Capacitor Module Bus Bar Elimination ESL Reduction
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Solution Overview
Problem
Existing power conversion devices with capacitor modules have a complex bus bar structure that increases size and manufacturing cost, and only partially suppresses equivalent series inductance (ESL), limiting the effectiveness of switching surge absorption.
Innovation Solution
A capacitor module with a dielectric block of alternating dielectric flat film and conductive layers, where pairs of terminals connect directly to power conversion circuits without a bus bar, reducing module size and cost, and utilizing resin films with thermosetting resin for enhanced heat resistance and low ESL.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bus bar structure is used to connect capacitor elements, then electrical connection is achieved, but the module size increases and manufacturing cost increases
Solution Approach 1:
The invention extracts and eliminates the bus bar component from the capacitor module structure. Instead of using separate bus bars to connect capacitor elements, the connection is achieved through the capacitor element terminals themselves, which are directly connected to the insulating case or mounting structure, thereby removing the need for additional bus bar components and reducing overall module size.
Solution Approach 2:
The invention merges the function of the bus bar connection with the capacitor element terminal structure. The terminal of each capacitor element serves dual purposes: as the electrical connection point and as the mounting interface, eliminating the need for separate bus bar components and reducing the number of parts in the assembly.
2Reliability
If a bus bar structure is used to connect capacitor elements, then electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The invention extracts and eliminates the bus bar component from the capacitor module structure. Instead of using separate bus bars to connect capacitor elements, the connection is achieved through the capacitor element terminals themselves, which are directly connected to the insulating case or mounting structure, thereby removing the need for additional bus bar components and reducing overall module size.
Solution Approach 2:
The invention discards the traditional bus bar component and recovers the connection function by integrating it into the capacitor element terminal structure. This eliminates the need for separate bus bar manufacturing, procurement, and assembly, thereby reducing manufacturing cost and simplifying the production process.
3Reliability
If bus bars are used to connect capacitor elements, then connection is established, but inductance of connection path increases
Solution Approach 1:
The invention extracts and eliminates the bus bar component from the capacitor module structure. Instead of using separate bus bars to connect capacitor elements, the connection is achieved through the capacitor element terminals themselves, which are directly connected to the insulating case or mounting structure, thereby removing the need for additional bus bar components and reducing overall module size.
Solution Approach 2:
The invention inverts the traditional connection approach by eliminating the separate bus bar component and using the capacitor element terminals themselves as the connection interface. This reversal of the connection architecture directly reduces the inductance of the connection path by removing the additional conductive path through bus bars.
4Reliability
If conventional capacitor module structure is used, then basic functionality is achieved, but ESL suppression is limited
Solution Approach 1:
The invention extracts and eliminates the bus bar component from the capacitor module structure. Instead of using separate bus bars to connect capacitor elements, the connection is achieved through the capacitor element terminals themselves, which are directly connected to the insulating case or mounting structure, thereby removing the need for additional bus bar components and reducing overall module size.
Solution Approach 2:
The invention inverts the traditional connection approach by eliminating the separate bus bar component and using the capacitor element terminals themselves as the connection interface. This reversal of the connection architecture directly reduces the inductance of the connection path by removing the additional conductive path through bus bars.
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
The solution results in a smaller, lower-cost power conversion device with improved ESL suppression, efficient switching surge absorption, and increased heat resistance, allowing for the use of lower withstand voltage switching elements and enhanced output density.
Implementation Method 1
a dielectric block having alternating dielectric flat film and conductive layers such that each adjacent pair of dielectric flat film layers is sandwiched by a respective pair of the conductive layers
Implementation Method 2
utilizing resin films with thermosetting resin for enhanced heat resistance
Data Source
AI summary
Provided is a capacitor module (10) for connection to a plurality of power conversion circuits, which includes: a dielectric part (11) that has a plurality of flat-film dielectric layers (18A, 18B) laminated; a capacitance formation part (12) that has conductors opposed to each other with the dielectric layers (18A, 18B) interposed therebetween within the dielectric part (11); and multiple pairs of output terminals (13A, 13B, 13C) that are connected respectively to the multiple power conversion circuits, where the multiple pairs of output terminals (13A, 13B, 13C) are connected to each other with the capacitance formation part (12) interposed therebetween.