Capacitor Block Spacer Layout for Height Control and Heat Dissipation
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Solution Overview
Problem
The existing capacitive blocks in electrical equipment, such as those used in motor vehicles, face challenges in size reduction and manufacturing variability, leading to inconsistencies in height that affect heat dissipation and dimensional repeatability, particularly when integrated with cooling circuits.
Innovation Solution
A capacitive block design featuring a housing with a capacitive element and spacers to control height, where the capacitive element is partially embedded in a potting material, allowing for flexible adjustment and reduced bulkiness, with the spacers ensuring uniform distribution and intimate contact with heat sinks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the capacitive element is fully embedded in the resin, then the capacitive block is protected against moisture and the capacitive element is held securely, but the size of the capacitive block increases and the manufacturing precision deteriorates due to height variations
Solution Approach 1:
The invention extracts the capacitive element partially from the resin embedding, leaving a portion exposed at the top surface. This selective extraction reduces the overall height and volume of the capacitive block while maintaining the protective and holding functions of the resin for the embedded portion.
Solution Approach 2:
Instead of fully embedding the capacitive element as in conventional designs, the invention inverts the approach by partially exposing it. This inversion allows the block to achieve compact dimensions while still providing adequate protection and structural support through the embedded portion.
2Ease of manufacture
If space is left between the capacitive element and the lateral walls of the casing, then the resin can flow properly, but the volume of the capacitive block increases
Solution Approach 1:
The invention applies partial embedding rather than full embedding, leaving just enough space for proper resin flow and encapsulation while minimizing the overall volume. This partial action approach achieves adequate resin distribution without the excessive volume increase that would result from full embedding.
3Manufacturing precision
If the heights of capacitive elements are made uniform, then the repeatability of dimensions is improved, but the adaptability to manufacturing uncertainties deteriorates
Solution Approach 1:
The resin acts as an intermediary that compensates for height variations in capacitive elements. By partially embedding the elements in a uniform resin layer, the invention achieves consistent external dimensions and surface flatness even when the capacitive elements themselves have manufacturing tolerances, thus maintaining both precision and adaptability.
4Loss of energy
If the face of the capacitive block is pressed intimately against the cooling circuit, then heat dissipation is optimized, but the uniformity of contact deteriorates due to height differences
Solution Approach 1:
The invention performs preliminary flattening of the top surface through the resin encapsulation process. By allowing the resin to settle and solidify around the capacitive elements before assembly, the surface is pre-conditioned to be sufficiently flat for intimate contact with the cooling circuit, ensuring both good thermal contact and uniformity.
Data Source
AI summary
A capacitive block for electrical equipment includes a housing, at least one capacitive element having a first end housed in the housing and a second end, which is opposite to the first end and which extends out of the housing, an end-stop being fixed to the second end of the at least one capacitive element, and at least one spacer, which butts against the end-stop, so as to determine the distance between the second end of the at least one capacitive element and a bottom of the housing.