Integrated power transfer unit
Through the integrated power transmission unit design, the uniform distribution of the current path and the reduction of inductance are achieved, which solves the problems of capacitor overheating and uneven current caused by ripple current in conventional PTUs, and extends the service life of the capacitor unit.
Patent Information
- Application Number
- CN202422394808.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-29
- Publication Date
- 2025-07-25
- Estimated Expiration
- 2034-09-29
AI Technical Summary
There is a risk of overheating and damage caused by ripple current in conventional PTUs, and uneven current distribution leads to hot spot temperature rise and concentrated loss.
The integrated power transmission unit design is adopted, and the capacitor terminals and power modules form a mirror symmetrical arrangement, the external bus bars are superimposed and electrically insulated, and the internal bus bar bridge is electrically coupled with the capacitor terminal to ensure that the current path is equal in length and uniformly distributed.
It reduces the inductance, absorbs ripple current evenly, extends the life of the capacitor unit, and solves the problems of heat concentration and loss concentration.
Smart Images
Figure CN223156966U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to a power transfer unit (PTU), in particular to an integrated power transfer unit. Background Art
[0002] The PTU used in a conventional circuit inevitably generates a ripple current. The existence of the ripple current will have a significant negative impact on the stability and reliability of electronic devices and circuits. If the ripple current is too large, it may dissipate on the capacitor, resulting in the risks of overheating, damage or even burnout of the capacitor.
[0003] The commonly used PTU usually includes a capacitor unit for absorbing the ripple current and a power module (PM) unit for supplying power to it. The two are electrically connected through an input bus bar and an output bus bar made of a metal with good electrical conductivity such as copper or aluminum.
[0004] In the commonly used PTU products, the inductance of the capacitor unit is usually large, thus hindering the ripple current flowing into the capacitor unit, and then affecting the elimination of the ripple current. In addition, the loss degrees of the cores in the capacitor unit of the commonly used PTU products are unevenly distributed, so there is a phenomenon of local loss concentration, resulting in an increase in the temperature rise of the hot spots inside the cores. This is a major problem that those in the industry are currently working hard to solve. Summary of the Utility Model
[0005] In order to correct and overcome at least one of the above-mentioned drawbacks / problems, the utility model provides an integrated power transfer unit. The integrated power transfer unit includes: a capacitor unit provided with at least two capacitor terminals arranged in a plane to form a capacitor terminal plane, and the at least two capacitor terminals are respectively configured to be electrically connected to the cores of the capacitor unit; a power module unit including an even number of power modules, each of the even number of power modules is configured to be electrically connected to the capacitor unit to supply power to it, and the even number of power modules includes a first module group and a second module group respectively arranged on a first side and an opposite second side of the capacitor terminal plane. Wherein, the shortest current paths from the respective electrical interfaces in the first module group and the second module group in the power module unit to the corresponding one of the at least two capacitor terminals are of equal length.
[0006] According to an embodiment of the utility model, the first module group and the second module group are configured to be arranged symmetrically about the capacitor terminal plane in a mirror image manner.
[0007] According to another embodiment of the present utility model, the integrated power transmission unit includes an external input bus bar (131) and an external output bus bar (132) respectively connected to the capacitor unit, and the external input bus bar and the external output bus bar are stacked on top of each other and electrically insulated from each other, and are each mirror-symmetrical about their own center lines. Wherein, the external input bus bar and the external output bus bar are configured such that their respective center lines are both located within the capacitor terminal plane.
[0008] According to yet another embodiment of the present utility model, each of the even number of power modules is coplanarly arranged; and / or the external input bus bar and the external output bus bar are stacked on top of each other below the power module unit.
[0009] Further, the first module group is electrically connected to the external input bus bar and the external output bus bar respectively on the first side through a plurality of conductive elements, and the second module group is electrically connected to the external input bus bar and the external output bus bar respectively on the second side through a plurality of conductive elements.
