Liquid-cooled DC filter capacitor power module

Abstract

The utility model relates to a liquid-cooled direct-current filter capacitor power module, which comprises a shell, a capacitor core group, a first polarity terminal, a second polarity terminal, a first insulated gate bipolar transistor (IGBT) busbar, a second IGBT busbar, a first parallel conducting strip, a second parallel conducting strip and epoxy resin, the capacitor core group, the first parallel conducting strip, the second parallel conducting strip, the inner end of the first polarity terminal, the inner end of the second polarity terminal, the inner end of the first IGBT busbar and the inner end of the second IGBT busbar are arranged in the shell through the opening, the opening is packaged by the epoxy resin, and a water-cooling heat dissipation structure is arranged in the shell. The water-cooling heat dissipation structure is arranged on one side of the first parallel conducting strip, and a water inlet pipe and a water outlet pipe are arranged on the water-cooling heat dissipation structure. When a large current passes through, the first parallel conducting strip is quickly cooled through the water-cooling heat dissipation structure, and heat of the water-cooling heat dissipation structure and the first parallel conducting strip is taken away by water, so that heat of the plurality of capacitor cores is dissipated, and the temperature of the whole capacitor power module is reduced.

Description

Technical Field

[0001] This utility model relates to the technical field of filter capacitor power modules, and in particular to a liquid-cooled DC filter capacitor power module. Background Technology

[0002] With the increasing demand for low-carbon, energy-saving, and cost-reduction development this year, the application of high-power power supplies in heating, smelting, melting, welding, UPS power supplies, photovoltaic inverters, energy storage, and other applications has gradually increased. Currently, the power output of high-power power supplies has gradually increased from the original 5kW~25kW to 100kW or even over 500kW.

[0003] Capacitors, as indispensable filtering components in circuits, play a crucial role in applications such as induction heating, electron beam welding, and photovoltaic inverters. Because capacitors generate heat under high-frequency ripple current, the industry currently commonly uses the following DC filtering devices as filtering components: Figure 1 As shown, it includes multiple cylindrical aluminum-shell capacitors (a) and a composite busbar (c). Multiple cylindrical aluminum-shell capacitors are connected in parallel on the composite busbar (c). However, the above-mentioned DC filter device has the following shortcomings: 1. Ventilation and heat dissipation are achieved by spacing adjacent capacitors at a certain distance, resulting in poor heat dissipation. 2. Each cylindrical aluminum-shell capacitor is installed individually on the composite busbar, requiring a base plate at the bottom. This type of filter device is inconvenient to install, and manual installation is time-consuming. With labor costs increasing year by year, the cost will gradually increase. 3. Replacing the capacitors in this type of filter device is difficult, making maintenance inconvenient. Therefore, the structure of the existing DC filter capacitor device needs further improvement. Summary of the Invention

[0004] The purpose of this invention is to provide a liquid-cooled DC filter capacitor power module with an integrated structure and high heat dissipation capacity. This invention can meet the application requirements of convenient installation and maintenance, high current carrying capacity, high heat dissipation capacity, low overall cost, and high overall performance.

[0005] The purpose of this utility model is achieved as follows:

[0006] A liquid-cooled DC filter capacitor power module includes a housing, a capacitor core assembly, a first polarity terminal, a second polarity terminal, a first IGBT busbar, a second IGBT busbar, a first parallel conductive sheet, a second parallel conductive sheet, and epoxy resin. The housing has an opening through which the capacitor core assembly, the first parallel conductive sheet, the second parallel conductive sheet, the inner ends of the first polarity terminal, the second polarity terminal, the first IGBT busbar, and the second IGBT busbar are inserted into the housing. The opening is encapsulated with epoxy resin. The first parallel conductive sheet is attached to one side of the capacitor core assembly, and the second parallel conductive sheet is attached to the other side of the capacitor core assembly. A water-cooling heat dissipation structure is provided inside the housing, located on one side of the first parallel conductive sheet. The water-cooling heat dissipation structure has an inlet pipe and an outlet pipe. When a large current passes through the capacitor core assembly, the present invention rapidly dissipates heat from the first parallel conductive sheet through a water-cooling structure. The water carries away the heat from the water-cooling structure and the first parallel conductive sheet, thereby dissipating heat for multiple capacitor cores, reducing the temperature of the entire capacitor power module, and improving the current carrying capacity and filtering power of the capacitor core assembly.

