Capacitor Bus Bar Structure for Easier Terminal Welding
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Solution Overview
Problem
Conventional capacitors face challenges in efficient connection work between the connection terminal portion of a bus bar exposed from the exterior body and an external terminal, requiring time and effort due to the need for additional support during welding or similar connection methods.
Innovation Solution
The capacitor design includes a bus bar with a connection terminal portion, a first extension portion, and a second extension portion, where the connection terminal portion is exposed from the exterior body with an opposite surface apart from one surface, and the extension portions are embedded in the exterior body, allowing for easy connection with external terminals without additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the connection terminal portion is exposed from the exterior body with opposite surface apart from one surface, then connection work becomes smooth and efficient, but the device structure becomes more complex
Solution Approach 1:
The bus bar is divided into three distinct segments: connection terminal portion, first extension portion, and second extension portion. Each segment serves a specific function - the connection terminal portion provides exposed connection surfaces, the extension portions provide structural support and electrical connection, and this segmentation enables smooth connection work while distributing the functional requirements across multiple components
Solution Approach 2:
The connection terminal portion is designed with its opposite surface positioned apart from the exterior body surface, creating a three-dimensional configuration that provides access to both surfaces. This dimensional arrangement allows connection work to be performed efficiently without requiring additional support structures, as the exposed opposite surface enables direct access for connection operations
2Reliability
If extension portions are embedded in the exterior body, then connection stability and heat dissipation improve, but manufacturing precision requirements increase
Solution Approach 1:
The extension portions are merged with the exterior body through embedding, where the first extension portion and second extension portion are positioned within the exterior body structure. This merging provides structural support and stable electrical connection, while the exterior body itself serves as the embedding medium, reducing the need for separate mounting structures
Solution Approach 2:
The extension portions are pre-configured with specific dimensions and orientations before final assembly. The first extension portion and second extension portion are designed with predetermined lengths and angles that enable them to be properly embedded in the exterior body, ensuring connection stability while accommodating reasonable manufacturing tolerances
3Temperature
If the opposite surface of connection terminal portion is positioned apart from exterior body, then heat dissipation efficiency improves, but the device volume increases
Solution Approach 1:
The connection terminal portion serves dual functions: it provides electrical connection surfaces and acts as a heat dissipation structure. By positioning the opposite surface apart from the exterior body, the connection terminal portion itself becomes the heat dissipation element, exposing both surfaces to air for natural convection and radiation cooling, eliminating the need for separate heat sinks
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 configuration enables smooth connection work between the bus bar and external terminals, reduces the risk of connection failure, and allows for effective heat dissipation, while also preventing damage to the capacitor element.
Implementation Method 1
a curing step of heating and curing the thermosetting resin filled in the casting mold to form an exterior body covering the capacitor element and a part of the bus bar
Data Source
AI summary
A capacitor includes a capacitor element, a bus bar, and an exterior body. The bus bar includes a connection terminal portion, a first extension portion, and a second extension portion. The connection terminal portion includes a connection surface exposed from the exterior body. An opposite surface of the connection terminal portion that is opposed to the connection surface is positioned apart from one surface of the exterior body, the opposite surface facing the one surface. Each of the first extension portion and the second extension portion extends from corresponding one of both ends in a first direction of the connection terminal portion, a part of the each of the first extension portion and the second extension portion extending in a direction intersecting with the connection surface and being embedded in the exterior body. The first extension portion is connected to the electrode inside the exterior body.