Resin-Film Capacitor Module for Compact Power Conversion
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Solution Overview
Problem
Conventional capacitor modules for power conversion apparatuses in electric vehicles and hybrid vehicles become larger due to the use of resin seal materials for potting, leading to increased size and potential weight issues.
Innovation Solution
A capacitor module design featuring a capacitor element wrapped with an exterior coating made of a resin film having electrical insulating properties, where the connection terminals protrude through notches in the resin film, eliminating the need for a container and resin seal material, thus maintaining a compact size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin seal materials for potting are used to insulate and protect the capacitor element, then electrical insulation and protection are improved, but the overall size of the capacitor module increases
Solution Approach 1:
The exterior coating is divided into multiple joining pieces that are joined together to form the complete coating. This segmentation allows the coating to conform to the capacitor element's shape while maintaining compact dimensions, eliminating the need for excessive seal material and reducing overall module size while preserving insulation effectiveness.
Solution Approach 2:
The patent uses a resin film-based exterior coating instead of bulky potting compounds. The thin film structure provides necessary electrical insulation and protection without adding significant volume, directly addressing the contradiction between insulation reliability and module size.
2Reliability
If connection terminals are insulated with resin seal material, then electrical insulation is improved, but the structure becomes more complex and manufacturing more difficult
Solution Approach 1:
The exterior coating serves multiple functions simultaneously: it provides electrical insulation for the capacitor element, protects against moisture and contaminants, and facilitates terminal connection through integrated protrusion openings. This multi-functionality reduces structural complexity compared to separate insulation and protection components.
Solution Approach 2:
Protrusion openings are formed in advance during the coating formation process, before final assembly. This preliminary action simplifies manufacturing by eliminating subsequent drilling or cutting operations, reducing both device complexity and manufacturing difficulty while maintaining insulation integrity.
3Ease of manufacture
If protrusion openings are formed by notches in the joining pieces, then terminal connection is simplified, but manufacturing precision requirements increase
Solution Approach 1:
By dividing the exterior coating into multiple joining pieces with notches, the formation of protrusion openings is simplified. Each joining piece can be manufactured with standard precision, and the notches align during assembly, reducing overall manufacturing precision requirements compared to forming openings in a single monolithic piece.
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 results in a smaller capacitor module with improved electrical insulation and moisture resistance, reducing the overall size and weight while simplifying the exterior structure and fixing mechanisms, thereby enhancing the power conversion apparatus's efficiency and cost-effectiveness.
Implementation Method 1
an exterior coating that includes a resin film having electrical insulating property and wraps the capacitor element except the plurality of connection terminals
Implementation Method 2
improved electrical insulation and moisture resistance
Data Source
AI summary
A capacitor module includes a capacitor element, a plurality of connection terminals for electrically connecting the capacitor element to a semiconductor module and a power supply that are another equipment, and an exterior coating that includes a resin film having electrical insulating property and wraps the capacitor element except the plurality of connection terminals.