Capacitor Unit Bus Bar Nesting for Compact Power Conversion
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Solution Overview
Problem
Conventional electric power conversion devices for electric compressors in vehicles have a large capacitor module due to the integral bus bar configuration, leading to increased device size.
Innovation Solution
A capacitor unit with a resin casing containing a capacitor main body and bus bars, where the bus bars are connected to the capacitor electrodes and the casing supports input and output terminals, allowing compact disposition and integration within the casing to reduce size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bus bar is connected to the outside of the capacitor module and is integrally formed with the capacitor module, then the capacitor module can be electrically connected to the bus bar, but the capacitor module increases in size
Solution Approach 1:
The bus bar is nested inside the capacitor module housing, with the capacitor components arranged around it. This nesting arrangement allows the bus bar to be electrically connected to the capacitor terminals while being contained within the compact housing, avoiding the need for external connections that would increase overall size.
Solution Approach 2:
The bus bar is positioned in a different spatial arrangement within the housing, extending along a dimension that allows it to connect to multiple capacitor terminals without increasing the external footprint of the module. The three-dimensional layout optimizes space utilization.
2Reliability
If the capacitor module increases in size due to the bus bar configuration, then the electrical connection is maintained, but the electric power conversion device increases in size
Solution Approach 1:
The bus bar is nested inside the capacitor module housing, allowing the capacitor components to be arranged around it in a compact configuration. This nesting eliminates the need for additional external space for bus bar mounting, thereby preventing increase in the overall electric power conversion device size.
Solution Approach 2:
The bus bar structure is merged with the capacitor module housing, where the housing serves dual purposes as both the enclosure and the mounting structure for the bus bar. This integration eliminates the need for separate bus bar mounting structures that would increase device size.
3Reliability
If the bus bar is integrally formed with the capacitor module, then the electrical connection is established, but the device complexity increases
Solution Approach 1:
The bus bar is integrated with the housing to form a unified structure, eliminating the need for separate mounting brackets, fasteners, and alignment features. This merging of functions reduces the number of components and simplifies the assembly process while maintaining reliable electrical connections.
Data Source
AI summary
A capacitor unit is integrally provided with: a capacitor main body; a pair of bus bars that are connected to a pair of corresponding electrodes of the capacitor main body; and a casing that internally contains the capacitor main body and the bus bars and is made of resin. The bus bars are each provided with an input terminal on a first end side to which a connection terminal of a high-voltage cable for DC power is connected, while being each provided with an output terminal on a second end side to which an inverter substrate is connected.