Inverter Housing Layout Without Separate Insulating Members
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Solution Overview
Problem
Existing electric power converters require additional insulating members to ensure insulation between conductor portions and housing, increasing manufacturing costs and device size.
Innovation Solution
The electric power converter design incorporates a housing with a base portion made of insulating resin material, where conductor portions are placed in contact with or near the base portion, eliminating the need for separate insulating members and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate insulating member is placed between the conductor portion and the housing, then the insulation property is ensured, but the number of constituent parts and manufacturing cost increase
Solution Approach 1:
The insulating function is merged into the housing base portion itself by making it from an insulating resin material. The base portion simultaneously serves as the housing structure and the insulating barrier, eliminating the need for separate insulating members while ensuring insulation between the conductor portion and housing.
Solution Approach 2:
The housing base portion performs multiple functions: it provides the structural housing framework, serves as the insulating barrier between conductor and housing, and supports the mounting of electrical components. This multi-functionality reduces the total number of parts needed in the system.
2Reliability
If an insulating member is placed between the conductor portion and the housing, then the insulation property is ensured, but the device size increases
Solution Approach 1:
The insulating function is integrated into the housing base portion itself rather than adding a separate insulating layer. This eliminates additional space requirements for separate insulating members while maintaining the necessary insulation distance between the conductor portion and housing.
3Device complexity
If the housing base portion is made of an insulating resin material, then separate insulating members are eliminated, but the housing material options are limited
Solution Approach 1:
The housing base portion uses insulating resin materials that can be combined with metal components (such as metal plates or metal-cored resins) to achieve both electrical insulation and mechanical strength. This composite approach provides material versatility while maintaining the insulating function integrated into the housing structure.
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 design reduces manufacturing costs and saves space while maintaining insulation properties between conductor portions and the housing, enhancing cooling efficiency and performance.
Implementation Method 1
the base portion is made of a resin material... ensuring an insulation property between the conductor portion and the housing
Data Source
AI summary
Provided is an electric power converter that includes an inverter which includes plural electric parts, a smoothing capacitor configured to smooth electric power, a housing configured to house the inverter and the smoothing capacitor and a first conductor portion configured to connect the smoothing capacitor and the inverter. The housing includes a base portion made of a resin material and a cover portion attached to the base portion to cover the inverter and the smoothing capacitor. The inverter and the smoothing capacitor are mounted on the base portion. The first conductor portion is placed in the vicinity of or in contact with the base portion of the housing in the middle of connection between the smoothing capacitor and the inverter.