Parallel Capacitor Current Collector Layout to Cut Copper Waste
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Solution Overview
Problem
Conventional capacitor structures integrating multiple capacitors are complex, costly, and inefficient in material usage due to the need for a single, large copper plate that meets the current-carrying requirements of all capacitors, leading to material waste.
Innovation Solution
A capacitor structure with a parallel cell combination using separate current collectors, where each collector's current-carrying area is tailored to its specific location, reducing material waste and cost by optimizing current-carrying specifications based on the current magnitude at each point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a whole confluence copper plate is used to connect all capacitors, then the current-carrying capacity requirement is met, but the material usage is excessive and cost increases
Solution Approach 1:
The patent divides the confluence copper plate into multiple separate copper busbars, each connecting to specific capacitors based on their current-carrying requirements. This segmentation allows each busbar to be sized appropriately for its specific function rather than using a single oversized plate for all connections.
Solution Approach 2:
The patent applies different current-carrying capacities to different regions of the capacitor assembly by assigning capacitors to different busbars based on their individual requirements. This creates a local optimization where each busbar has the precise current-carrying capacity needed for its specific group of capacitors.
2Ease of manufacture
If a whole confluence copper plate is used, then connection simplicity is maintained, but structural complexity increases and processing difficulty arises
Solution Approach 1:
The confluence copper plate is segmented into multiple independent busbars, each with its own mounting holes and connection points. This segmentation simplifies the manufacturing process by allowing each busbar to be processed and mounted independently, rather than requiring complex processing of a single large plate.
3Reliability
If a whole confluence copper plate is used, then all capacitors are connected, but the processing difficulty and cost increase
Solution Approach 1:
By dividing the connection system into multiple smaller busbars, each with fewer connection points, the manufacturing process becomes simpler and more manageable. Each busbar can be processed, drilled, and mounted independently, reducing the overall processing difficulty compared to a single large plate.
Solution Approach 2:
Each busbar is designed with the specific current-carrying capacity and connection configuration needed for its assigned capacitors, allowing for optimized local processing rather than requiring a single complex plate design that must accommodate all variations.
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 solution effectively reduces material waste and cost while meeting high-capacity requirements by using individual current collectors with tailored specifications, optimizing conductor usage in capacitor structures.
Implementation Method 1
same poles of each two adjacent cells of the plurality of cells are connected through a corresponding current collector, and a current-carrying area of each of the plurality of current collectors configured to be determined based on a magnitude of a current at a location of said collector
Data Source
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AI summary
A capacitor structure and a power converter are provided. The capacitor structure includes a parallel cell combination, and the parallel cell combination includes a plurality of cells and a plurality of current collectors. In the parallel cell combination: the cells are connected in parallel, and the poles connected in parallel are respectively connected with other devices through corresponding confluence points. Same poles of two adjacent cells are connected through a corresponding current collector, and the current-carrying specifications of each current collector is lower than the current-carrying requirements of a confluence point of a corresponding pole. That is to say, a conductor that implements the parallel connection of the cells is no longer a whole copper plate, but the individual current collectors, thus realizing the reduction of the cost of the conductor material.