A thin film capacitor for electric vehicles with high heat dissipation

Abstract

The utility model relates to electric automobile parts technical field discloses a high heat dissipation film capacitor for electric automobile, including the casing, the inside of casing is provided with the buffer pad, the side of buffer pad away from the casing is assembled with the core, the top of core is assembled with copper busbar no.

Description

Technical Field

[0001] This utility model relates to the field of electric vehicle component technology, and in particular to a high heat dissipation film capacitor for electric vehicles. Background Technology

[0002] In the core components of new energy vehicles, film capacitors are the second most important component in motor controllers after power modules. They play a role in DC support in the motor controller circuit. Firstly, they absorb the high-amplitude pulsating current drawn from the inverter to the "DC-Link" and prevent it from generating a high-amplitude pulsating voltage across the impedance of the "DC-Link", thus keeping the power supply voltage fluctuation at the inverter end within the allowable range. Secondly, they prevent the influence of voltage overshoot and transient overvoltage from the "DC-Link" on the inverter.

[0003] Electric vehicles use film capacitors as DC support capacitors, which use high-temperature polypropylene film as the dielectric. They have advantages such as self-healing ability, strong overvoltage resistance, and long life. However, film capacitors have a strict upper limit on the operating temperature. Under the operating conditions of electric vehicles, the environment inside the controller box where the capacitor works is already very high. In addition, the capacitor itself will carry a high-frequency, high-current flow, and the heat generated by the capacitor itself will make its operating temperature even higher.

[0004] Existing thin-film capacitors for electric vehicles typically rely on potting materials and casings to conduct heat from the internal core and electrodes to the outside. However, the variety of potting materials and casings results in different thermal conductivityes between different materials, and the distance of conduction affects the thermal resistance of the capacitor. This leads to complex operating conditions and a high risk of failure in capacitor applications. The internal temperature rises due to heat generation from the core and busbars, reducing the capacitor's lifespan. Under severe conditions, it can even lead to serious consequences such as core melting and explosion. Therefore, a high-heat-dissipation thin-film capacitor for electric vehicles is proposed to solve the above problems. Summary of the Invention

[0005] To overcome the above shortcomings, this utility model provides a high-heat-dissipation film capacitor for electric vehicles, aiming to improve the problems of single heat dissipation method, difficult thermal resistance control, complex operating conditions, high failure risk and shortened life of existing film capacitors for electric vehicles.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A high-heat-dissipation film capacitor for electric vehicles includes a housing, a buffer pad disposed inside the housing, a core mounted on the side of the buffer pad away from the housing, a copper busbar one mounted on the top of the core, a copper busbar two mounted on the bottom of the core, a potting compound disposed inside the housing, a heat dissipation assembly disposed inside the housing, an insulating plate disposed inside the housing, a mounting assembly disposed on the outside of the housing, and a copper plate disposed inside the housing. The heat dissipation component includes a cooling metal plate disposed at the bottom of the housing, and a heat dissipation channel is provided on the outer side of the core.

[0007] As a further description of the above technical solution: The mounting assembly includes a mounting block, the central portion of which is fitted with bolts.

[0008] As a further description of the above technical solution: The core and the copper busbar are respectively fixedly connected to lead-out electrode one and lead-out electrode two at the ends away from the core.

[0009] As a further description of the above technical solution: Both lead-out electrode one and lead-out electrode two are located in the middle of the housing.

[0010] As a further description of the above technical solution: Both the first copper busbar and the second copper busbar are connected to the core via the copper plate.

[0011] As a further description of the above technical solution: An insulating plate is provided between the first copper busbar and the second copper busbar.

[0012] As a further description of the above technical solution: The cooling metal plate is specifically made of composite aluminum plate to provide thermal conductivity and corrosion resistance, and the copper plate is specifically made of copper plate to provide high electrical conductivity.

[0013] As a further description of the above technical solution: The mounting block has a mounting hole in the middle, and the mounting block is located in the middle of the mounting hole.

