DC link capacitor assembly and a cooling device used therefor

Abstract

The present utility model provides a DC link capacitor assembly for a power converter unit. The DC link capacitor assembly comprises an input capacitor, an output capacitor, a busbar channel, and a housing. The input capacitor and the output capacitor are housed in the busbar channel and electrically connected to the terminals on the busbar channel. The input capacitor, the output capacitor, and the busbar channel are housed and fixed together in the housing and form a stand-alone component with the housing. The stand-alone component can be mounted directly on the power converter unit and electrically connected to external components via the terminals on the busbar channel.The present utility model enables the DC link capacitors to withstand high currents and contributes to reducing the overall size of the PTU. The present utility model further provides a cooling device for the aforementioned DC link capacitor assembly, which can effectively solve the problem of the DC link capacitor's high heat generation.

Description

FIELD OF THE INVENTION

[0001] The present utility model relates to a power electronic device and a cooling system used for the same, in particular a DC link capacitor assembly and a cooling device used for the same. STATE OF THE ART

[0002] A power transformation unit (PTU) is a power electronic device in hydrogen vehicles that can convert low-voltage direct current to high-voltage direct current, or vice versa. After conversion, the current is fed through the PTU's interface to power other devices. Key components in the PTU are the DC link capacitors, which are capable of filtering the power supply ripple generated in the DC-DC converter.

[0003] The DC link capacitors consist of an input capacitor and an output capacitor. The input capacitor and output capacitor are typically soldered onto a printed circuit board (PCB) and have a low capacitance. Therefore, more capacitors are typically required to handle the same current, increasing the PCB size and, in turn, leading to larger PTU dimensions. This may not meet customer requirements.

[0004] In addition, the DC link capacitors generate large amounts of heat, which is why effective cooling is required to ensure their stable long-term operation.

[0005] Therefore, in this area, there is a need for DC link capacitors that can withstand higher currents and take up less space, and in this area, there is also a need for a cooling device that can cool the DC link capacitors efficiently. CONTENTS OF THE UTILITY MODEL

[0006] A technical problem that the present utility model is intended to solve is to provide a DC link capacitor assembly which, on the one hand, has a dimension that meets the requirements and, on the other hand, can supply a high current sufficient for the PTU.

[0007] To solve the aforementioned technical problem, the present utility model provides a DC link capacitor assembly for a power converter unit. The DC link capacitor assembly comprises an input capacitor, an output capacitor, a busbar channel, and a housing. The input capacitor and the output capacitor are housed in the busbar channel and electrically connected to the terminals on the busbar channel. The input capacitor, the output capacitor, and the busbar channel are jointly housed and fixed in the housing and form a stand-alone component with the housing. The stand-alone component can be mounted directly on the power converter unit and is electrically connected to external components via the terminals on the busbar channel.

[0008] According to an advantageous embodiment of the present utility model, the busbar channel in which the input capacitor and the output capacitor are accommodated is glued or snapped onto the housing.

[0009] According to an advantageous embodiment of the present utility model, the busbar channel in which the input capacitor and the output capacitor are accommodated is glued to the housing by means of heat-dissipating adhesive.

[0010] According to an advantageous embodiment of the present utility model, the housing consists of metallic or non-metallic heat dissipating material or of plastic.

[0011] According to an advantageous embodiment of the present utility model, the housing is provided with a connecting structure for mounting the stand-alone component to the power converter unit, wherein the connecting structure is an eyelet with a bore, and the bore serves to receive a screw for fastening the stand-alone component to the power converter unit by means of a threaded connection.

[0012] Another technical problem to be solved by the present utility model is to provide a highly efficient cooling device for the DC link capacitors used in high-voltage products in order to ensure proper operation of the DC link capacitors.

[0013] To solve the aforementioned technical problem, the present utility model further provides a cooling device for the DC link capacitor assembly. The cooling device comprises at least one upper cooler mounted from above next to the busbar channel of the DC link capacitor assembly, and a lower cooler mounted from below next to the housing of the DC link capacitor assembly.

[0014] According to an advantageous embodiment of the present utility model, the upper cooler and the lower cooler are flat liquid coolers.

[0015] According to an advantageous embodiment of the present utility model, the upper cooler has an opening through which the terminals of the busbar channel are exposed, wherein the size and position of the opening are designed such that all terminals of the busbar channel are exposed.

[0016] According to an advantageous embodiment of the present utility model, the lower cooler is the housing cooler of the power converter unit.

[0017] According to an advantageous embodiment of the present utility model, when the cooling device comprises both an upper cooler and a housing cooler, the upper cooler is mounted on the housing cooler and is in fluid communication with the housing cooler so that coolant can flow through the upper cooler and the housing cooler simultaneously and dissipate heat.

