Capacitor Module Bus Bar Layout for Compact Insulation Reliability
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Solution Overview
Problem
Existing capacitor modules with multiple capacitor groups suffer from deteriorated insulation quality due to bubbles in the insulating resin, which hinders effective insulation and makes downsizing difficult.
Innovation Solution
A capacitor module design featuring a case with an opening, multiple capacitor groups, bus bars, and an insulating member between electrode contact portions, surrounded by sealing resin, which enhances insulation by securing distance and reducing bus bar spacing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bus bars are closely spaced to reduce module size, then productivity and downsizing are improved, but insulation reliability deteriorates due to bubbles in the insulating resin
Solution Approach 1:
An insulating member is introduced as an intermediary component between the first and second bus bars. This insulating member physically separates the bus bars and prevents direct contact, while also providing a barrier that excludes bubbles from the insulating resin from reaching the electrode contact portions. This resolves the contradiction by enabling closer bus bar spacing without compromising insulation reliability.
Solution Approach 2:
The insulating member provides localized insulation enhancement specifically at the critical region where electrode contact portions of the bus bars meet. Rather than requiring uniform insulation throughout the entire module, the insulating member concentrates insulation protection where it is most needed, allowing reduced spacing in other areas and enabling downsizing while maintaining reliability.
2Reliability
If partition plates are used to separate capacitor groups, then insulation is improved, but device complexity and volume increase
Solution Approach 1:
The insulating member extracts and concentrates the insulation function specifically at the bus bar interface, removing the need for comprehensive partition plates that would separate entire capacitor groups. By taking out the essential insulation requirement and addressing it locally at the electrode contact portions, the design achieves insulation improvement without the complexity and volume penalty of full partition plate structures.
Data Source
AI summary
A capacitor module is provided with a case with a bottom surface and an opening, a first capacitor group including first capacitors each having first and second electrodes, and a side surface connecting the first and second electrodes, a second capacitor group including second capacitors each having third and fourth electrodes, and a side surface connecting the third and fourth electrodes, a first bus bar having an electrode contact portion in contact with the first electrode, a second bus bar having an electrode contact portion in contact with the third electrode, a third bus bar having an electrode contact portion commonly in contact with the second electrode and the fourth electrode, a sealing resin filled in the case; and an insulating member provided between the electrode contact portion of the first bus bar and the electrode contact portion of the second bus bar and surrounded by the sealing resin.