[0007] The present invention can be further improved in the following ways.

[0008] As a further embodiment, the capacitor core assembly is composed of multiple capacitor cores arranged side by side. A first parallel conductive sheet is connected in parallel to one end of the multiple capacitor cores, and a second parallel conductive sheet is connected in parallel to the other end of the multiple capacitor cores. The inner ends of the first IGBT busbar and the second IGBT busbar are respectively connected to the first parallel conductive sheet and the second parallel conductive sheet. The inner ends of the first polarity terminal and the second polarity terminal are respectively connected to the first parallel conductive sheet and the second parallel conductive sheet.

[0009] As a further solution, the water-cooled heat dissipation structure is welded to the first parallel conductive sheet, which results in higher heat dissipation efficiency and also facilitates installation and production.

[0010] As a further solution, the water-cooled heat dissipation structure is attached to one side of the first parallel conductive sheet, thereby improving the heat dissipation efficiency of this invention.

[0011] As a further solution, the water-cooled heat dissipation structure is a water-cooled plate, which is provided with a water-flow cavity, the water inlet pipe and the water outlet pipe, respectively. The water-flow cavity is connected to the water inlet pipe and the water outlet pipe.

[0012] As a further solution, the water-cooled heat dissipation structure is a water-cooling pipe, with the inlet pipe, outlet pipe and water-cooling pipe integrated into one unit. The water-cooling pipe is readily available and easy to install.

[0013] As a further solution, the capacitor core assembly, the first parallel conductive sheet, and the second parallel conductive sheet are all wrapped with insulating material to prevent leakage of the capacitor power module.

[0014] As a further option, the insulating material is mica paper, aramid fiber paper, glass fiber, carbon fiber, or heat shrink tubing.

[0015] As a further solution, a temperature sensor is installed on the housing to monitor the temperature of the capacitor power module.

[0016] As a further solution, the inlet and outlet pipes extend out of the outer casing to facilitate connection to external cold water pipes.

[0017] Both the inlet and outlet pipes are fitted with insulating sleeves to prevent leakage and electric shock.

[0018] As a further option, the water-cooled heat dissipation structure is made of aluminum or copper, which have good thermal conductivity and high heat exchange efficiency.

[0019] As a further option, the capacitor core is made into a cylindrical or flat shape by a winding process using a metallized thin film. The metallized thin film is made by plasma roughening treatment of PS, PP, EPN, PET, PEN, PPS, PEEK, PEEKK, PI, PTFE, PEI, or PMI, followed by metallization evaporation.

[0020] As a further embodiment, a vapor-deposited metal layer is disposed on the metallized thin film. The vapor-deposited metal layer includes a non-thickened region, a transition region, and a thickened region, with the transition region located between the non-thickened region and the thickened region. The width of the thickened region ranges from 3 to 5 mm, and its sheet resistance ranges from 1 to 4 Ω. The width of the transition region ranges from 6 to 30 mm, and its sheet resistance ranges from 10 to 20 Ω. The sheet resistance of the non-thickened region ranges from 15 to 60 Ω.

[0021] The beneficial effects of this utility model are as follows:

[0022] 1. When a large current passes through the capacitor core assembly, the present invention rapidly dissipates heat from the first parallel conductive sheet through a water-cooling heat dissipation structure. The water carries away the heat from the water-cooling heat dissipation structure and the first parallel conductive sheet, thereby dissipating heat for multiple capacitor cores, reducing the temperature of the entire capacitor power module, and improving the current carrying capacity and filtering power of the capacitor core assembly.

[0023] 2. This invention integrates the capacitor core assembly, the first polarity terminal, the second polarity terminal, the first IGBT busbar, the second IGBT busbar, the first parallel conductive sheet, and the second parallel conductive sheet all onto a housing, and then encapsulates them with epoxy resin. Compared with previous capacitor filtering devices, this invention adopts an integrated design, which simplifies the structure, makes installation convenient and easy, and shortens the installation time. Moreover, the overall cost of this invention is reduced. This invention does not require an additional composite busbar, reducing the use of composite busbars and reducing labor installation costs.