[0014] This utility model has the following beneficial effects: 1. In this utility model, the good thermal conductivity of the copper plate can quickly absorb the heat generated by the core, while the high thermal conductivity of the composite aluminum plate can quickly dissipate the heat, thereby greatly improving the heat dissipation efficiency of the capacitor. The heat dissipation channel set on the outside of the core and the cooling metal plate work together to allow the heat to flow and dissipate out of the shell, further optimizing the heat dissipation effect and helping to improve the stability of the film capacitor in high-temperature environments.

[0015] 2. In this utility model, the installation hole in the middle of the mounting block and the bolt cooperation make the film capacitor easier to install, and can be quickly and firmly fixed in the required position, improving installation efficiency and meeting the installation needs in practical applications. Attached Figure Description

[0016] Figure 1 This is a three-dimensional schematic diagram of a high heat dissipation film capacitor for electric vehicles proposed in this utility model; Figure 2 This is a schematic diagram of the core structure of a high-heat-dissipation thin-film capacitor for electric vehicles proposed in this utility model; Figure 3 This is a schematic diagram of the copper plate structure of a high heat dissipation film capacitor for electric vehicles proposed in this utility model; Figure 4 This is a schematic diagram of the cooling metal plate of a high-heat-dissipation thin-film capacitor for electric vehicles proposed in this utility model.

[0017] Legend: 1. Housing; 2. Buffer pad; 3. Core; 4. Copper busbar one; 5. Copper busbar two; 6. Lead electrode one; 7. Lead electrode two; 8. Potting compound; 9. Copper plate; 10. Heat dissipation assembly; 11. Cooling metal plate; 12. Insulating plate; 13. Mounting assembly; 14. Mounting block; 15. Mounting hole; 16. Bolt; 17. Heat dissipation channel. Detailed Implementation

[0018] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0019] Reference Figure 2 and Figure 4An embodiment of this utility model provides a high heat dissipation film capacitor for electric vehicles, comprising a housing 1, a buffer pad 2 disposed inside the housing 1, a core 3 mounted on the side of the buffer pad 2 away from the housing 1, a copper busbar 4 mounted on the top of the core 3, a copper busbar 5 mounted on the bottom of the core 3, a potting compound 8 disposed inside the housing 1, a heat dissipation assembly 10 disposed inside the housing 1, an insulating plate 12 disposed inside the housing 1, a mounting assembly 13 disposed on the outside of the housing 1, and a copper plate 9 disposed inside the housing 1. The heat dissipation assembly 10 includes a cooling metal plate 11, which is disposed at the bottom of the housing 1. A heat dissipation channel 17 is provided on the outer side of the core 3. The core 3 and the copper busbar 4 are respectively fixedly connected to the end away from the core 3 with lead-out electrode 6 and lead-out electrode 7. An insulating plate 12 is provided between the copper busbar 4 and the copper busbar 5.

[0020] Specifically, the buffer pad 2 helps to cushion the internal mounting structure when it encounters external pressure, protecting the internal structure. The copper busbar 1 4 and copper busbar 2 5 connect the lead electrode 1 6 and lead electrode 2 7, allowing the heat of the core 3 to dissipate, reducing heat dissipation pressure and improving stability. The potting material 8 transfers heat to the copper plate 9, which absorbs heat quickly with its high electrical and thermal conductivity, reducing the temperature around the core 3 and extending its service life. The heat dissipation channel 17 allows hot air to circulate, optimizing the heat dissipation path. The composite aluminum cooling metal plate 11 has excellent thermal conductivity and corrosion resistance, efficiently dissipating heat, reducing the internal temperature, and enhancing the adaptability and reliability of the film capacitor in harsh environments.

[0021] Reference Figure 1 and Figure 3 The mounting component 13 includes a mounting block 14, a bolt 16 is mounted in the middle of the mounting block 14, and a mounting hole 15 is provided in the middle of the mounting block 14. The mounting block 14 is located in the middle of the mounting hole 15.

[0022] Specifically, by opening mounting holes 15 on the mounting block 14 and using bolts 16, the film capacitor can be quickly and securely fixed in the required position, reducing problems such as loosening and displacement caused by improper installation, and helping to ensure the reliable operation of the film capacitor.

