Bent Laminate Bus Bar Insulation for Power Conversion
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Solution Overview
Problem
Power conversion apparatuses face challenges in maintaining pressure tightness and design flexibility due to the stretching of insulation films in bent laminate bus bars, which affects the reliability and downsizing of the apparatus.
Innovation Solution
A power conversion apparatus featuring a layered laminate bus bar assembly with bent laminate bus bars, where insulating material is strategically positioned between the bus bars to maintain insulation and prevent pressure tightness loss, allowing for more design freedom and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If laminate bus bars are bent to achieve wiring routing flexibility and downsizing, then design freedom and compactness are improved, but insulation film stretches and pressure tightness decreases
Solution Approach 1:
The insulating material is disposed between the laminate bus bars before bending, in advance protecting the insulation film from stretching damage during the bending process, thereby maintaining pressure tightness while achieving wiring routing flexibility
Solution Approach 2:
An insulating material is introduced as an intermediary substance between the laminate bus bars. This intermediary prevents direct contact and reduces stress concentration on the insulation film during bending, resolving the contradiction between flexibility and pressure tightness
2Volume of moving object
If laminate bus bars are bent for downsizing and design freedom, then apparatus size is reduced, but insulation film integrity deteriorates
Solution Approach 1:
The insulating material is pre-positioned between the laminate bus bars before bending operations, protecting the insulation film from stretching and damage, thereby maintaining manufacturing precision while enabling downsizing through bending
Solution Approach 2:
The structure combines laminate bus bars with insulating material to form a composite assembly. This composite structure provides both the mechanical flexibility needed for downsizing and the insulation protection needed to maintain film integrity
3Reliability
If layered laminate bus bars are used with insulating material between layers, then insulation reliability is improved, but assembly complexity increases
Solution Approach 1:
The insulating material is integrated directly between the laminate bus bar layers, merging the insulation function into the structural assembly itself. This eliminates separate insulation components and simplifies assembly while maintaining insulation reliability
Data Source
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AI summary
According to the present invention, first and second laminate bus bars 2a and 2b that electrically connect a filter capacitor 3 and a switching module 4 respectively have: opposing surfaces 23a and 23b; opposing surfaces 24a and 24b; and bent parts 21a and 21b that respectively connect the opposing surfaces 23a and 23b and the opposing surfaces 24a and 24b. An insulating material15 is arranged between the opposing surfaces 23a and 23b and/or between the opposing surfaces 24a and 24b.