[0024] 3. This utility model adds a temperature sensor, which allows users to monitor the temperature of the capacitor power module.

[0025] 4. The water-cooled heat dissipation structure of this utility model is welded to the first parallel conductive sheet as a whole, which has higher heat dissipation efficiency and is also convenient for installation and production. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of an existing DC filter capacitor device.

[0027] Figure 2 This is a schematic diagram of the structure of the liquid-cooled DC filter capacitor power module according to Embodiment 1 of this utility model.

[0028] Figure 3 This is a structural schematic diagram of the liquid-cooled DC filter capacitor power module according to Embodiment 1 of this utility model from another angle.

[0029] Figure 4 This is a top view of the liquid-cooled DC filter capacitor power module according to Embodiment 1 of this utility model.

[0030] Figure 5 yes Figure 4 Sectional view at point AA.

[0031] Figure 6 yes Figure 4 Sectional view at point BB.

[0032] Figure 7 This is an exploded view of the liquid-cooled DC filter capacitor power module according to Embodiment 1 of this utility model.

[0033] Figure 8 This is a schematic diagram of the capacitor core of Embodiment 1 of this utility model.

[0034] Figure 9 This is a schematic diagram of the structure of the liquid-cooled DC filter capacitor power module according to Embodiment 2 of this utility model.

[0035] Figure 10 This is a top view of the liquid-cooled DC filter capacitor power module of Embodiment 2 of this utility model.

[0036] Figure 11 yes Figure 10 Sectional view at point CC.

[0037] Figure 12 yes Figure 10 Sectional view at point DD.

[0038] Figure 13 This is an exploded view of the liquid-cooled DC filter capacitor power module of Embodiment 2 of this utility model. Detailed Implementation

[0039] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0040] Example 1, as Figures 2 to 8 As shown, a liquid-cooled DC filter capacitor power module includes a housing 1, a capacitor core assembly 2, a first polarity terminal 3, a second polarity terminal 4, two first IGBT busbars 5, two second IGBT busbars 6, a first parallel conductive sheet 7, a second parallel conductive sheet 8, and epoxy resin 13. The housing 1 has an opening 11 through which the inner ends of the capacitor core assembly 2, the first parallel conductive sheet 7, the second parallel conductive sheet 8, the first polarity terminal 3, the second polarity terminal 4, the two first IGBT busbars 5, and the two second IGBT busbars 6 are inserted into the housing 1. The opening 11 is encapsulated by epoxy resin 13. The first parallel conductive sheet 7 is attached to one side of the capacitor core assembly 2, and the second parallel conductive sheet 8 is attached to the other side of the capacitor core assembly 2. The housing 1 has a water-cooling heat dissipation structure located on one side of the first parallel conductive sheet 7. The water-cooling heat dissipation structure has an inlet pipe 18 and an outlet pipe 19.

[0041] This is a more specific technical solution of the present invention.

[0042] The capacitor core assembly 2 is composed of multiple capacitor cores 21 arranged side by side. The first parallel conductive sheet 7 is connected in parallel to one end of the multiple capacitor cores 21, and the second parallel conductive sheet 8 is connected in parallel to the other end of the multiple capacitor cores 21. The inner end of the first IGBT busbar 5 and the inner end of the second IGBT busbar 6 are respectively connected to the first parallel conductive sheet 7 and the second parallel conductive sheet 8. The inner end of the first polarity terminal 3 and the inner end of the second polarity terminal 4 are respectively connected to the first parallel conductive sheet 7 and the second parallel conductive sheet 8.

[0043] The first IGBT busbar 5 and the second IGBT busbar 6 are arranged in pairs, with the outer ends of the first IGBT busbar 5 and the outer ends of the second IGBT busbar 6 spaced apart and arranged side by side.

[0044] The outer end of the first IGBT busbar 5 is provided with a plurality of first IGBT polarity terminals 51, and the outer end of the second IGBT busbar 6 is provided with a plurality of second IGBT polarity terminals 61 corresponding to the positions of the plurality of first IGBT polarity terminals 51. The first IGBT polarity terminals and the second IGBT polarity terminals correspond one-to-one.