[0023] Reference Figure 2 and Figure 3 Both lead-out electrode 6 and lead-out electrode 7 are located in the middle of the housing 1, and both copper busbar 4 and copper busbar 5 are connected to the core 3 through copper plate 9.

[0024] Specifically, lead-out electrode 6 and lead-out electrode 7 are set as positive and negative terminals respectively, which facilitates connection with external circuits. When the capacitor is working, the current generated by the core 3 is conducted through copper busbar 4 and copper busbar 5. With the help of the good conductivity of copper plate 9, the current is efficiently transmitted to lead-out electrode 6 and lead-out electrode 7, realizing current exchange with external circuits.

[0025] Working principle: When the film capacitor is working, the core 3 generates heat. The heat is transferred through copper busbar 1 4 and copper busbar 2 5 to the connected lead electrode 1 6 and lead electrode 2 7. Some of the heat is dissipated to the outside in this way. At the same time, the heat generated by the core 3 is conducted to the potting material 8. The potting material 8 transfers the heat to the surrounding copper plate 9. Because the copper plate 9 is made of copper, it has high electrical conductivity and good thermal conductivity, and can quickly absorb heat. The heat dissipation channel 17 on the outside of the core 3 allows hot air to flow in it, accelerating heat dissipation. The heat will continue to be transferred downwards to the cooling metal plate 11. The cooling metal plate 11 is made of composite aluminum plate, which has good thermal conductivity and corrosion resistance, and can efficiently dissipate heat, further reducing the internal temperature of the capacitor. When the film capacitor needs to be installed, the mounting holes 15 opened in the mounting block 14 are used to fix the capacitor in the required position with bolts 16, completing the quick installation.

[0026] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A high-heat-dissipation thin-film capacitor for electric vehicles, comprising a housing (1), characterized in that: The housing (1) is provided with a buffer pad (2) inside. A core (3) is installed on the side of the buffer pad (2) away from the housing (1). A copper busbar one (4) is installed on the top of the core (3). A copper busbar two (5) is installed on the bottom of the core (3). A potting compound (8) is provided inside the housing (1). A heat dissipation assembly (10) is provided inside the housing (1). An insulating plate (12) is provided inside the housing (1). An installation assembly (13) is provided on the outside of the housing (1). A copper plate (9) is provided inside the housing (1). The heat dissipation assembly (10) includes a cooling metal plate (11), which is disposed at the bottom of the housing (1), and a heat dissipation channel (17) is provided on the outside of the core (3).

2. The high heat dissipation film capacitor for electric vehicles according to claim 1, characterized in that: The mounting assembly (13) includes a mounting block (14) with a bolt (16) fitted in the middle of the mounting block (14).

3. A high-heat-dissipation film capacitor for electric vehicles according to claim 1, characterized in that: The core (3) and the copper busbar (4) are respectively fixedly connected to lead-out electrode (6) and lead-out electrode (7) at the ends away from the core (3).

4. A high-heat-dissipation film capacitor for electric vehicles according to claim 3, characterized in that: Both the first lead-out electrode (6) and the second lead-out electrode (7) are located in the middle of the housing (1).

5. A high-heat-dissipation film capacitor for electric vehicles according to claim 1, characterized in that: Both the first copper busbar (4) and the second copper busbar (5) are connected to the core (3) through the copper plate (9).

6. A high-heat-dissipation film capacitor for electric vehicles according to claim 1, characterized in that: An insulating plate (12) is provided between the first copper busbar (4) and the second copper busbar (5).

7. A high-heat-dissipation film capacitor for electric vehicles according to claim 1, characterized in that: The cooling metal plate (11) is specifically made of composite aluminum plate to provide thermal conductivity and corrosion resistance. The copper plate (9) is specifically made of copper plate to provide high electrical conductivity.

8. A high-heat-dissipation film capacitor for electric vehicles according to claim 2, characterized in that: The mounting block (14) has a mounting hole (15) in the middle, and the mounting block (14) is located in the middle of the mounting hole (15).

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