[0018] The technical solution provided in this utility model integrates the input capacitor and the output capacitor into a single housing, allowing the DC link capacitor assembly to withstand high current and contributing to a reduction in the overall size of the PTU. Furthermore, the use of a cooling device, particularly the dual-cooler design, also solves the problem of the high heat generation of the DC link capacitor. DESCRIPTION OF THE CHARACTERS

[0019] To enable those skilled in the art to gain a more comprehensive understanding of the present utility model, the specific embodiments of the present utility model are described in detail below with reference to the figures. Where: Fig. 1 shows a plan view of the DC link capacitor assembly of the present utility model; Fig. 2 shows a perspective exploded view of the Fig. 1 shown DC link capacitor assembly; Fig. 3 shows an exploded perspective view of the cooling device for the DC link capacitor assembly of the present utility model; and Fig. 4 shows a perspective assembly view of the Fig. 3 shown cooling device. Explanation of the reference symbols of the figures: 1 DC link capacitor assembly 11 Input capacitor 12 Output capacitor 13 Busbar duct 131 terminal 14 housings 141 Connection structure 2 cooling device 21 Upper radiator 211 Opening 22 Lower radiator. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0020] In order to illustrate the present utility model more clearly, a concrete embodiment is described in detail below with reference to the figures, although the present utility model is not limited to the embodiment described below.

[0021] It should be noted that the terms used in this document for directional indications such as "top", "bottom", "upper part" and "lower part" are only intended to describe the structure of the product with regard to the figures, whereby the directions indicated only reflect the orientation shown in the figures for "top and bottom" and "upper part or lower part" and do not represent the actual orientation of use of the product.

[0022] According to one aspect of the present utility model, a DC link capacitor assembly 1 is provided. The DC link capacitor assembly 1 is used in the power converter unit (PTU) in new energy vehicles and serves to filter the power supply ripple generated in the DC-DC converter to provide a stable voltage for the following associated components.

[0023] Fig. 1 to 2 show the DC link capacitor assembly 1, where Fig. 1 a plan view of the DC link capacitor assembly 1 and Fig. 2 is an exploded perspective view of the DC link capacitor assembly 1.

[0024] As in Fig. 1 to 2, the DC link capacitor assembly 1 of the present utility model comprises an input capacitor 11, an output capacitor 12, a bus bar 13, and a housing 14. The input capacitor 11 and the output capacitor 12 are both received in the bus bar 13 and electrically connected thereto. The electrical connection is established by electrically connecting the positive and negative poles of the capacitors to the positive and negative terminals of the bus bar 13, respectively. The connection between the capacitors and the bus bar 13 can be established by wires, solder joints, or special connectors. The input capacitor 11, the output capacitor 12, and the bus bar 13 are received and fixed together in the housing 14 and form an independent component with the housing 14.The stand-alone component is connected to external components via terminals 131 of busbar channel 13. The stand-alone component can be mounted directly to the PTU housing as a whole. By using the DC link capacitor assembly of the present utility model, the area of ​​the capacitors can be reduced and the layout of the PTU can be simplified.

[0025] Preferably, the busbar channel 13, in which the input capacitor 11 and the output capacitor 12 are accommodated, is secured in the housing 14, for example, by gluing it to the housing 14 with adhesive, thereby forming a unit with the housing 14. Optionally, the adhesive can be a heat-dissipating adhesive.

[0026] Any other suitable connection method is also possible. For example, the busbar channel 13, which houses the input capacitor 11 and the output capacitor 12, can be secured in the housing 14 by snap-in connections. In this case, a snap-in connection for the busbar channel 13 can be provided on the bottom or side of the housing 14, or the internal dimensions of the housing 14 can be slightly smaller than the external dimensions of the busbar channel 13, so that the two are connected by press fitting. There are no restrictions on the material of the housing 14. For example, the housing 14 can be made of plastic. However, it is advantageous if the housing 14 is made of a rigid material with good heat dissipation properties. For example, any metallic or non-metallic heat dissipating material is suitable.For example, the housing 14 can be made of materials such as copper, aluminum, silver, graphite, graphene, silicon carbide, diamond, or ceramic. According to an advantageous embodiment, the housing 14 can be made of aluminum. In the case of high current or high heat generation, it may be considered to provide recesses in the housing to assist heat dissipation. Heat-dissipating adhesive can also be used to assist heat dissipation. The aforementioned embodiments can be used individually or in combination.

[0027] Preferably, a connecting structure 21 is provided on the housing 14 in order to mount the DC link capacitor assembly 1 to the PTU housing or to mount other components, such as a cooling device, to the DC link capacitor assembly 1. In the illustrated embodiment, the connecting structure 141 is shown as an eyelet with a bore, wherein a screw, a pin or a bolt can be passed through the bore in order to fasten the DC link capacitor assembly 1 to an associated component, for example to the PTU housing, such as Fig. 3 to 4 shows.

