INTEGRATED POWER TRANSFER UNIT

Abstract

The present utility model provides an integrated power transfer unit (PTU). The PTU comprises the following: a capacitor unit having at least two capacitor terminals arranged within a single plane, thereby forming a capacitor terminal plane, each of these capacitor terminals being configured to be electrically connected to a core of the capacitor unit; a power module unit (PM unit) comprising an even number of PMs, the PMs comprising a first module group and a second module group, each arranged on a first side and an opposite second side of the capacitor terminal plane, respectively. The shortest current paths from the electrical interfaces of the first module group and the second module group of the PM units to their respective associated capacitor terminals are of equal length.The integrated PTU of the present utility model enables the current paths from the capacitor terminals of the capacitor unit to the electrical interfaces of the PM unit within the PTU to be essentially the same length and as short as possible. This allows the current from the PM unit to flow evenly through the capacitor terminals into the individual cores of the capacitor unit.

Description

AREA OF INVENTION

[0001] The present utility model relates to a power transfer unit (PTU), in particular an integrated power transfer unit. STATE OF THE ART

[0002] The power consumption unit (PTU) used in conventional circuits inevitably generates a ripple current. This ripple current significantly affects the stability and reliability of electronic devices and circuits. Excessive ripple current can lead to losses in the capacitor, potentially resulting in overheating, damage, or even failure.

[0003] A typical PTU comprises a capacitor unit for absorbing ripple currents and a power module unit (PM unit) for powering the capacitor unit, with these being electrically interconnected via input and output buses made of metals with good conductivity, such as copper or aluminum.

[0004] In a typical PTU product, the capacitor unit's inductance is usually high, which impedes the flow of ripple current into the capacitor unit, thus impairing ripple current elimination. Furthermore, in a typical PTU product, the individual cores of the capacitor unit have varying degrees of loss, resulting in an uneven loss distribution and leading to higher hotspot temperatures within the core. This is a significant problem that the industry is currently working to resolve. CONTENTS OF THE INSTRUCTION MANUAL

[0005] To remedy or overcome at least one of the aforementioned defects / problems, this utility model provides an integrated power transfer unit. The integrated power transfer unit comprises the following: a capacitor unit provided with at least two capacitor terminals arranged within a single plane, thereby forming a capacitor terminal plane, wherein the at least two capacitor terminals are each configured to be electrically connected to a core of the capacitor unit; a power module unit comprising an even number of power modules, each configured to be electrically connected to the capacitor unit to supply it with power, wherein the even number of power modules comprises a first module group and a second module group, each located on a first side and a second side, respectively.are arranged on a second, opposite side of the capacitor connection plane. The shortest current paths from the electrical interfaces of the first and second module groups of the power module unit to the respective associated capacitor terminals of the at least two capacitor connections are of equal length.

[0006] According to one embodiment of the present utility model, the first module group and the second module group are configured to be arranged in a mirror-symmetrical manner with respect to the capacitor connection plane.

[0007] According to another embodiment of the present utility model, the integrated power transfer unit comprises an external input bus (131) and an external output bus (132), each connected to the capacitor unit, wherein the external input bus and the external output bus are arranged one above the other and electrically isolated from each other and are each mirror-symmetrical with respect to their own center line, wherein the external input bus and the external output bus are configured such that their own center lines are located within the capacitor connection plane.

[0008] According to a further embodiment of the present utility model, the external input bus and the external output bus are arranged one above the other below the power module unit.

[0009] Furthermore, it is provided that the first module group is electrically connected to the external input bus and the external output bus via several conductive elements on the first side, while the second module group is electrically connected to the external input bus and the external output bus via several conductive elements on the second side.

[0010] Furthermore, it is provided that the current path includes an input current path and an output current path, wherein the input current path and the output current path are of equal length between each of the power modules and the associated capacitor terminal.

[0011] It is further provided that the capacitor unit comprises an internal input bus and an internal output bus, each connected to the core, each of the internal input bus and the internal output bus comprising: a first extension section and a second extension section, which are separate from each other, wherein the first extension section and the second extension section are arranged coplanarly and each are in electrical contact with the associated core of the cores; and a bridging section configured to connect the first extension section to the second extension section and to form a recess with respect to an extension plane in which the first and second extension sections are located, the recess being configured to accommodate and be electrically coupled to the capacitor terminal of the capacitor unit.

[0012] Furthermore, it is provided that the bridging section is designed as several discrete strips that are arranged parallel to each other and extend in the same direction as the first and second extension sections.

