Case-Mold Capacitor Bus Bar Dimensional Accuracy

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Solution Overview

Problem

Conventional case-mold-type capacitors face challenges in achieving high dimensional accuracy between bus bars, leading to errors in positioning and increased material costs due to the need for precise alignment and removal of common connection portions.

Innovation Solution

The introduction of a sealing plate that fixes bus bars to the case, allowing them to pass through and be securely attached, eliminating the need for precise alignment and reducing material waste by integrating the sealing plate as part of the case's structure, thereby enhancing dimensional accuracy and reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If bus bars are attached independently to the metallized film capacitor element, then the capacitor can be assembled, but dimensional accuracy between terminal portions deteriorates due to positioning errors

Engineering Contradiction:

Improvedimensional accuracy between bus barsVSAvoidalignment complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges multiple bus bars into a single integrated bus bar structure with a common connection portion. This unified structure is attached to the capacitor element as one piece, eliminating the need for separate alignment operations between multiple bus bars and thereby improving dimensional accuracy between terminal portions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The common connection portion is designed and formed as part of the bus bar structure before attachment to the capacitor element. This preliminary integration ensures that the relative positions of terminal portions are predetermined and maintained during the attachment process, preventing positioning errors.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If a common connection portion is added to integrate bus bars, then dimensional accuracy improves, but material costs increase and additional components are required

Engineering Contradiction:

Improvedimensional accuracy between bus barsVSAvoidmaterial cost

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The common connection portion is formed as an integral part of the bus bar itself, merging the function of multiple bus bars into a single component. This eliminates the need for separate common connection portions or additional fastening components, thereby controlling material costs while achieving improved dimensional accuracy.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If bus bars are disposed with high dimensional accuracy, then connection precision improves, but the manufacturing process becomes more difficult and time-consuming

Engineering Contradiction:

Improvepositioning accuracy of bus barsVSAvoidmanufacturing process simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The common connection portion is pre-formed as part of the bus bar structure before attachment to the capacitor element. This preliminary integration establishes the precise relative positions of terminal portions in advance, simplifying the attachment process and reducing the time and difficulty of achieving high positioning accuracy.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10079098B2Case-mold-type capacitor and method for producing same

Publication Date: 2018.09.18 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

A case-mold-type capacitor includes a capacitor element, first and second bus bars connected to the first and second electrodes of the capacitor element, a case accommodating the capacitor element and the first and second bus bars, and a mold resin filling the case therein. The case has a cutaway portion provided therein. A sealing plate joined to the case so as to seal the cutaway portion. The first and second bus bars pass through the sealing plate and are fixed to the sealing plate. The case-mold-type capacitor improves dimensional accuracy between terminal portions of the first and second bus bars without increasing material cost, and has high reliability.