Capacitor Busbar Overhang Structure for Interference-Free Assembly
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Solution Overview
Problem
The existing capacitor assembly process is hindered by the complex shape and structure of busbars, leading to difficulties in inserting the capacitor element unit due to overlapping components, which can result in poor workability and potential soldering issues due to elastic protruding pieces interfering with the insertion direction.
Innovation Solution
The capacitor design incorporates elastically depressible connecting protrusions on the busbars, allowing for lateral insertion of the capacitor element unit, which absorbs tolerances and reduces interference, enabling smooth assembly and improved soldering performance by guiding the insertion and distributing pressing forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the first busbar has an intricately-structured overhang that vertically overlaps the second electrode terminal, then the capacitor can achieve compact structure and improved electrical performance, but the second busbar becomes difficult to move downward and insert laterally due to interference from the overlapping components
Solution Approach 1:
The connecting protrusion is designed to be elastically deformable, transitioning from a static obstacle to a dynamic component that adapts during assembly. When the capacitor element unit is inserted laterally, the protrusion elastically deforms to accommodate the passing components, then returns to its original shape to provide electrical connection, thus resolving the interference issue while maintaining the compact structure
Solution Approach 2:
The connecting protrusion changes its physical state from rigid to flexible during the assembly process. By incorporating elastic properties, the protrusion can temporarily change its position and shape to allow lateral insertion of the capacitor element unit, then revert to its connection-ready state, thereby enabling both compact design and ease of assembly
2Adaptability or versatility
If elastic protruding pieces are added to absorb tolerances during insertion, then manufacturing adaptability improves, but the protruding pieces may interfere with the insertion direction and worsen assembly workability
Solution Approach 1:
The elastic protrusion is strategically positioned at specific locations where it can absorb dimensional tolerances without interfering with the lateral insertion path. By localizing the tolerance absorption function to areas that do not obstruct the insertion direction, the design achieves both adaptability and ease of assembly
Solution Approach 2:
The protrusion is designed to deform in a direction perpendicular to the insertion path, allowing it to absorb tolerances in the vertical dimension while leaving the horizontal insertion dimension unobstructed. This dimensional separation enables tolerance absorption without interfering with assembly workability
3Ease of operation
If the second busbar is laterally inserted to follow the lower surface of the overhang, then interference with the capacitor element unit insertion is reduced, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The connecting protrusion is pre-configured in an elastic state before assembly, positioned to automatically deform and clear the insertion path when the capacitor element unit is inserted. This preliminary preparation eliminates the need for complex sequential assembly steps, reducing both interference and assembly time
Solution Approach 2:
The elastic protrusion automatically performs the function of clearing the insertion path through its own elastic deformation, without requiring external intervention or complex positioning mechanisms. The component self-adjusts to facilitate the lateral insertion of the capacitor element unit, simplifying the assembly process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the workability of capacitor assembly by ensuring the capacitor element unit can be properly inserted and soldered without interference from protruding pieces, improving the assembly process and reducing the risk of soldering defects such as increased ESL and ESR.
Implementation Method 1
at least one of the first electrode terminal and the second electrode terminal having a connecting protrusion, the connecting protrusion being elastically depressible in response to contact with the electrode surface of the capacitor element unit
Data Source
AI summary
A second busbar is provided that has a second electrode terminal and a second connection terminal. A first busbar is provided that has a first electrode terminal, a lateral side coupler, an overhang, and a first connection terminal. The first electrode terminal and/or the second electrode terminal has a protruding piece for connection (connecting protrusion). This protruding piece is elastically depressible in response to contact with an electrode surface of a capacitor element unit inserted from an opposite side of the lateral side coupler across a space between the first and second electrode terminals.