[0028] Preferably, a cooling device can be installed on the DC link capacitor assembly 1. For example, coolers can be mounted above and / or below the DC link capacitor assembly 1. The coolers are arranged so that they are adjacent either to the busbar channel from above or to the housing 14 from below, so that the coolers are in close contact with the DC link capacitor assembly 1, which promotes heat transfer and thus improves the cooling effect. Preferably, the cooler can be fixed to the connecting structure 141 of the housing 14. As shown in Fig. 3, an upper cooler 21 can be arranged above the DC link capacitor assembly 1.

[0029] According to this aspect of the present utility model, the input capacitor, the output capacitor, and the busbar channel are housed in a single housing, forming a self-contained component that can reduce the area of ​​the capacitors. Furthermore, the self-contained component can be directly mounted in the PTU housing, simplifying the PTU layout, resulting in a more compact PTU structure and a reduction in overall size. The DC link capacitor assembly of the present utility model makes it possible to successfully implement the capacitor function with a smaller PTU. Furthermore, since the DC link capacitors are integrated into a self-contained component, high-capacity input and output capacitors can be used, making the DC link capacitor assembly capable of withstanding larger currents.

[0030] Typically, DC link capacitors generate a large amount of heat during operation, so effective heat dissipation is required to ensure long-term stable operation of the DC link capacitors. Therefore, the present utility model also provides a cooling device for the DC link capacitor assembly, which helps the capacitors efficiently dissipate heat to ensure their proper operation.

[0031] The cooling device 2 used for heat dissipation can be arranged around the capacitors, for example, above, below, or all around the capacitors. The cooling device 2 used for heat dissipation can form a unit with the input capacitor 11 and the output capacitor 12. For example, cooling fins can be arranged on the capacitors. The cooling device can also be a separate device located above, below, or on the side of the DC link capacitor assembly 1. The separate cooling device can be an air cooling device or a liquid cooling device. The separate cooling device can be a heat pipe system in which air or coolant flows through the heat pipe to dissipate heat. Of course, the cooling device for heat dissipation described above can also be arranged in combination.

[0032] In the following, with reference to Fig. 3 to 4, an embodiment of the cooling device 2 for the DC link capacitor assembly 1 of the present utility model is described in detail. Fig. 3 shows a perspective exploded view of the cooling device 2, and Fig. 4 shows an assembly view of the cooling device 2 from Fig. 3.

[0033] The cooling device 2 for the DC link capacitor assembly 1 of the present utility model comprises the upper cooler 21 and / or the lower cooler 22. In other words, the cooling device 2 may comprise either only the upper cooler 21, only the lower cooler 22, or both the upper cooler 21 and the lower cooler 22.

[0034] According to one embodiment, the cooling device 2 may comprise only the upper cooler 21. The upper cooler 21 may be mounted on the DC link capacitor assembly 1 by snapping, threading, gluing, or other methods. For example, the upper cooler 21 may be mounted on the eyelet 141 of the housing 2 via a projection structure. As shown in Fig. 3, the upper cooler 21 is located above the DC link capacitor assembly 1 and is adjacent to the busbar channel 13 of the DC link capacitor assembly 1 from above, with both being in close contact to improve the cooling effect.

[0035] Preferably, the upper cooler 21 is provided with openings 211 at suitable locations so that the terminals 131 of the busbar channel 13 are exposed, allowing the DC link capacitor assembly 1 to be connected to external components via its terminals 131. In the illustrated embodiment, an opening 211 is provided in the center of the upper cooler 21 along the longitudinal direction to expose all terminals 131 of the busbar channel 13. The length and width of the opening 211 are dimensioned to precisely accommodate and expose all terminals 131 of the busbar channel 13.

[0036] The upper cooler 21 can be designed in any desired shape. According to an advantageous embodiment, the upper cooler 21 is a separate, flat cooling device that can dissipate the heat from the DC link capacitor assembly 1 by circulating coolant. Preferably, the surface of the upper cooler 21 is dimensioned such that it largely covers the top of the DC link capacitor assembly 1. The upper cooler 21 can preferably have a protrusion structure on its edges to facilitate attachment to the PTU housing or other components.

[0037] According to a further embodiment, the cooling device 2 for the DC link capacitor assembly 1 may comprise only the lower cooler 22. The lower cooler 22 is arranged below the DC link capacitor assembly 1 and adjoins the housing 14 in order to dissipate the heat of the capacitors from below. The construction of the lower cooler 22 may be substantially the same as that of the upper cooler 21, but the opening may be omitted. The lower cooler 22 may be a separate cooling device. The lower cooler 22 may be mounted to the housing 14 by snapping, threading, gluing, or other methods. In the Fig. In the embodiment shown in Figures 3 to 4, the lower cooler 22 is attached with screws to the housing 14 of the DC link capacitor assembly 1. Advantageously, the lower cooler 22 can be the housing cooler of the PTU.

