Segmented Cylindrical Capacitor Housing for Weight Reduction

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional capacitor devices with attached capacitors face issues of bulkiness, high weight, poor heat dissipation, and reduced strength due to multiple holes in metal blocks and the need for openings in holders for thermal contracting resin tubes.

Innovation Solution

A capacitor device design where multiple capacitor units are integrated within a housing case with cylindrical sections aligned in the same direction, filled with a resin material for enhanced heat dissipation and structural integrity, and manufactured through extrusion molding for cost-effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If multiple holes are created in a metal block to insert capacitors, then capacitors can be mounted, but the device becomes bulky and heavy with poor heat dissipation

Engineering Contradiction:

Improvecapacitor mountingVSAvoiddevice weight

Core Design Contradiction:

Ease of manufactureVSWeight of stationary object

Solution Approach 1:

The housing case is divided into multiple cylindrical housing sections that are longitudinally aligned and joined together, each section accommodating a capacitor unit. This segmented structure replaces the conventional solid metal block with holes, reducing weight while maintaining manufacturing ease and capacitor mounting capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The housing case uses a composite structure combining multiple cylindrical sections joined together, creating a lightweight yet strong housing that improves heat dissipation compared to solid metal blocks, while maintaining ease of capacitor mounting

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If an opening is created in the holder for pulling out resin tube, then capacitor can be attached, but the holder strength is reduced

Engineering Contradiction:

Improvecapacitor attachmentVSAvoidholder strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The resin tube insertion process is extracted and performed from the end of the cylindrical housing sections rather than requiring openings in the holder. This eliminates the need for strength-reducing openings while maintaining ease of capacitor attachment

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of pulling the resin tube through openings in the holder, the invention inverts the approach by inserting the resin tube from the end of the cylindrical housing sections, maintaining holder strength while achieving capacitor attachment

Inventive Principle:

Principle #13The other way round (Inversion)

3Weight of stationary object

If housing sections are made thinner to reduce weight, then device becomes lighter, but strength and heat dissipation surface area are reduced

Engineering Contradiction:

Improvehousing case weightVSAvoidhousing case strength

Core Design Contradiction:

Weight of stationary objectVSStrength

Solution Approach 1:

The housing case uses cylindrical housing sections with curved surfaces instead of flat plates. This curvature provides structural strength comparable to thicker flat materials while reducing overall weight and increasing external surface area for heat dissipation

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Weight of stationary object

If housing sections are made thinner to reduce weight, then device becomes lighter, but heat dissipation surface area is reduced

Engineering Contradiction:

Improvehousing case weightVSAvoidheat dissipation surface area

Core Design Contradiction:

Weight of stationary objectVSArea of stationary object

Solution Approach 1:

The cylindrical shape of the housing sections provides a larger external surface area compared to equivalent-volume flat structures, enabling effective heat dissipation even with thin-walled construction, thus reducing weight while maintaining heat dissipation capability

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 design results in a slimmer, lighter, and more robust capacitor device with improved heat dissipation properties and reduced manufacturing costs, while maintaining the structural integrity and securing the capacitor units firmly within the housing case.

Implementation Method 1

the gap is filled in with a resin material... the heat dissipation properties can be improved

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9484154B2Capacitor device and method for manufacturing same

Publication Date: 2016.11.01 NIPPON CHEMI CON CORP

AI summary

An object of the invention is to provide a capacitor device that can be made slimmer and lighter and that enables the strength and heat dissipation properties to be improved. A capacitor device (1) has a plurality of capacitor units (2) integrally housed within a housing case (3), the housing case (3) having cylindrical housing sections (5) for housing the capacitor bodies. The housing sections (5) are longitudinally aligned in the same direction and are joined together as an integrated whole. A capacitor unit (2) is inserted via an opening (9) at one end of each of the housing sections (5) so that the entire circumference of the capacitor unit (2) is covered by the corresponding housing section (5). The housing sections (5) have a uniform thickness at least on the outer side along the outer periphery of the capacitor units.