Integrated electromagnetic interference filter

Claim 2

An inductor assembly for attenuating both common mode and differential mode electromagnetic interference conducted emissions from electrical, electronic, or electromechanical equipment, said inductor assembly comprising: an outer core of permeable material defining an outer window; an inner core of permeable material disposed in said outer window and defining an inner window; a first power lead for connecting said equipment to a source of electrical power said first lead being wound about only said outer core; a second power lead for connecting said equipment to said source of electrical power, said second lead being wound about both said cores to produce an unbalanced field in said inner core in response to differential-mode interference, thereby attenuating said differential-mode interference, said first and second leads being wound to produce a balanced field in said outer core in response to the power current flow in said first and second power leads, and to produce an unbalanced field in said outer core in response to common-mode interference, thereby attenuating said common-mode interference.

Claim 3

An inductor assembly as set forth in claim 1 wherein said outer core has a permeability of at least about 4500.

Claim 4

An inductor assembly as set forth in claim 1 wherein said outer core is formed of ferrite.

Claim 5

An inductor assembly as set forth in claim 1 wherein said inner core has a permeability of at least about 70.

Claim 6

An inductor assembly as set forth in claim 1 wherein said inner core is formed of powdered iron.

Claim 7

An inductor assembly as set forth in claim 1 wherein each of said power leads have substantially the same number of turns.

Claim 8

An inductor assembly as set forth in claim 6 wherein the turns of each of said power leads is in the range of 30 to 60.

Claim 9

An electromagnetic interference filter adapted for connection between electrical, electronic or electromechanical equipment the operation of which causes noise, and a power source for said equipment, said filter comprising: a first conductor connected between said equipment and said power source; a second conductor connected between said equipment and said power source; an inner core of permeable material disposed in said outer window and defining an inner window, said first conductor including a first winding wound about only said outer core, said second conductor including a second winding which is wound about both of said cores to produce an unbalanced field in said inner core in response to differential-mode interference, thereby attenuating said differential-mode interference, said first and second windings being wound to produce a balanced field in said outer core in response to the power current flow in said first and second windings, and to produce an unbalanced field in said outer core in response to common-mode interference, thereby attenuating said common-mode interference, a first differential mode noise capacitor connected across said conductors and between said power source and said windings; a second differential mode noise capacitive element connected across said conductors and between said windings and said equipment; a first common mode capacitive element connected from said first conductor to ground adjacent said second differential mode capacitor; and a second common mode capacitive element connected from said second conductor to ground adjacent said second differential mode capacitor whereby said filter assembly passes low frequency conducted power and filters high frequency conducted common mode and differential mode noise emissions.

Claim 10

An electromagnetic interference filter adapted for connection between electrical, electronic or electromechanical equipment the operation of which causes noise, and a power source for said equipment, said filter comprising: a first conductor connected between said equipment and said power source; a second conductor connected between said equipment and said power source; an inner core of permeable material disposed in said outer window and defining an inner window, said first conductor including a first winding wound about only said outer core, said second conductor including a second winding which is wound about both of said cores to produce an unbalanced field in said inner core in response to differential-mode interference, thereby attenuating said differential-mode interference, said first and second windings being wound to produce a balanced field in said outer core in response to the power current flow in said first and second windings, and to produce an unbalanced field in said outer core in response to common-mode interference, thereby attenuating said common-mode interference, a first differential mode noise capacitor connected across said conductors and between said power source and said windings; a second differential mode noise capacitive element connected across said conductors and between said windings and said equipment; a first common mode capacitive element connected from said first conductor to ground adjacent said second differential mode capacitor; and a second common mode capacitive element connected from said second conductor to ground adjacent said second differential mode capacitor whereby said filter assembly passes low frequency conducted power and filters high frequency conducted common mode and differential mode noise emissions.