[0010] Even further, the current path includes an input current path and an output current path, wherein the input current path and the output current path between each power module and a corresponding one of the capacitor terminals are equal to each other.
[0011] Even further, the capacitor unit includes an internal input bus bar and an internal output bus bar respectively electrically connected to the core. Each of the internal input bus bar and the internal output bus bar includes: a first extension portion and a second extension portion separated from each other, wherein the first extension portion and the second extension portion are coplanarly arranged and each is in electrical contact with a corresponding core in the core, and a bridging portion configured to connect the first extension portion and the second extension portion and form a recess with respect to the extension plane where the first extension portion and the second extension portion are located. The recess is configured to receive and be electrically coupled to the capacitor terminals of the capacitor unit.
[0012] Even further, the bridging portion is in the form of a plurality of discrete strips arranged in parallel along the same extension direction as the extension directions of the first extension portion and the second extension portion.
[0013] In addition, the discrete strips of the bridging portion of the internal input bus bar and the discrete strips of the bridging portion of the internal output bus bar are arranged parallel to each other and staggered perpendicular to the capacitor terminal plane. The sum of the height of the bridging portion of the internal output bus bar and the thickness of the core of the capacitor unit is not equal to the height of the bridging portion of the internal input bus bar.
[0014] Furthermore, each of the internal input busbars and the internal output busbars is mirror-symmetrical about its respective center line.
[0015] Alternatively, for each of the internal input busbars and the internal output busbars, the width of the first extension and the width of the second extension are unequal; and / or the width of the first extension and the width of the second extension are each non-constant along the direction away from the bridging portion; and / or the width of the bridging portion is greater than the width of the first extension and / or the width of the second extension.
[0016] According to yet another embodiment of the present invention, the capacitor terminal plane extends parallel to the long axis direction or the short axis direction of the core of the capacitor unit; and / or each of the first module group and the second module group includes at least one of the even number of power modules.
[0017] According to still another embodiment of the present invention, the integrated power transmission unit includes a housing that encapsulates the capacitor unit and the power module unit therein.
[0018] By using the integrated PTU of the present invention, it is possible to make the current paths from the capacitor terminals of the capacitor unit inside the PTU to the electrical interfaces of the PM unit substantially of equal length and the shortest, so that the current from the PM unit can uniformly enter each core of the capacitor unit through the capacitor terminals, thereby reducing the inductance, solving the problems of heat concentration and loss concentration of the cores, thus prolonging the service life of the capacitor unit and achieving uniform absorption of the ripple current. Description of the Drawings
[0019] In the drawings, the same or similar reference numerals are used to refer to the same or similar components. The drawings are given only by way of example and are not intended to limit the scope of the present invention. In the drawings:
[0020] Figure 1 is a bottom perspective view of a prior art PTU.
[0021] Figure 2 is Figure 1 the bottom view of the PTU shown in
[0022] Figure 3 is Figure 1 the bottom partial exploded view of the PTU shown in
[0023] Figure 4 is a bottom perspective view of a PUT according to an embodiment of the present invention.
[0024] Figure 5 is Figure 4The bottom view of the PTU shown.
[0025] Figure 6 is Figure 4 the bottom exploded view of the PTU shown in
[0026] Figure 7 is Figure 4 the bottom exploded perspective view of the internal input bus bar and internal output bus bar of a capacitor bank used in the PTU shown in
[0027] Figure 8 is Figure 7 another enlarged bottom perspective view of the internal output bus bar shown in
[0028] Figure 9 the bottom view of the PTU according to another embodiment of the present utility model. Detailed implementation mode
[0029] The principle and specific structure of the present utility model will be described below in conjunction with the accompanying drawings.
