Metal-Case Capacitor Bus Bar Isolation for Leakage Control
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Solution Overview
Problem
In capacitors with metal cases, the contact between bus bars and the case can lead to current leakage, causing heat buildup and potential insulation issues, especially when used in applications like electric vehicles where large currents flow.
Innovation Solution
A capacitor design that includes a metal case with a non-contact configuration between the bus bars and the case, utilizing an insulating member with mounting portions to securely position the capacitor element unit, ensuring insulation and improved heat dissipation through a metal case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the bus bar is in contact with the metal case, then the structural support is improved, but current leakage and heat buildup occur
Solution Approach 1:
The patent introduces an insulating plate as an intermediary component between the bus bar and the metal case. This insulating plate prevents direct contact while maintaining structural support, thereby eliminating current leakage pathways and heat buildup issues without compromising the mechanical strength of the capacitor assembly.
Solution Approach 2:
The patent segments the contact interface between the bus bar and metal case by inserting an insulating plate. This segmentation separates the conductive path from the structural support function, allowing the bus bar to be mechanically supported while electrically isolated from the metal case.
2Temperature
If the bus bar is in contact with the metal case, then the heat dissipation is improved, but current leakage occurs
Solution Approach 1:
The insulating plate serves as a mediator that allows thermal energy to dissipate from the bus bar to the metal case while preventing electrical current leakage. The plate's thermal conductivity enables heat transfer, while its electrical insulation properties block current flow, thus resolving the contradiction between heat dissipation and insulation.
3Stability of the object's composition
If the capacitor element unit is securely positioned, then the stability is improved, but the bus bar may contact the case
Solution Approach 1:
The insulating plate acts as a positioning intermediary that ensures the capacitor element unit is securely held in place while simultaneously preventing the bus bar from contacting the metal case. The plate's structural design provides mechanical support for stable positioning while its insulating properties maintain electrical isolation.
Data Source
AI summary
Capacitor includes a capacitor element unit and a case that is made of a metal and houses the capacitor element unit. The capacitor element unit includes a capacitor element, a first bus bar and a second bus bar that are connected to the capacitor element, and an insulating member disposed between the first bus bar and the second bus bar. The insulating member includes a first mounting portion, and the case includes a second mounting portion to which the first mounting portion is attached so that the capacitor element unit is located at a predetermined position with respect to the case while the first bus bar and the second bus bar are not in contact with the case.