Integrated Capacitor Module Bus Bars for Compact Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing capacitor modules using laminate films for exterior covering face challenges in securing insulation between terminal electrodes and bus bars, and in reducing size while maintaining effective bonding and insulation.
Innovation Solution
A capacitor module design featuring a case with recesses to house capacitors, where bus bars are integrally connected to terminal electrodes, with specific connection portions positioned to ensure insulation and facilitate bonding, and a method for fabricating this module that includes preparing a case with recesses and connecting bus bars to terminal electrodes using ultrasonic welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars are separately mounted on capacitors using conventional methods, then insulation between terminal electrodes can be maintained, but the module size increases and bonding reliability decreases
Solution Approach 1:
The bus bar and case are integrated into a single molded structure, eliminating the need for separate mounting operations. The bus bar is formed as an integral part of the case during the molding process, which reduces the number of components and assembly steps while ensuring consistent positioning and reliable bonding to terminal electrodes.
Solution Approach 2:
The bus bar is pre-formed and positioned within the case during the molding process before the capacitor assembly is completed. This preliminary formation of the bus bar structure ensures proper alignment and reduces subsequent assembly complexity, contributing to both size reduction and bonding reliability.
2Reliability
If conventional capacitor modularization is used, then assembly is simplified, but insulation between terminal electrodes and bus bars is insufficient
Solution Approach 1:
The case is designed with differentiated regions: insulating portions that contact the capacitor body and terminal electrodes, and conductive bus bar portions that make selective electrical connections. This local differentiation of material properties ensures proper insulation where needed while maintaining electrical connectivity where required, all within a single integrated structure.
Solution Approach 2:
The case incorporates both insulating and conductive materials in a single molded structure. The insulating portions are made from electrically insulating material, while the bus bar portions are made from electrically conductive material, creating a composite structure that simultaneously provides insulation and electrical connection functions.
3Reliability
If more space is allocated for insulation between terminal electrodes and bus bars, then insulation performance improves, but the module size increases
Solution Approach 1:
The insulating structure utilizes three-dimensional space efficiently by extending insulating portions vertically and laterally in multiple directions. The insulating portions project from the case in directions that maximize separation between conductive elements without requiring additional horizontal space, thereby maintaining insulation performance while minimizing module footprint.
Solution Approach 2:
The bus bar is nested within the case structure, with insulating portions surrounding and separating the conductive bus bar portions. This nested arrangement ensures that insulation is provided in multiple directions simultaneously, maximizing electrical isolation within a compact volume.
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 provides improved insulation and reduced size for the capacitor module, enabling easier bonding of terminal electrodes and bus bars while effectively utilizing space, resulting in a more compact and reliable module.
Implementation Method 1
connecting bus bars to terminal electrodes using ultrasonic welding
Data Source
AI summary
A capacitor module is provided that includes one or more capacitors that each include a main-body covered with a laminate film, and a first terminal electrode and a second terminal electrode exposed from the main-body. A case is provide with recesses for housing the one or more capacitors, a first bus bar integrally incorporated in the case and electrically connected to the first terminal electrodes, and a second bus bar integrally incorporated in the case and electrically connected to the second terminal electrodes. The first bus bar includes one or more first connection portions connected to the respective first terminal electrodes of the capacitors disposed in the recesses, and the second bus bar includes one or more second connection portions connected to the respective second terminal electrodes of the capacitors disposed in the recesses.