Resin-Integrated Power Conversion Unit for Bus Bar Insulation
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Solution Overview
Problem
Existing power conversion units face challenges in reducing size due to the need for large distances between bus bars and metal chassis, requiring additional space for fastening, which increases the overall unit size and complexity.
Innovation Solution
The power conversion unit integrates the terminal and chassis with resin, eliminating the need for separate fastening components and allowing for a more compact design, while ensuring insulation and noise suppression through a resin-based structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal is made larger to increase distance between bus bars and metal chassis for insulation, then insulation performance is improved, but the size of the power conversion unit increases
Solution Approach 1:
The terminal and chassis are integrated into a single resin component, eliminating the need for separate fastening structures and reducing overall size while maintaining insulation performance through the inherent insulating properties of the resin material
Solution Approach 2:
The terminal and chassis are formed as an integral resin structure, utilizing the insulating properties of resin material to provide both structural support and electrical insulation, eliminating the need for additional insulation layers or spacing
2Reliability
If separate fastening components are used to connect terminal and chassis, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The terminal and chassis are merged into a single integral resin component, eliminating separate fastening parts and reducing structural complexity while maintaining connection reliability through the integrated design
Solution Approach 2:
The resin terminal-chassis integration performs multiple functions simultaneously: providing structural support, ensuring electrical insulation, and maintaining mechanical connection, thereby eliminating the need for separate fastening components
3Manufacturing precision
If multiple separate components are used for terminal and chassis assembly, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The terminal and chassis are manufactured as a single integral resin component, reducing the number of assembly steps and simplifying manufacturing processes while maintaining dimensional accuracy through molded integration
Data Source
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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.