Capacitor Busbar Structure With Swelling Fit for Vibration Resistance
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Solution Overview
Problem
The existing busbar structures in capacitors suffer from poor fitting strength and vibration resistance due to inadequate positioning of insulating and opposing plate portions, often resulting in deformation and reduced natural frequency.
Innovation Solution
The busbar structure incorporates an insulating plate with a swelling that integrates with protruding fitting parts on the busbar plate portions, allowing for enhanced contact area and stability, thereby improving fitting strength and vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If projections are simply fitted into holes for positioning, then the structure is simple, but the fitting strength is poor and vibration resistance degrades
Solution Approach 1:
The positioning structure is segmented into multiple functional elements: projections on the insulating plate, corresponding holes in the busbar plate portions, and recesses for lateral retention. This segmentation allows each element to contribute specifically to different aspects of positioning and securing, improving overall fitting strength while maintaining structural clarity
Solution Approach 2:
The positioning mechanism uses a nested configuration where projections are inserted into holes, and recesses are formed within the plate portions to receive the projections laterally. This nested arrangement creates multiple levels of mechanical interlocking, significantly enhancing fitting strength without proportionally increasing complexity
2Ease of manufacture
If projections are simply fitted into holes, then manufacturing is easy, but positional accuracy degrades due to poor fitting strength
Solution Approach 1:
The insulating plate is pre-formed with projections that extend from its surfaces, and the busbar plate portions are pre-formed with corresponding holes and recesses. This preliminary preparation of positioning features before final assembly ensures that when components are joined, the positional accuracy is already established by the precisely formed interlocking features
Solution Approach 2:
The positioning system combines different material properties: the insulating plate material forms rigid projections, while the busbar plate portions (conductive material) receive these projections in precisely formed holes and recesses. This composite approach leverages the structural properties of each material to achieve both ease of manufacture and high positional accuracy
3Strength
If fasteners like bolts or nuts are used for positioning, then positional fixation is strong, but the production process becomes complicated and thin plate portions may deform
Solution Approach 1:
The positioning function and the insulating plate structure are merged into a single integrated component. The insulating plate simultaneously provides electrical insulation and contains integrated projections for positioning, eliminating the need for separate fasteners while maintaining strong positional fixation through the unified structural design
Solution Approach 2:
The insulating plate's projections serve dual purposes: they provide structural support for the insulating plate itself and simultaneously function as positioning elements that fit into the busbar plate portions. This self-service mechanism eliminates the need for external fasteners, simplifying the overall structure while maintaining strong positioning
Data Source
AI summary
The insulating plate has a swelling protruding in a first direction that is a direction a first plate portion toward a second plate portion. The swelling is formed integral with the insulating plate. The first plate portion has a first fitting part protruding in the first direction and formed integral with this plate portion. The first fitting part is fitted, in the first direction, onto one surface side of the swelling of the insulating plate. The second plate portion has a second fitting part protruding in the first direction and formed integral with this plate portion. The second fitting part is fitted, in a second direction opposite to the first direction, onto the other surface side of the swelling.