Resin-Integrated Power Converter Terminal for Bus Bar Insulation
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Solution Overview
Problem
Existing power conversion units require increased size to ensure insulation between bus bars and metal chassis, necessitating additional space for fastening, which complicates the design and increases the unit's dimensions.
Innovation Solution
The power conversion unit integrates the terminal and chassis components, including a resin-formed bottom portion and metal box portion, allowing for reduced size by eliminating the need for a flange and simplifying the configuration, while maintaining sufficient insulation and noise suppression through a shield and insulating members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal is increased in size to ensure insulation between bus bars and metal chassis, then insulation reliability is improved, but the size of the power conversion unit increases
Solution Approach 1:
The patent merges the terminal and chassis into a single integrally formed resin component. This integration eliminates the need for separate insulation measures between the terminal and metal chassis, as the resin material inherently provides insulation. The merging reduces the overall number of components and simplifies the structure while maintaining insulation reliability, thereby preventing the increase in unit size that would result from enlarging the terminal.
Solution Approach 2:
The patent employs composite material construction by integrating resin (insulating material) with metal chassis components. The terminal and chassis are formed as one piece using resin material, which combines the structural properties of metal with the insulating properties of resin. This composite approach ensures insulation between bus bars and the metal chassis without requiring additional insulation components or increased terminal dimensions.
2Reliability
If a flange and fastening space are added to connect the terminal and metal chassis, then connection reliability is improved, but the device complexity and size increase
Solution Approach 1:
The patent applies the merging principle by integrating the terminal and chassis into a single component. The flange and fastening structures that would normally be separate parts are incorporated into the integral resin formation. This eliminates the need for separate fastening operations and reduces structural complexity while maintaining connection reliability through the inherent structural integrity of the integrally formed component.
Solution Approach 2:
The patent changes the material parameter from metal to resin for the terminal-chassis integration. This material parameter change enables the terminal and chassis to be formed as one piece without requiring mechanical fastening. The resin material's properties allow for integral formation that inherently provides both connection and insulation functions, thereby reducing device complexity while maintaining connection reliability.
Data Source
AI summary
A power conversion unit is provided with a power conversion module performing conversion between direct current power and alternating current power, a first bus bar connected to the power conversion module and inputting and outputting the power, a chassis housing the power conversion module, and a terminal connecting the first bus bar and a second bus bar connected to an external device. The terminal and at least a part of the chassis are integrally formed of a resin.