductors, wherein the one or more filter cores are formed of a material different than the conductive material and are configured to reduce electromagnetic emissions from the one or more conductors.

2. The assembly of claim 1, wherein the one or more conductors include a bus bar.

3. The assembly of claim 1, wherein the one or more filter cores surround each of the one or more conductors.

4. The assembly of claim 1, wherein the one or more conductors include a plurality of conductors.

5. The assembly of claim 4, wherein the one or more filter cores include a separate filter core for each conductor.

6. The assembly of claim 5, further comprising at least one electrical insulator disposed on or in the assembly and configured to electrically insulate each conductor of the plurality of conductors.

7. The assembly of claim 6, wherein the plurality of conductors and each filter core are stacked.

8. The assembly of claim 7, wherein each filter core is formed directly on the plurality of conductors such that each filter core is in electrical communication with each conductor, the assembly further comprising at least one electrical insulator disposed between each filter core of each conductor to electrically isolate each filter core and each conductor.

9. The assembly of claim 4, wherein the one or more filter cores includes a continuous filter core surrounding the plurality of conductors.

10. The assembly of claim 9, further comprising an electrical insulator disposed between each conductor and the continuous filter core to electrically isolate each conductor from each filter core.

11. The assembly of claim 1, wherein the one or more conductors are made of copper.

12. The assembly of claim 1, wherein the one or more filter cores are additively manufactured on the one or more conductors.

13. The assembly of claim 12, wherein the one or more filter cores are sprayed on the one or more conductors.

14. The assembly of claim 4, wherein the one or more filter cores are non-conductive.

15. A method for forming a conductor assembly, comprising:

additively manufacturing one or more filter cores on one or more conductors to form the conductor assembly.

16. The method of claim 15, wherein additively manufacturing includes plasma spraying ferrous powder on the one or more conductors.

17. The method of claim 15, wherein additively manufacturing includes cold spraying ferrous powder on the one or more conductors.

18. The method of claim 17, further comprising controlling a particle size of the ferrous powder to control an electromagnetic characteristic of the one or more filter cores additively manufactured on the one or more conductors.

19. The method of claim 15, further comprising disposing a dielectric between each filter core of each conductor.