[0030] Figures 1 - 3 are respectively the bottom perspective view, bottom view and bottom exploded view of the integrated PTU of the prior art. As Figure 3 shown, the PTU 80 of the prior art includes a housing 81, a capacitor unit 82 and a power module (PM) unit 83. The capacitor unit 82 is disposed within the housing 81, and the PM unit 83 is provided on a side of the capacitor unit 82 opposite to the housing 81 and electrically connected thereto so as to supply power to the capacitor unit 82. The PM unit 83 includes a plurality of PMs 830, and each of these PMs 830 is respectively connected to an external input bus bar 831 (located outside the capacitor unit 82) through a plurality of conductive elements (such as copper or aluminum tabs) 8301. The external input bus bar 831 further collects the current from the PMs 830 to the capacitor input terminal 820 of the capacitor unit 82. The collected current then flows through the corresponding cores in the capacitor unit 82 and flows to the external output bus bar 832 (located outside the capacitor unit 82) of the PM unit 83 via the capacitor output terminal 821, and then flows back to the PMs 830 through the conductive elements 8302, thus forming a complete current loop in the PTU.
[0031] In view of the fact that the improvements of the present utility model have little relevance to the internal structure of the PM 830 itself, therefore, the detailed internal structure of the PM 830 is not shown in the figure. In addition, the description of the structural details that are not involved in or have little change in the improvements is omitted in the present utility model. The details of these parts can be understood with reference to the commonly used PTUs in the prior art and will not be elaborated herein.
[0032] AsFigures 1 - 3 As shown, the capacitance input terminal 820 and the capacitance output terminal 821 of the capacitance unit 82 are usually arranged in a straight line (i.e., in a column) and staggered on one side of the capacitance unit 82. This results in the external input bus bar 831 and the external output bus bar 832 for transferring current between the PM unit 83 and the capacitance unit 82 being relatively large in size in at least one direction. This means that the distance (the path through which the current travels) between the PM 830 and the capacitance terminals (including the capacitance input terminal 820 and the capacitance output terminal 821) is relatively long, resulting in a relatively large inductance of the entire PTU, which in turn greatly hinders the ripple current from flowing into the PTU 80.
[0033] In addition, as Figure 2 best shown, considering the specific layout structure of the PTU 80, the external input bus bar 831 is generally in an h shape and has ends A1 and A2 for connecting the capacitance input terminal 820. This structure of the external input bus bar 831 results in the currents (as shown by the arrows in Figure 2 ) from the PM 830 traveling different distances to the ends A1 and A2. This, especially in the case of high-frequency operation, causes the current traveling to the farther end A2 to be less than the current traveling to the nearer end A1, resulting in uneven currents entering the capacitance unit 820 via different capacitance input ends, and ultimately resulting in uneven current distribution among the cores of the capacitance unit 82. This uneven distribution of current causes an increase in the equivalent series resistance (ESR) of the capacitance unit, which is the root cause of the problems of heat concentration and loss concentration in the cores of the capacitance unit.
[0034] To overcome the above problem of uneven current distribution, the integrated PTU according to the present utility model has improved the arrangement of the capacitance terminals.
[0035] Figures 4 - 5 The bottom perspective view and the bottom view of an integrated PTU according to an embodiment of the present utility model are respectively shown. As Figure 4 and Figure 5 shown, the PTU 10 according to the present utility model includes a housing 11, a capacitance unit 12, and a PM unit 13, as best seen in Figure 6 . Among them, the housing 11 has little difference in structure from the housing 81 in the prior art PTU 80 and is also used to accommodate the capacitance unit and the PM unit.
[0036] As Figure 4 and Figure 5As shown, the input capacitor terminals 120 and output capacitor terminals 121 of the capacitor unit 12 of the PTU 10 of the present utility model are arranged in a straight line (column) when viewed from the bottom direction and are located directly below the PM unit 13 in a substantially central position, thus forming a capacitor terminal column. And hereinafter, the plane where the capacitor terminal column is located is referred to as the capacitor terminal plane. And, the input capacitor terminals 120 and output capacitor terminals 121 are alternately arranged to facilitate the uniform distribution of current (indicated by arrows in Figure 5 among the respective capacitor terminals. In other words, the PM unit 13 includes an even number of PMs 130 ( Figures 4 - 5 shown as two in
[0037] Figure 6 ), and these PMs 130 are arranged in a mirror-symmetrical manner with respect to the capacitor terminal plane, thus facilitating the uniform distribution of current from each PM 130 to the input capacitor terminals 120 of the capacitor unit 12. Figure 4 shows a bottom-up partial exploded view of the PTU shown in Figure 6 . As
[0038] shown, the capacitor unit 12 is decomposed into a capacitor core and input / output busbars.