[0045] The outer casing 1 is rectangular, the opening 11 is rectangular, the first polar terminal 3 and the second polar terminal 4 are located on the first side edge and the second side edge of the opening 11, respectively, a pair of first IGBT busbars 5 and second IGBT busbars 6 are located on the third side edge of the opening 11, and another pair of first IGBT busbars 5 and second IGBT busbars 6 are located on the fourth side edge of the opening 11.

[0046] This is a more detailed technical solution of the present invention.

[0047] The water-cooled heat dissipation structure is welded to the first parallel conductive sheet 7 as a whole.

[0048] The water-cooled heat dissipation structure is a water-cooled plate 90, which is provided with a water-flow cavity 93, the water inlet pipe 18 and the water outlet pipe 19. The water-flow cavity 93 is connected to the water inlet pipe 18 and the water outlet pipe 19 respectively.

[0049] The water-cooled heat dissipation structure is made of aluminum or copper.

[0050] The outer casing 1 is provided with connecting ears 12 for mounting and fixing.

[0051] A temperature sensor 16 is provided on the outer casing 1.

[0052] This is a more detailed technical solution of the present invention.

[0053] The inlet pipe 18 and the outlet pipe 19 extend out of the outer casing 1, respectively. Both the inlet pipe and the outlet pipe are fitted with insulating sleeves.

[0054] The capacitor core assembly 2, the first parallel conductive sheet 7, and the second parallel conductive sheet 8 are together wrapped with insulating material, which is mica paper, aramid fiber paper, glass fiber, carbon fiber, or heat shrink sleeve.

[0055] The insulating material is mica paper, aramid fiber paper, glass fiber, carbon fiber, or heat shrink tubing.

[0056] This is a more optimized technical solution of the present invention.

[0057] The capacitor core 21 is made into a cylindrical or flat shape by a winding process using a metallized thin film 22. The metallized thin film 22 is made of PS, PP, EPN, PET, PEN, PPS, PEEK, PEEKK, PI, PTFE, PEI, or PMI through plasma roughening treatment to increase the surface roughness of the metallized thin film 22, and then metallized by vapor deposition.

[0058] A vapor-deposited metal layer 23 is disposed on the metallized thin film 22. The vapor-deposited metal layer 23 includes a non-thickened region, a transition region, and a thickened region. The transition region is located between the non-thickened region and the thickened region. The width of the thickened region ranges from 3 to 5 mm, and the sheet resistance ranges from 1 to 4 Ω. The width of the transition region ranges from 6 to 30 mm, and the sheet resistance ranges from 10 to 20 Ω. The sheet resistance of the non-thickened region ranges from 15 to 60 Ω.

[0059] The vapor-deposited metal layer 23 is a composite or multi-layer material structure of one or more of the following materials: aluminum, copper, zinc, or silver.

[0060] The end of capacitor core 21 is coated with a metal layer, the material of which is tin-zinc, zinc, aluminum, or zinc-aluminum alloy.

[0061] The two ends of the capacitor core 21 are respectively welded to the first parallel conductive sheet 7 and the second parallel conductive sheet 8. The ends of the capacitor core 21 are welded with brazing material, which is tin-zinc, zinc, aluminum or silver. The welding method of the ends of the capacitor core 21 is laser welding, electron beam welding or iron welding.

[0062] The working principle of this utility model is as follows:

[0063] In the circuit where the capacitor power module of this utility model is connected to the load, multiple IGBT modules in the load circuit are installed on the first IGBT polarity terminal and the second IGBT polarity terminal. Multiple capacitor cores filter the current of the load. Multiple capacitor cores 21 generate heat under the action of high-frequency ripple current. External cold water enters the water-cooled plate from the water inlet pipe 18. The heat is transferred to the water-cooled plate through the first parallel conductive sheet 7. When the water passes through the water-cooled plate, it will exchange heat with the water-cooled plate or the water-cooled pipe. Then the water is discharged from the water outlet pipe 19. The water carries away the heat of the water-cooled plate, thereby dissipating heat for the multiple capacitor cores 21, thereby improving the current carrying capacity and filtering power of the capacitor core group 2.

