Capacitor Module Vibration Resistance via Segmented Holder Design

Solution Overview

Problem

Capacitor modules in vehicles experience vibrations due to clearances between capacitors and holders, leading to potential rupture of lead wires and breakage near soldered portions, compromising vibration resistance and assembling workability.

Innovation Solution

A capacitor module design featuring a lower holder with a first holding portion and an upper holder with a second holding portion that apply a pressing force to the leg of the lead wire, securing it towards the capacitor body, thereby reducing vibrations and enhancing vibration resistance and assembling workability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If clearances are provided between the capacitor barrel and holder containers for easy assembly, then assembling workability is improved, but vibration resistance deteriorates due to vibrations causing lead wire rupture and soldered portion breakage

Engineering Contradiction:

Improveassembling workabilityVSAvoidvibration resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The holding structure is divided into two distinct portions: a first holding portion that provides clearance for easy assembly, and a second holding portion that provides vibration resistance. This segmentation allows each portion to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the holder are given different characteristics: the first holding portion has a larger diameter for easy assembly, while the second holding portion has a smaller diameter for vibration resistance. This local differentiation of properties resolves the contradiction between assembly ease and vibration resistance.

Inventive Principle:

Principle #3Local quality

2Reliability

If the lead wire is held firmly to prevent vibrations, then vibration resistance is improved, but assembling workability deteriorates due to difficulty in positioning and insertion

Engineering Contradiction:

Improvevibration resistanceVSAvoidassembling workability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The holding structure is divided into two distinct portions: a first holding portion that provides clearance for easy assembly, and a second holding portion that provides vibration resistance. This segmentation allows each portion to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first holding portion is designed to facilitate preliminary positioning and insertion of the lead wire during assembly, while the second holding portion provides the firm holding for vibration resistance. The preliminary action of easy insertion is separated from the final firm holding function.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If the holder diameter is reduced to eliminate clearances and improve vibration resistance, then vibration resistance is improved, but assembling workability deteriorates due to difficulty in containing the capacitor

Engineering Contradiction:

Improvevibration resistanceVSAvoidassembling workability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The holding structure is divided into two distinct portions: a first holding portion that provides clearance for easy assembly, and a second holding portion that provides vibration resistance. This segmentation allows each portion to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The holder employs asymmetric design with different diameters at different positions: the first holding portion has a larger diameter for easy assembly, while the second holding portion has a smaller diameter for vibration resistance. This asymmetric structure resolves the contradiction between assembly ease and vibration resistance.

Inventive Principle:

Principle #4Asymmetry

Data Source

PatentUS8981239B2Capacitor module

Publication Date: 2015.03.17 PANASONIC HOLDINGS CORP

AI summary

A capacitor body is laterally contained in a lower holder, to be then pressed by an upper holder. A lead wire is led from the capacitor body in an axial direction, and then, bent toward a wiring board, thereby forming a leg soldered to the wiring board. The lower holder includes a first holding portion extending outward and having a supporter disposed in a stationary state whereas the upper holder includes a second holding portion extending outward and having a bridge stretched between a pair of elastically deformable arms. The first and second holding portions are urged toward the capacitor body, and therefore, axially hold a part of the leg of the lead wire. This configuration can prevent any breakage of a soldered portion of the lead wire due to vibrations so as to enhance vibration resistance.