Bus Bar Capacitor Filter Assembly Without Welding Plates
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Solution Overview
Problem
Existing electronic assemblies for power semiconductors in power electronics have a complex design with numerous components, leading to high manufacturing costs and time consumption, and require additional components like welding plates for connections, which complicates assembly and reduces mechanical robustness.
Innovation Solution
A filter assembly comprising a first and second bus bar directly connected to a capacitor via a material-locking and electrically conductive connection, preferably a laser welded joint, eliminating the need for additional components and simplifying the manufacturing process while ensuring a robust and efficient electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional components like welding plates are used to connect capacitor to bus bars, then electrical connection is achieved, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent merges the electrical connection function directly into the bus bar structure itself, eliminating the need for separate welding plates. The bus bar is designed with integrated connection features that directly attach to the capacitor terminals, combining what were previously separate components (bus bar and welding plate) into a single integrated element, thereby reducing device complexity while maintaining reliable electrical connection.
2Reliability
If additional components like welding plates are used to connect capacitor to bus bars, then electrical connection is achieved, but manufacturing time increases
Solution Approach 1:
By integrating the connection function into the bus bar design, the patent eliminates the need for separate assembly steps involving welding plates. The bus bar can be directly attached to the capacitor in a single operation, reducing the number of manufacturing steps and overall assembly time while ensuring reliable electrical connection.
3Reliability
If additional components like welding plates are used to connect capacitor to bus bars, then electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent reduces manufacturing cost by eliminating the need for separate welding plate components and their associated assembly operations. The integrated bus bar design requires fewer materials and less complex manufacturing processes, thereby reducing overall production costs while maintaining the reliability of the electrical connection between capacitor and bus bar.
4Reliability
If multiple components are used for connection, then electrical connection is achieved, but material and weight increase
Solution Approach 1:
By combining the bus bar and connection element into a single integrated component, the patent eliminates the need for separate welding plates and other intermediate components. This integration reduces the total material required and consequently decreases the overall weight of the electrical assembly while maintaining reliable electrical connection.
5Reliability
If multiple components are used for connection, then electrical connection is achieved, but assembly complexity increases
Solution Approach 1:
The patent simplifies assembly by integrating the connection function into the bus bar itself, eliminating the need for separate welding plates and multiple assembly steps. The integrated design allows for direct attachment to the capacitor, reducing assembly complexity and the number of components that need to be handled and positioned during assembly.
6Ease of manufacture
If direct connection is made between capacitor and bus bar, then manufacturing cost decreases, but connection quality must be ensured
Solution Approach 1:
The patent applies local quality by designing specific connection regions on the bus bar with optimized geometries and surface properties tailored for high-quality direct attachment to capacitor terminals. The bus bar includes locally enhanced connection features such as enlarged attachment surfaces, recesses, or protrusions at the connection points, ensuring precise alignment and robust electrical connection while maintaining cost-effective manufacturing throughout the rest of the structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a cost-effective, mechanically robust, and efficient design with simplified assembly, enabling high-quality electrical connections and optimal power transfer, while reducing material and weight, and allowing for flexible manufacturing.
Implementation Method 1
the connection is a laser welded joint
Data Source
AI summary
The invention relates to a filter assembly (40) of an electronic assembly (50) comprising a first bus bar (1), a second bus bar (2), and a capacitor (3), wherein the capacitor (3) is directly connected to each of the two bus bars (1, 2) by means of a material-locking and electrically conductive connection (4).