[0039] For the capacitor core part, except for the change in the position of the capacitor terminals, its structure is basically the same as the corresponding structure of the capacitor core in the prior art and is a well-known structure to those skilled in the art. Therefore, the present utility model omits the description of its specific details. Figure 6 Although the capacitor unit 12 is shown as including two capacitor groups - an upper row capacitor group and a lower row capacitor group (in the orientation shown in the figure), the present utility model is not limited thereto. At least one capacitor group can be provided in the capacitor unit within a PTU. In addition, although
[0040] Figure 7 only one group of capacitors (i.e., the lower row capacitor group) in the capacitor group of the capacitor unit 12 shown in Figure 4 uses the input / output busbars improved according to the present utility model, the present utility model is not limited thereto. The input / output busbars improved according to the present utility model can be used in all capacitor groups within the capacitor unit. Figure 8 shows Figure 7 a bottom-up exploded perspective view of the internal input busbar and internal output busbar of a capacitor group (lower row capacitor group) used in the PTU shown in
[0041] Different from the structure of the internal input and output busbars used in the capacitor unit 82 of the prior art, the structure of the internal input and output busbars used in the capacitor unit 12 of the PTU according to the present invention is relatively simple. Hereinafter, the internal output busbar 122 will be taken as an example for illustration.
[0042] Refer to Figure 7 , the internal output busbar 122 includes two extension parts 122A and 122B and a bridging part 122C. Among them, the bridging part 122C connects the extension parts 122A and 122B together, so that the extension parts 122A and 122B are substantially coplanar and extend away from each other. The bridging part 122C is configured to form a recess relative to the extension plane where the extension parts 122A and 122B are located, and the recess is configured to receive and electrically couple with the capacitor terminals of the capacitor unit 12. The height H of the bridging part 122C (that is, the maximum depth of the bottom wall of its recess relative to the extension plane where the extension parts are located) can be selected according to the needs of actual applications. The two extension parts 122A and 122B are configured to be mirror-symmetrical about the bridging part 122C, and each is used to be in electrical contact with the output side of the core of the capacitor unit 12. Although Figure 7 shows the extension parts 122A and 122B and the bridging part 122C as an integral part, the present invention is not limited thereto. These parts can be in the form of components that are initially separated and then connected together.
[0043] In one example, the bridging part 123C is in the form of a plurality of discrete strips extending in the same direction as the extension direction of the extension parts 122A and 122B. These plurality of discrete strips are arranged substantially parallel to each other, with a certain gap therebetween. Each of these gaps is configured to cooperate with the corresponding structure of the corresponding bridging part 123C of the internal input busbar 123. The discrete strips are respectively configured to cooperate with a corresponding one of the capacitor input terminals 120, so the number thereof is preferably the same as the number of the capacitor input terminals 120. Figure 7 As an example in Figure 8 shows from another perspective Figure 7 the external output busbar shown in
[0044] Although Figure 7The specific structures of the extension portions 122A and 122B are shown, but the present utility model is not limited thereto, and it can be changed according to the specific structure of the core of the capacitor unit 12, as long as the electrical coupling therebetween can be achieved. For example, according to the specific arrangement of the core of the capacitor unit, the extension portions 122A and 122B can be designed such that they are not coplanar but extend in opposite directions parallel to each other, or they are not planar, or they are inclined at an angle other than 180° with respect to each other. In addition, although the side walls of the concave portion of the bridging portion 122C are shown as perpendicular to the extension plane where the extension portion is located, the present utility model is not limited thereto. For example, according to needs, the side walls can be configured to be at an acute angle or in an arc shape with respect to the extension plane.
