Insert-Molded Capacitor Busbar Insulation for Precise Assembly
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Solution Overview
Problem
Existing insulating members, such as insulating paper or sheets, are difficult to handle and prone to deformation, leading to positional and dimensional inaccuracies, which can result in insulation failures and increased production costs due to the need for careful handling and expertise.
Innovation Solution
A busbar structure with an insulating member made of mold resin, integrated through insert molding, ensuring high precision in relative positioning and dimensional accuracy by avoiding deformation and improving handleability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating paper or sheet is used as insulating member, then insulation between busbars is achieved, but the insulating member is difficult to handle and prone to deformation leading to positional and dimensional inaccuracies
Solution Approach 1:
The patent changes the material parameter of the insulating member from thin, soft insulating paper/sheet to hard insulating resin. This parameter change transforms the insulating member from a deformable, difficult-to-handle material to a rigid, easy-to-position material that maintains its shape during assembly, thereby resolving the contradiction between achieving insulation reliability and maintaining manufacturing precision.
Solution Approach 2:
The patent uses composite material structure where the insulating resin is integrated with the busbar structure. The insulating resin combines electrical insulation properties with mechanical rigidity, creating a composite solution that simultaneously provides reliable insulation and precise positioning without the handling difficulties of traditional insulating paper.
2Reliability
If insulating paper or sheet is used, then insulation is provided, but careful handling and expertise are required increasing production cost
Solution Approach 1:
By changing the material parameter from soft insulating paper to hard insulating resin, the patent eliminates the need for careful manual handling and expertise. The rigid insulating resin can be easily positioned and fixed during assembly, significantly reducing labor requirements and production costs while maintaining insulation reliability.
Solution Approach 2:
The hard insulating resin structure is designed to be self-positioning and self-supporting during assembly. Unlike thin insulating paper that requires manual manipulation, the rigid resin structure maintains its shape and position automatically, enabling simpler assembly processes and reducing the need for skilled operators, thereby lowering production costs.
3Use of energy by moving object
If opposing plate portions are disposed in proximity against each other, then low inductance is achieved, but insulation distance may be insufficient risking dielectric breakdown
Solution Approach 1:
The patent extends the insulating structure from a two-dimensional thin sheet to a three-dimensional hard insulating resin form. This dimensional change allows the insulating member to provide sufficient creepage distance and insulation strength even when busbars are disposed in close proximity, enabling low inductance design while maintaining insulation reliability through the added dimensional presence of the rigid insulator.
4Reliability
If thin insulating paper or sheet is used, then insulation is provided, but the insulating member hardly retains its original shape and increases resistance to stress
Solution Approach 1:
The patent fundamentally changes the physical parameter of the insulating member from thin and soft to hard and rigid. The hard insulating resin retains its original shape under stress and during assembly, providing stable dimensional characteristics and reliable insulation geometry, unlike thin insulating paper that deforms easily and loses its intended configuration.
Data Source
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AI summary
The insulating member is integrated with only one of the busbars by insert molding in which one of opposing plate members in either one of the busbars is used as an insert target. The insulating member includes an insulation active portion, a reinforcing portion and a connecting portion. The insulation active portion is disposed on a back-surface side of one of the opposing plate portions and is interposed between the back-surface side and the other one of the opposing plate portions. The reinforcing portion is disposed on the front-surface side of the one of the opposing plate portions. The connecting portion serves to connect the insulation active portion and the reinforcing portion into an integral unit. In the insulating member, lower end regions of the insulation active portion, reinforcing portion and connecting portion, which are close to the capacitor element and extending from an upper-surface side to a lower-surface side of a side plate portion, are embedded in a mold resin that covers the side plate portion.