Capacitor Stack Insulation Using Shaped Films With Flaps
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Solution Overview
Problem
Existing methods for insulating capacitors in implantable medical devices, such as defibrillators, are labor-intensive and prone to errors, leading to potential short circuits and production losses due to manual application of insulation strips.
Innovation Solution
The use of shaped insulating films with flaps that conform to the capacitor's profile, overlapping to cover edges and gaps, ensuring reliable electrical isolation without excess material or improper installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual application of insulation strips is used, then installation flexibility is maintained, but labor intensity increases and errors occur leading to short circuits
Solution Approach 1:
The insulating film is divided into multiple segments including a body portion and multiple flaps. The flaps are further segmented to cover different portions of the capacitor edges. This segmentation allows each flap to be precisely positioned to cover specific areas, ensuring complete insulation coverage while simplifying the application process and reducing errors.
Solution Approach 2:
The insulating film is pre-formed with flaps that are already positioned and shaped to conform to the capacitor profile before application. This preliminary configuration eliminates the need for manual folding and positioning during installation, reducing labor intensity and preventing installation errors that could lead to short circuits.
2Adaptability or versatility
If manual insulation application is used, then adaptability to different capacitor sizes is possible, but installation errors and short circuits increase
Solution Approach 1:
The insulating film features flaps with different dimensions and configurations tailored to cover specific portions of the capacitor edges. Each flap is designed with local quality variations to match the specific geometry requirements of different capacitor profiles, ensuring precise coverage and insulation while maintaining adaptability to various capacitor sizes.
3Reliability
If overlapping flaps are used, then complete edge coverage is achieved, but material consumption increases
Solution Approach 1:
The flaps are designed to overlap partially over the capacitor edges, providing excessive coverage in critical areas where insulation reliability is most important. This partial overlapping ensures complete edge coverage and prevents short circuits, while the overlap is controlled to minimize unnecessary material consumption.
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 method provides efficient and reliable electrical insulation of capacitors, preventing short circuits and reducing production losses by ensuring accurate coverage and alignment of insulating films.
Implementation Method 1
The first insulating film may be bonded to the stacked capacitor with an adhesive. The second insulating film may be bonded to the capacitor and to overlapped portions of the first insulating film with an adhesive.
Data Source
AI summary
A medical device capacitor assembly can include a capacitor including a plurality of anodes and cathodes, wherein the capacitor has a first major face, a second major face opposite the first major face, and a third face extending between the first major face and the second major face. A first insulating film can be sized and shaped to assemble against the first major face, and can include a first set of flaps sized and shaped to cover at least a portion of the third face. A second insulating film sized and shaped to assemble against the second major face, and can include a second set of flaps sized and shaped to cover at least a portion of the third face.