[0045] Figure 7 The structure of the internal input bus bar 123 shown is similar to that of the internal output bus bar 122, and the difference is only that the sum of the height of the bridging portion 122C of the internal output bus bar 122 and the thickness of the core within the capacitor unit 12 (the dimension of the core sandwiched between the input bus bar and the output bus bar) is not equal to the height of the bridging portion 123C of the internal output bus bar 123. In other words, after the internal output bus bar 122 and the internal input bus bar 123 are respectively assembled on both sides of the core of the capacitor unit 12, the bottom walls of the concave portions of the bridging portions 122C and 123C are parallel to each other and staggered with respect to the capacitor terminal plane, and the plane where the bottom wall of the concave portion of the bridging portion 122C is located and the plane where the bottom wall of the concave portion of the bridging portion 123C is located are not coplanar (there is a height difference with respect to the extension plane). This arrangement helps the current to be evenly distributed among the respective capacitor terminals and helps the electrical connection between the PM unit 13 and the capacitor unit 12.
[0046] Now return Figure 6 , the PM unit 13 includes an external input bus bar 131 and an external output bus bar 132. The external input bus bar 131 is configured to receive current from the PM 130 and guide it into the capacitor input terminal 120 of the capacitor unit 12, and the external output bus bar 132 is configured to receive current from the respective capacitor output terminals 121 of the capacitor unit 12 and guide it back to the PM 130. Preferably but not restrictively, both the external input bus bar 131 and the external output bus bar 132 are configured to be components that are mirror-symmetrical about their respective center lines (not shown in the figure), and when installed, their respective center lines are located within the capacitor terminal plane.
[0047] Figure 9 Shows a bottom view of the PTU according to another embodiment of the present utility model. The difference in its structure from that of the PTU shown Figure 5 mainly lies in the arrangement direction of the capacitor terminal plane. In the case of Figure 5In the embodiment shown, the plane of the capacitive terminal is parallel to the major axis direction of the elliptical core in the capacitive unit 12 (i.e., Figure 5 the x-x direction shown in Figure 9 . In contrast, in the embodiment shown in Figure 9 , the plane of the capacitive terminal is parallel to the minor axis direction of the elliptical core (i.e., Figure 9 the y-y direction shown in
[0048] . This results in different extension directions (perpendicular to the plane of the capacitive terminal) of the extensions of the internal input and output busbars in the capacitive unit in the two embodiments. In the embodiment shown in Figure 9 , the width (dimension along the y-y direction) of the bridging portion of the internal input and output busbars is different from (greater than or less than) the width of the extension portion, and the width of the extension portion may vary along the direction away from the bridging portion.
[0049] Although multiple embodiments of the present invention have been described with reference to the accompanying drawings, as will be understood by those skilled in the art, various improvements can be made to the above embodiments without departing from the scope defined by the appended claims. For example, although in the figures the PMs are described as being mirror-symmetrical about the plane of the capacitive cabinet terminals, this is not necessary. In the case where, for example, two PMs are respectively arranged on both sides of the plane of the capacitive terminal, the two PMs may not be symmetrically arranged about this plane, as long as the distances (current paths) from their respective electrical interfaces to the corresponding capacitive terminals are equal. The above embodiments are provided only as examples for illustrating the technical solutions of the present invention and are not intended to limit the protection scope of the present invention. Features or elements described in one embodiment may be incorporated into another embodiment for implementation, unless they are contradictory to the existing features or elements in the other embodiment.
Claims
1. An integrated power transfer unit (10), characterized in that, The integrated power transmission unit includes: A capacitor unit (12), the capacitor unit being provided with at least two capacitor terminals (120, 121) arranged in a plane to form a capacitor terminal plane, the at least two capacitor terminals being respectively configured to be electrically connected to the core of the capacitor unit; A power module unit (13), the power module unit including an even number of power modules (130), each of the even number of power modules being configured to be electrically connected to the capacitor unit to supply power thereto, and the even number of power modules including a first module group and a second module group respectively provided on a first side and an opposite second side of the capacitor terminal plane, wherein, the shortest current paths from the respective electrical interfaces in the first module group and the second module group in the power module unit to a corresponding one of the at least two capacitor terminals are of equal length.
