Nested Capacitor Collars for Dense, Vibration-Resilient Mounting
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Solution Overview
Problem
Traditional capacitor clamps require a significant footprint area for installation, leading to inefficient packaging and increased strain on high-voltage capacitors due to rigid connections, which are prone to shock and vibration, and often necessitate insulation sleeves that limit mounting options.
Innovation Solution
A mounting system using complementary mounting collars with nested riser and base collar portions, featuring elastomeric O-rings for radial retention, allowing vertical installation and minimizing spacing between capacitors, and providing a resilient interface to absorb shock and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional radial fastener clamps are used to secure capacitors, then the capacitor is firmly mounted to the support structure, but the clamp requires a large footprint area that increases the envelope size of the electronics assembly
Solution Approach 1:
The mounting collar is designed with a nested structure comprising an outer collar portion and an inner collar portion that fit concentrically within each other. The inner collar portion has an inner diameter smaller than the outer collar portion's inner diameter, creating a nested configuration that reduces the overall footprint area while maintaining secure mounting capability through the combined structure of both collar portions
Solution Approach 2:
The invention transitions from a two-dimensional radial mounting approach to a three-dimensional nested cylindrical configuration. By utilizing the vertical dimension with the nested collar portions extending axially, the design achieves secure mounting without increasing the horizontal footprint area, effectively moving the mounting function into the vertical dimension
2Reliability
If traditional radial fastener clamps are used, then the capacitor is securely mounted, but the rigid-to-rigid interface connection transfers shock and vibration loads directly to the capacitor's electrical connection point
Solution Approach 1:
The mounting collar is designed with a resilient material that changes the mechanical properties of the mounting interface from rigid to compliant. This parameter change in material rigidity allows the collar to absorb and attenuate shock and vibration loads, preventing direct transmission to the capacitor's electrical connection point while maintaining secure mounting
Solution Approach 2:
The resilient mounting collar acts as an intermediary element between the support structure and the capacitor. This intermediate component absorbs and dissipates shock and vibration energy, serving as a buffer that protects the capacitor's electrical connection point from direct exposure to harmful mechanical loads
3Area of stationary object
If high-voltage capacitors are tightly packaged together to maximize density, then the envelope size is reduced, but the capacitors become more prone to strain from shock and vibration due to their larger mass
Solution Approach 1:
The resilient material of the mounting collar changes the dynamic response characteristics of the capacitor mounting system. By introducing compliance into the mounting interface, the collar reduces the transmission of shock and vibration loads to the capacitor, enabling high-voltage capacitors to be tightly packaged without increasing their susceptibility to mechanical strain
4Reliability
If insulation sleeves are added to high-voltage capacitors for safety, then electrical insulation is improved, but mounting options are limited because the insulation sleeve cannot be removed or tampered with
Solution Approach 1:
The mounting collar serves as an intermediary mounting mechanism that interfaces with the capacitor through its body rather than requiring removal or modification of the insulation sleeve. This intermediate approach allows the insulation sleeve to remain intact for electrical safety while the collar provides secure mechanical mounting through its resilient grip on the capacitor body
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
The system achieves denser capacitor packaging, reduces strain on electrical connections, and effectively attenuates shock and vibration, while accommodating insulation sleeves without modification.
Implementation Method 1
a radial retention component (e.g., elastomeric O-ring) supported about an inner surface of the collar body operable to apply a radial compression force to the capacitor
Implementation Method 2
the mounting collar... providing a resilient interface to absorb shock and vibration
Implementation Method 3
these high-voltage capacitors are desired to be as tightly packaged together as possible... that reduce or eliminate strain on the electrical connection interface between the capacitors and a circuit board
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
A mounting collar comprises a collar body comprising an opening for receiving at least a portion of an electronics component of an electronics assembly, and a radial retention component supported about an inner surface of the opening of the collar body. The radial retention component is operable to apply a radial force on the electronics component to at least partially support the electronics component. A mounting system comprises a first mounting collar for mounting a first electronics component to a support structure, and a second mounting collar for mounting a second electronics component to the support structure. The first and second mounting collars can be nested together to minimize a distance between the first and second electronics components. The first and second mounting collars can each comprise an elastomeric O-ring to reduce strain between the electronics components and the circuit board. Associated systems and methods are provided.