Claim 11

An electromagnetic interference filter adapted for connection between electrical, electronic or electromechanical equipment the operation of which causes noise, and a power source for said equipment, said filter comprising: a capacitor winding having a pair of ends and including a first, a second and a third insulative layer with each of said layers extending substantially from one end of said capacitor winding to the other end of said capacitor winding; a first electrode disposed between said first and second insulative layers; a second electrode disposed between said second and third layers; a third electrode positioned on the outside of said third layer away from said second electrode, one of said electrodes extending to said one end of said capacitor winding and short of the other end of the capacitor winding, another of said electrodes terminating short of said one end and extending to said other end, and the remaining electrode extending intermediate said ends and terminating short of each of said ends; a conductive tab electrically connected to said remaining electrode and extending beyond said one winding end, said tab being insulated at the location where it passes aid one end; conductive means at least partially covering said winding one end, making electrical contact with multiple turns of said one electrode and including a lead; conductive means at least partially covering said winding other end, making electrical contact with multiple turns of the other electrode and including a lead; and at least one inductor comprising an outer core of permeable material defining an outer window; an inner core of permeable material disposed in said outer window and defining an inner window, said first conductor including an first winding wound about only said outer core, said second conductor including a second winding which is wound about both of said cores to produce an unbalanced field in said inner core in response to differential-mode interference, thereby attenuating said differential-mode interference, said first and second windings being wound to produce a balanced field in said outer core in response to the power current flow in said first and second windings, and to produce an unbalanced field in said outer core in response to common-mode interference, thereby attenuating said common-mode interference, said inductor having a first lead connected to said conductive means making electrical contact with said one electrode, and a second lead connected to said conductive means making electrical contact with said other electrode.

Claim 12

An electromagnetic interference filter adapted for connection between electrical, electronic or electromechanical equipment the operation of which causes noise, and a power source for said equipment, said filter comprising: a capacitor winding having a pair of ends and including a first, a second and a third insulative layer with each of said layers extending substantially from one end of said capacitor winding to the other end of said capacitor winding; a first electrode disposed between said first and second insulative layers; a second electrode disposed between said second and third layers; a third electrode positioned on the outside of said third layer away from said second electrode, one of said electrodes extending to said one end of said capacitor winding and short of the other end of the capacitor winding, another of said electrodes terminating short of said one end and extending to said other end, and the remaining electrode extending intermediate said ends and terminating short of each of said ends; a conductive tab electrically connected to said remaining electrode and extending beyond said one winding end, said tab being insulated at the location where it passes aid one end; conductive means at least partially covering said winding one end, making electrical contact with multiple turns of said one electrode and including a lead; conductive means at least partially covering said winding other end, making electrical contact with multiple turns of the other electrode and including a lead; and at least one inductor comprising an outer core of permeable material defining an outer window; an inner core of permeable material disposed in said outer window and defining an inner window, said first conductor including an first winding wound about only said outer core, said second conductor including a second winding which is wound about both of said cores to produce an unbalanced field in said inner core in response to differential-mode interference, thereby attenuating said differential-mode interference, said first and second windings being wound to produce a balanced field in said outer core in response to the power current flow in said first and second windings, and to produce an unbalanced field in said outer core in response to common-mode interference, thereby attenuating said common-mode interference, said inductor having a first lead connected to said conductive means making electrical contact with said one electrode, and a second lead connected to said conductive means making electrical contact with said other electrode.

Claim 13

An electromagnetic interference filter as set forth in claim 9 wherein said first electrode is said one of said electrodes, said third electrode is another of said electrodes, and said second electrode is said remaining electrode.

Claim 14

An electromagnetic interference filter as set forth in claim 10 wherein said first electrode is a metallization formed on said first insulative layer and said third electrode is a metallization formed on said third insulative layer.

Claim 15

An electromagnetic interference filter as set forth in claim 11 wherein said first and third layers are formed of a plastic film.

Claim 16

An electromagnetic interference filter as set forth in claim 9 wherein said conductive means in electrical contact with said one electrode is a weldment between said first lead of said inductor and said one electrode, and said conductive means in electrical contact with said other electrode is a weldment between said second lead of said inductor and said other electrode.