Power Conversion Apparatus Bus Bar Insulation Segmentation
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Solution Overview
Problem
Conventional power conversion apparatuses require a large amount of insulating resin to seal both positive and negative electrode bus bars, leading to increased manufacturing costs.
Innovation Solution
The power conversion apparatus is designed such that only the AC bus bar group is sealed with insulating resin, while the DC bus bar group is not, with seats formed on the resin to mount the unsealed bus bars, reducing the amount of resin needed and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If both positive electrode bus bar and negative electrode bus bar are sealed with insulating resin, then insulation reliability is improved, but manufacturing cost increases due to large amount of resin required
Solution Approach 1:
The bus bar group is divided into two segments: AC bus bars that require insulation and DC bus bars that do not. By segmenting the sealing requirement, only the AC bus bars are sealed with insulating resin, reducing the total amount of resin needed while maintaining necessary insulation reliability
Solution Approach 2:
Different sealing treatments are applied to different parts of the bus bar system based on local insulation requirements. AC bus bars receive full sealing with insulating resin where insulation is critical, while DC bus bars use localized insulation only at connection points, optimizing resin usage according to actual needs
2Reliability
If both AC bus bar group and DC bus bar group are sealed with insulating resin, then insulation performance is improved, but the complexity of sealing process increases
Solution Approach 1:
The sealing process is segmented into two distinct procedures: one for AC bus bars requiring complete sealing, and another for DC bus bars requiring only localized insulation. This segmentation simplifies each individual sealing process while maintaining overall insulation performance
Solution Approach 2:
Instead of sealing all bus bars uniformly, the invention inverts the approach by leaving DC bus bars unsealed and applying resin only where absolutely necessary. This inversion simplifies the sealing process by eliminating unnecessary sealing steps while maintaining insulation performance
Data Source
AI summary
A power conversion apparatus includes a plurality of semiconductor modules and a plurality of bus bars. The plurality of bus bars include a positive electrode bus bar connected to a positive electrode power terminal, a negative electrode bus bar connected to a negative electrode power terminal, and a plurality of AC bus bars connected to an AC power terminal. Of a DC bus bar group Including the positive electrode bus bar and the negative electrode bus bar, and an AC bus bar group including the plurality of AC bus bars, part of one of the bus bar groups is sealed with insulating resin, and the other of the bus bar groups is not sealed with insulating resin. A seat is formed on the insulating resin sealing the one of the bus bar groups, and the other of the bus bar groups is mounted on a seat face of the seat.