Capacitor Module Sensor Layout for Compact Abnormality Detection
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Solution Overview
Problem
Existing capacitor modules face challenges in downsizing due to the size requirements of temperature sensors used for detecting overheating or overcurrent, which increases the overall module size.
Innovation Solution
A capacitor module design that incorporates a sensor detector arranged in the dead space between curved portions of capacitors, allowing for compact placement without affecting the module's design, utilizing bus bars with positioning protrusions to securely position the sensor elongated portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a temperature sensor is arranged in the case to detect overheat state, then abnormality detection capability is improved, but the module size increases
Solution Approach 1:
The sensor is relocated from the case (external dimension) to the internal space between capacitor curved portions (internal dimension), changing the spatial arrangement from case-mounted to inter-component placement. This dimensional shift enables abnormality detection without increasing overall module volume.
Solution Approach 2:
The sensor is nested within the existing module structure by placing it in the dead space between capacitor curved portions. This nesting approach allows the sensor to be accommodated within the existing footprint without requiring additional external space, effectively hiding the sensing function within the module's internal geometry.
2Reliability
If a sensor is placed in the case, then abnormality detection is achieved, but the device complexity increases due to additional positioning components
Solution Approach 1:
The capacitor curved portions themselves provide the positioning function for the sensor. The natural geometry of the curved portions creates a self-positioning mechanism where the sensor is held in place by the physical constraints of the capacitor arrangement, eliminating the need for separate positioning components or fixtures.
Solution Approach 2:
The positioning function is extracted from dedicated positioning components and integrated into the capacitor structure itself. The curved portions serve dual purposes: maintaining capacitor integrity and providing sensor positioning, thereby removing the need for separate positioning elements.
3Ease of manufacture
If dead space is utilized for sensor placement, then manufacturing cost is reduced by eliminating positioning components, but sensor positioning precision may be affected
Solution Approach 1:
The asymmetric arrangement of the sensor between the curved portions creates a unique positioning geometry. The sensor is placed in a specific asymmetric location where the curved portions naturally constrain its position, ensuring precise and repeatable placement during manufacturing without requiring additional positioning features.
Data Source
AI summary
A capacitor module that includes: a first capacitor; a second capacitor; a first bus bar having a support surface supporting the first capacitor and the second capacitor such that a first side surface of the first capacitor and a second side surface of the second capacitor face each other in a first direction along the support surface and define a space separating a curved portion of the first side surface and a curved portion of the second side surface in the first direction, the first bus bar electrically connected to a first electrode of the first capacitor and a third electrode of the second capacitor; a second bus bar electrically connected to a second electrode of the first capacitor and a fourth electrode of the second capacitor; and a sensor including a detector arranged in the space.