[0038] Preferably, the cooling device 2 for the DC link capacitor assembly 1 comprises both the upper cooler 21 and the lower cooler 22. The upper cooler 21 and the lower cooler 22 can be connected to each other so that the DC link capacitor assembly 1 is clamped between them. According to an advantageous embodiment, the lower cooler 22 can be the housing cooler of the PTU. If the housing cooler is configured as a liquid cooling device, the upper cooler 21 can also be designed as a liquid cooling device to connect the liquids of the upper cooler 21 and the housing cooler, and the coolant can circulate in both coolers, thereby cooling the DC link capacitor assembly 1 simultaneously from above and below.This allows the bottom of the DC link capacitor assembly to contact the surface of the chassis cooler. The upper cooler is then mounted on the PTU chassis, allowing the upper cooler to communicate with the chassis cooler, allowing cooling water to flow through both coolers to dissipate heat. The dual cooler structure more effectively solves the problem of excessive heat generation. This allows the DC link capacitor assembly to be used in high-voltage products (for example, in the PTU) or other high-power devices with DC link capacitors.

[0039] In summary, the design innovation of the present utility model lies in the integration of the input capacitor and the output capacitor into a single housing, which allows the DC link capacitors to withstand high currents and contributes to reducing the overall size of the PTU. Furthermore, the cooling device of the present utility model uses an upper and lower dual cooler structure, which can effectively solve the problem of high heat generation. This allows the DC link capacitor assembly to be used in high-voltage products or high-power devices.

[0040] The specific embodiments mentioned serve only to illustrate the present utility model, but do not constitute a limitation of the present utility model. Those skilled in the art may make various modifications and variations without departing from the inventive concept of the present utility model, so that all equivalent technical solutions fall within the scope of protection of the present utility model, wherein the scope of protection of the present utility model is defined by the patent claims.

Claims

[1] DC link capacitor assembly (1) for a power converter unit, characterized by that the DC link capacitor assembly (1) comprises an input capacitor (11), an output capacitor (12), a busbar channel (13) and a housing (14), wherein: The input capacitor (11) and the output capacitor (12) are accommodated in the busbar channel (13) and electrically connected to the terminals on the busbar channel (13); and The input capacitor (11), the output capacitor (12) and the busbar channel (13) are housed together in the housing (14) and fixed and form an independent component with the housing (14), wherein the independent component can be mounted directly on the power converter unit and electrically connected to external components using the terminals on the busbar channel (13). [2] DC intermediate circuit capacitor assembly (1) according to claim 1, characterized by that the busbar channel (13), in which the input capacitor (11) and the output capacitor (12) are accommodated, is glued or snapped onto the housing (14). [3] DC intermediate circuit capacitor assembly (1) according to claim 2, characterized by that the busbar channel (13), in which the input capacitor (11) and the output capacitor (12) are accommodated, is glued to the housing (14) with heat dissipating adhesive. [4] DC intermediate circuit capacitor assembly (1) according to claim 1, characterized by that the housing (14) is made of metallic or non-metallic heat dissipating material or of plastic. [5] DC intermediate circuit capacitor assembly (1) according to one of claims 1 to 4, characterized byin that the housing (14) has a connecting structure (141) which serves to mount the stand-alone component to the power converter unit, wherein the connecting structure (141) is an eyelet with a bore and the bore serves to receive a screw in order to fasten the stand-alone component to the power converter unit with a threaded connection. [6] Cooling device (2) for a DC intermediate circuit capacitor assembly (1) according to one of claims 1 to 5, characterized by that the cooling device (2) comprises at least one upper cooler (21) which is mounted from above next to the busbar channel (13) of the DC link capacitor assembly (1) and a lower cooler (22) which is mounted from below next to the housing (14) of the DC link capacitor assembly (1). [7] Cooling device (2) according to claim 6, characterized bythat the upper cooler (21) and the lower cooler (22) are flat liquid coolers. [8] Cooling device (2) according to claim 6 or 7, characterized by that the upper cooler (21) has an opening (211) which exposes the terminals of the busbar channel (13), the size and position of the opening (211) being designed such that all terminals of the busbar channel (13) are exposed. [9] Cooling device (2) according to claim 6, characterized by that the lower cooler (22) is the housing cooler of the power converter unit. [10] Cooling device (2) according to claim 9, characterized by that, when the cooling device (2) comprises both an upper cooler (21) and a housing cooler, the upper cooler (21) is mounted on the housing cooler and there is a connection of the fluids with the housing cooler so that coolant can flow through the upper cooler (21) and the housing cooler at the same time and dissipate heat.

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