[0064] Example 2, as Figures 9 to 13 As shown, the implementation method of Embodiment 2 is similar to that of Embodiment 1, with the only difference being that the water-cooled heat dissipation structure is a water-cooled pipe 91, and the water inlet pipe 18 and the water outlet pipe 19 are integrated with the water-cooled pipe 91. The water-cooled pipe is easy to install, easy to connect, and easy to obtain.

[0065] Example 3 is similar to the implementation of Example 1, except that the water-cooled heat dissipation structure is attached to one side of the first parallel conductive sheet 7, and the water-cooled heat dissipation structure achieves heat transfer by contacting the first parallel conductive sheet 7.

Claims

1. A liquid-cooled DC filter capacitor power module, comprising a housing, a capacitor core assembly, a first polarity terminal, a second polarity terminal, a first IGBT busbar, a second IGBT busbar, a first parallel conductive sheet, a second parallel conductive sheet, and epoxy resin. The housing has an opening through which the capacitor core assembly, the first parallel conductive sheet, the second parallel conductive sheet, the inner ends of the first polarity terminal, the second polarity terminal, the first IGBT busbar, and the second IGBT busbar are inserted into the housing. The opening is encapsulated with epoxy resin. The first parallel conductive sheet is attached to one side of the capacitor core assembly, and the second parallel conductive sheet is attached to the other side of the capacitor core assembly. The module is characterized in that... The outer casing is equipped with a water-cooling heat dissipation structure, which is located on one side of the first parallel conductive sheet. The water-cooling heat dissipation structure is equipped with an inlet pipe and an outlet pipe.

2. The liquid-cooled DC filter capacitor power module according to claim 1, characterized in that the capacitor... The core assembly consists of multiple capacitor cores arranged side by side. A first parallel conductive plate is connected in parallel to one end of the multiple capacitor cores, and a second parallel conductive plate is connected in parallel to the other end of the multiple capacitor cores. The inner ends of the first IGBT busbar and the second IGBT busbar are respectively connected to the first parallel conductive plate and the second parallel conductive plate. The inner ends of the first polarity terminal and the second polarity terminal are respectively connected to the first parallel conductive plate and the second parallel conductive plate.

3. The liquid-cooled DC filter capacitor power module according to claim 1, characterized in that, The water-cooled heat dissipation structure is welded to the first parallel conductive sheet as a whole.

4. The liquid-cooled DC filter capacitor power module according to claim 1, characterized in that, The water-cooled heat dissipation structure is attached to one side of the first parallel conductive sheet.

5. The liquid-cooled DC filter capacitor power module according to claim 3 or 4, characterized in that, The water-cooled heat dissipation structure is a water-cooled plate, which is provided with a water cavity, the water inlet pipe and the water outlet pipe, and the water cavity is connected to the water inlet pipe and the water outlet pipe respectively.

6. The liquid-cooled DC filter capacitor power module according to claim 3 or 4, characterized in that, The water-cooled heat dissipation structure consists of water-cooling pipes, with the inlet pipe, outlet pipe, and water-cooling pipes integrated into one unit.

7. The liquid-cooled DC filter capacitor power module according to claim 2, characterized in that, The capacitor core assembly, the first parallel conductive sheet, and the second parallel conductive sheet are all wrapped together with insulating material, which is mica paper, aramid fiber paper, glass fiber, carbon fiber, or heat shrink sleeve.

8. The liquid-cooled DC filter capacitor power module according to claim 1, characterized in that, A temperature sensor is installed on the casing.

9. The liquid-cooled DC filter capacitor power module according to claim 1, characterized in that the capacitor... The core is made into a cylindrical or flat shape by a winding process using a metallized thin film. The metallized thin film is made by plasma roughening treatment of PS, PP, EPN, PET, PEN, PPS, PEEK, PEEKK, PI, PTFE, PEI, or PMI, followed by metallization evaporation.

10. The liquid-cooled DC filter capacitor power module according to claim 9, characterized in that, A metallized thin film has a vapor-deposited metal layer, which includes a non-thickened region, a transition region, and a thickened region. The transition region is located between the non-thickened region and the thickened region. The width of the thickened region ranges from 3 to 5 mm, and its sheet resistance ranges from 1 to 4 Ω. The width of the transition region ranges from 6 to 30 mm, and its sheet resistance ranges from 10 to 20 Ω. The sheet resistance of the non-thickened region ranges from 15 to 60 Ω.

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