Busbar Module Layout for Capacitor Thermal Isolation
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Solution Overview
Problem
Existing power converters face challenges in reducing thermal influence on capacitors due to heat generated by busbars, as the busbars are typically positioned close to capacitors, leading to potential heat transfer and thermal issues.
Innovation Solution
A power converter design that includes a busbar module with a fixed portion protruding towards the capacitor, integrated with a molded insulating resin and secured to the casing, positioning the busbar at a distance from the capacitor to prevent heat transfer, thereby reducing thermal influence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the busbar is positioned close to the capacitor, then the device complexity is reduced and space is saved, but thermal influence from the busbar affects the capacitor
Solution Approach 1:
A resin layer is introduced as an intermediary substance between the busbar and the capacitor. This resin layer acts as a thermal barrier that prevents heat transfer from the busbar to the capacitor, while still allowing the components to be positioned close together in the housing, thus maintaining structural simplicity while eliminating thermal interference.
2Reliability
If the busbar is covered with molded insulating resin, then electrical insulation is improved, but heat dissipation from the busbar is reduced
Solution Approach 1:
The resin coating is applied selectively to specific portions of the busbar rather than the entire surface. This local application provides electrical insulation where needed (at connection points and critical areas) while leaving other portions of the busbar exposed or with reduced coating, allowing heat to dissipate more effectively from those areas.
3Object-affected harmful factors
If the busbar module includes a fixed portion protruding toward the capacitor, then thermal isolation is improved, but the device complexity increases
Solution Approach 1:
The fixed portion that provides thermal isolation is integrated directly into the busbar module structure itself, merging the fastening function and thermal barrier function into a single component. This eliminates the need for separate thermal barrier components and reduces overall assembly complexity despite the protruding geometry.
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
This configuration effectively isolates the capacitor from heat generated by the busbar, reducing thermal impact and enhancing the stability and performance of the power converter, especially in applications like in-vehicle power conversion devices.
Implementation Method 1
the busbar is covered with a molded insulating resin
Implementation Method 2
the busbar is covered with a molded insulating resin
Implementation Method 3
The fixed portion has a shape protruding toward the capacitor from the busbar and is located between the busbar and the capacitor when the busbar module and the capacitor are viewed in a height direction
Data Source
AI summary
The power converter includes a capacitor connected to a power conversion unit, and a busbar module having a busbar covered with a molded insulating resin. The busbar module includes a fixed portion provided integrally with the busbar module and fixed to a casing by a fastener. The fixed portion has a shape protruding toward the capacitor from the busbar when the busbar module and the capacitor are viewed in a height direction. The fixed portion is located between the busbar and the capacitor unit.