Folded Insulating Film for High-Voltage Electrical Devices
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Solution Overview
Problem
Existing electrical insulation systems in high-voltage electrical equipment, such as inverters and DC-DC converters for electric and hybrid vehicles, face durability issues due to the limited lifespan of adhesive materials used for insulation, leading to potential short circuits over time.
Innovation Solution
An electrical device with a folded insulating film that provides insulation between conductors and the housing, where one part of the film is secured by protrusions within a cavity filled with a polymerizable material, eliminating the need for adhesive materials and ensuring long-term insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive material is used to fix insulating films between conductors and housing, then the insulating films can be securely positioned, but the adhesive material deteriorates over time leading to short circuits
Solution Approach 1:
The invention removes the adhesive material from the insulation system entirely. The insulating films are fixed mechanically through folding and positioning within the housing cavity, eliminating the chemical bonding agent that deteriorates over time. This extraction of the harmful element (adhesive) resolves the contradiction by providing a durable mechanical alternative.
Solution Approach 2:
The insulating film structure is designed to be self-fixing through its folded configuration. The film's own geometry and positioning within the cavity provide the fixation mechanism, without requiring external adhesive materials. The system uses its own structural properties to achieve the fixation function.
2Reliability
If separate insulating films are used between conductors and housing, then insulation is provided, but the system becomes complex requiring multiple components
Solution Approach 1:
The invention combines multiple insulation functions into a single integrated insulating film structure. One continuous film provides insulation between conductors and housing, between conductors themselves, and maintains spatial separation. This merging reduces the number of separate components while maintaining comprehensive insulation coverage.
Solution Approach 2:
The single insulating film performs multiple insulation functions simultaneously: isolating conductors from housing, isolating conductors from each other, and maintaining structural organization. This multi-functional approach eliminates the need for separate dedicated insulating components for each function.
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 solution provides durable and reliable electrical insulation, preventing short circuits and ensuring the longevity of electrical equipment by using a self-retaining insulating film that maintains its shape without relying on adhesive materials, thus enhancing the operational stability of high-voltage electrical components.
Implementation Method 1
a cavity (11) of the casing (10) filled with a polymerizable material
Data Source
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AI summary
The invention relates to an electrical device comprising: a housing (10) including a cavity (11) receiving an electrical component, and at least two conductors connected to the electrical component so as to supply it with electrical energy, the two conductors being superimposed and extending parallel to each other, said device being characterized in that it comprises an electrical insulating film folded over itself around a fold (P), and of which a first part (F1) located on one side of the fold (P) comes against a surface of a first conductor so as to electrically insulate it, and a second part (F2) located on the other side of the fold (P) is inserted between the two conductors so as to electrically insulate them from each other.