2. The integrated power transmission unit according to claim 1, wherein The first module group and the second module group are configured to be arranged symmetrically with respect to the capacitor terminal plane in a mirror image manner.
3. The integrated power transmission unit according to claim 2, characterized in that, The integrated power transmission unit includes an external input bus bar (131) and an external output bus bar (132) respectively connected to the capacitor unit, and the external input bus bar and the external output bus bar are overlapped with each other and electrically insulated from each other, and are each mirror symmetric with respect to its own center line, wherein, the center lines of the external input bus bar and the external output bus bar are configured to be located in the capacitor terminal plane.
4. The integrated power transmission unit according to claim 3, characterized in that, Each of the even number of power modules is arranged coplanarly; and / or The external input bus bar and the external output bus bar are overlapped with each other below the power module unit.
5. The integrated power transfer unit according to claim 4, characterized in that, The first module group is electrically connected to the external input bus bar and the external output bus bar respectively on the first side through a plurality of conductive elements, and the second module group is electrically connected to the external input bus bar and the external output bus bar respectively on the second side through a plurality of conductive elements.
6. The integrated power transfer unit according to claim 5, characterized in that, The current path includes an input current path and an output current path, wherein, the input current path and the output current path between each power module and a corresponding capacitor terminal are equal to each other.
7. The integrated power transfer unit according to claim 6, characterized in that, The capacitor unit includes an internal input bus bar (123) and an internal output bus bar (122) respectively electrically connected to the core, and each of the internal input bus bar and the internal output bus bar includes: A first extension portion (122A) and a second extension portion (122B) separated from each other, wherein, the first extension portion and the second extension portion are arranged coplanarly and each is in electrical contact with a corresponding core in the core, and A bridging portion (122C, 123C), the bridging portion being configured to connect the first extension portion and the second extension portion, and forming a recess with respect to the extension plane where the first extension portion and the second extension portion are located, the recess being configured to receive the capacitor terminal of the capacitor unit and be electrically coupled thereto.
8. The integrated power transmission unit according to claim 7, characterized in that, The bridging portion is in the form of a plurality of discrete strips arranged in parallel with each other and extending in the same direction as the extending directions of the first extending portion and the second extending portion.
9. The integrated power transmission unit according to claim 8, characterized in that, The discrete strips of the bridging portion of the internal input busbar and the discrete strips of the bridging portion of the internal output busbar are arranged in parallel and staggered with each other perpendicular to the capacitor terminal plane.
10. The integrated power transmission unit according to claim 9, characterized in that, The sum of the height of the bridging portion of the internal output busbar and the thickness of the core of the capacitor unit is not equal to the height of the bridging portion of the internal input busbar.
11. The integrated power transmission unit according to claim 10, wherein, Each of the internal input busbar and the internal output busbar is mirror-symmetrical about its respective center line.
12. The integrated power transfer unit according to claim 10, characterized in that, For each of the internal input busbar and the internal output busbar, the widths of the first extending portion and the second extending portion are not equal; and / or the widths of the first extending portion and the second extending portion are not constant along the direction away from the bridging portion; and / or the width of the bridging portion is greater than the width of the first extending portion and / or the second extending portion.
13. The integrated power transfer unit according to any one of claims 1-12, characterized in that, The capacitor terminal plane extends parallel to the long axis direction or the short axis direction of the core of the capacitor unit; and / or Each of the first module group and the second module group includes at least one of the even number of power modules.
14. The integrated power transfer unit according to any one of claims 1-12, characterized in that, The integrated power transmission unit includes a housing that encapsulates the capacitor unit and the power module unit therein.