Insert-Molded Capacitor Busbar Insulation for Precise Positioning
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Solution Overview
Problem
The existing busbar structures with thin, soft insulating paper or sheets face challenges in maintaining precise positioning and dimensional accuracy, leading to potential insulation failures and increased production costs due to handling difficulties and susceptibility to deformation over time.
Innovation Solution
A busbar structure with a mold resin-based insulating member integrated using insert molding, which provides higher hardness and shape retention, ensuring precise positioning and dimensional accuracy, and is less prone to deformation, thereby improving handling and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thin insulating paper or sheet is used between opposing busbars, then insulation is provided, but positioning precision and dimensional accuracy deteriorate due to deformability
Solution Approach 1:
The insulating member is changed from thin paper/sheet to a thick, rigid structure made of molded resin. This parameter change in material form and thickness transforms the insulating member from deformable to shape-retaining, simultaneously ensuring insulation reliability and positioning precision.
Solution Approach 2:
The insulating member is formed as a composite structure integrating multiple functions: insulation (resin material), positioning (protrusions fitting into recesses), and mechanical support (rigid framework). This composite approach resolves the contradiction by combining properties that were previously separate.
2Reliability
If thin insulating paper or sheet is used, then insulation between busbars is achieved, but handling difficulty increases leading to operational errors
Solution Approach 1:
The insulating member is transformed from a thin, flexible material to a thick, rigid molded structure. This parameter change dramatically improves handleability, allowing operators to position and install the insulating member without special expertise or careful manual manipulation.
Solution Approach 2:
The insulating member's rigid structure and integrated protrusions enable self-positioning during assembly. The protrusions automatically align with recesses in the busbars, reducing the need for skilled manual adjustment and minimizing operational errors.
3Reliability
If insulating paper is adhered by handwork, then insulation is provided, but productivity decreases due to difficult handling and repositioning
Solution Approach 1:
Changing the insulating member from thin paper to a thick molded structure eliminates the need for delicate handwork. The rigid structure can be quickly positioned and fixed, transforming the assembly process from a time-consuming manual operation to an efficient, repeatable procedure.
Solution Approach 2:
The insulating member is pre-formed with integrated protrusions during molding, before assembly. This preliminary action of creating self-positioning features eliminates the need for time-consuming alignment and adjustment during assembly, significantly improving productivity.
4Reliability
If thin insulating paper is used, then insulation is provided, but resistance to stress deteriorates over time
Solution Approach 1:
The insulating member is changed from a thin, flexible material to a thick, rigid structure. This parameter change in thickness and rigidity provides inherent resistance to stress and deformation, maintaining structural stability and insulation reliability over time without deteriorating.
Solution Approach 2:
The molded resin structure creates a composite system where the insulating member also serves as a mechanical support element. This multi-functional composite structure simultaneously provides insulation, stress resistance, and long-term structural stability.
Data Source
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.