Rotational Wire Holder with Arc Recesses for Snubber Circuit Bundling
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Solution Overview
Problem
The existing methods for bundling snubber circuit wires in power converters require a large number of process steps, including wrapping glass tape around each wire, which compromises operation efficiency and can damage the wire coatings, leading to insufficient insulating strength for high-voltage applications.
Innovation Solution
A wire holder with rotationally symmetric wall portions and arc-shaped recesses that align and securely hold wires, allowing for a band-shaped bundling device to be wound around the holder instead of individual wires, reducing the number of process steps and minimizing wire damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass tape is wound around each wire for protection, then insulating strength is maintained, but the number of process steps increases and operation efficiency decreases
Solution Approach 1:
The patent merges the protection function from individual wire wrapping into a collective bundling structure. The bundling band simultaneously secures multiple wires while the holder structure provides unified protection, eliminating the need for separate glass tape wrapping around each individual wire.
Solution Approach 2:
The bundling band and holder structure serve multiple functions simultaneously: they provide mechanical support, electrical insulation, and structural organization for multiple wires in a single component system, replacing the need for separate protection steps for each wire.
2Reliability
If glass tape is wound around each wire, then wire protection is achieved, but the complexity of the bundling process increases
Solution Approach 1:
The patent combines multiple protection and organization functions into a single bundling operation. The holder with its recesses and the bundling band work together as an integrated system that protects and organizes multiple wires simultaneously, reducing the process from multiple individual wire treatments to a single collective operation.
3Reliability
If wires are bundled tightly to reduce inductance, then surge voltage is suppressed, but wire coatings may be damaged
Solution Approach 1:
The holder structure with pre-formed recesses is prepared in advance to receive and properly position the wires. The recesses are designed with dimensions that accommodate the wire coatings, ensuring proper spacing and alignment before bundling, which prevents excessive compression that could damage the coatings while still achieving tight enough bundling for low inductance.
4Reliability
If multiple process steps are used for wire bundling, then wire protection is ensured, but manufacturing time increases
Solution Approach 1:
The patent combines protection, alignment, and bundling functions into a single integrated process step. The holder structure provides pre-positioned recesses that automatically align multiple wires, and the bundling band secures them simultaneously, eliminating the need for separate protection steps for each wire and significantly reducing total manufacturing time.
Data Source
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AI summary
A wire holder (1) is provided which allows for reduced number of process steps required in bundling wires. The wire holder (1) is for relative alignment of a plurality of wires upon bundling the wires, and includes a plurality of wall portions (11, 21, 31) formed rotationally symmetric to one another, provided to project in a direction orthogonal to an axis O serving as a rotation symmetry axis, and extending along the axis O. Between opposite ones of the wall portions (11, 21, 31), recesses (41, 51, 61) each having an arc shape in cross section are formed to hold the wires. Each of the recesses (41, 51, 61) has a span length of not less than 85% of the diameter of each of the wires. By fitting the wires into the recesses (41, 51, 61) and arranging them along the rotation symmetry axis, the wires can be aligned.