[0013] Furthermore, it is provided that the discrete strips of the bridging section of the internal input bus and the discrete strips of the bridging section of the internal output bus are arranged parallel to each other, offset perpendicular to the capacitor terminal plane. The sum of the height of the bridging section of the internal output bus and the thickness of the core within the capacitor unit is not equal to the height of the bridging section of the internal input bus.

[0014] Furthermore, it is provided that each of the internal input bus and the internal output bus is designed to be mirror-symmetrical to its own center line.

[0015] Optionally, the following applies to both the internal input bus and the internal output bus: the width of the first extension section differs from the width of the second extension section; and / or the width of the first extension section and the width of the second extension section are not constant along a direction away from the bridging section; and / or the width of the bridging section is greater than the width of the first and / or the second extension section.

[0016] According to a further embodiment of the present utility model, it is provided that the capacitor connection plane runs parallel to the longitudinal axis or short axis of the core of the capacitor unit; and / or that the first module group and the second module group each comprise at least one of the even number of power modules.

[0017] According to a further embodiment of the present utility model, the integrated power transmission unit comprises a housing in which the capacitor unit and the power module unit are encapsulated.

[0018] The integrated power distribution unit (PTU) of the present utility model enables the current paths from the capacitor terminals of the capacitor unit to the electrical interfaces of the PM unit within the PTU to be essentially the same length and as short as possible. This allows the current from the PM unit to flow evenly through the capacitor terminals into the individual cores of the capacitor unit, reducing inductance and resolving problems associated with heat and loss concentration in the cores. This extends the service life of the capacitor unit and achieves uniform absorption of ripple currents. DESCRIPTION OF THE FIGURES

[0019] In the figures, identical or similar reference numerals represent identical or similar components. The figures serve only as examples and are not intended to limit the scope of this utility model. The following applies in the figures: Fig. Figure 1 is a spatial view from below of a PTU according to the state of the art. Fig. 2 is a view from below of the PTU Fig. 1. Fig. Figure 3 is an exploded partial view from below of the PTU. Fig. 1. Fig. Figure 4 is a spatial view from below of a PUT according to an embodiment of the present utility model. Fig. 5 is a view from below of the PTU Fig. 4. Fig. Figure 6 is an exploded partial view from below of the PTU. Fig. 4. Fig. Figure 7 is an exploded spatial view from below of an internal input bus and an internal output bus of a capacitor bank located in the PTU. Fig. 4 is used. Fig. Figure 8 is a spatial magnification view from below of the internal input bus. Fig. 7. Fig. Figure 9 is a view from below of a PTU according to another embodiment of the present utility model. DETAILED DESCRIPTION OF THE EXECUTION FORMS

[0020] The following describes the functionality and specific structure of the present utility model with reference to the attached drawings.

[0021] Fig. Figures 1 to 3 each show a state-of-the-art integrated PTU in a spatial view from below, a view from below, and an exploded partial view from below, respectively. As in Fig. As shown in Figure 3, the PTU 80 according to the prior art comprises a housing 81, a capacitor unit 82, and a power module unit (PM unit) 83. The capacitor unit 82 is mounted inside the housing 81, with the PM unit 83 being arranged on a side of the capacitor unit 82 facing away from the housing 81 and electrically connected to it to supply power to the capacitor unit 82. The PM unit 83 comprises several PM 830s, each of which is connected via several conductive elements (for example, copper or aluminum tabs) 8301 to the external input bus 831, which is located outside the capacitor unit 82.The currents from the PM 830 are then collected from the external input bus 831 at a capacitor input terminal 820 of the capacitor unit 82 and subsequently flow through the associated core of the capacitor unit 82 and through a capacitor output terminal 821 into an external output bus 832 of the PM unit 83, which is located outside the capacitor unit 82. These currents then flow back to the PM 830 via conductive elements 8302, thus forming a complete current loop within the PTU.

[0022] Since the improvements of this utility model are not substantially related to the internal structure of the PM 830 itself, the detailed internal structure of the PM 830 is not shown in the figures. Furthermore, descriptions of design details that are not involved in the improvements or have only undergone minor modifications are omitted in this utility model. For relevant details, reference is made to the PTU commonly used in the prior art, which is why it will not be discussed further here.

[0023] As in Fig. As shown in Figures 1 to 3, the capacitor input terminal 820 and the capacitor output terminal 821 of the capacitor unit 82 are typically arranged in a straight line (i.e., in a column) and offset on one side of the capacitor unit 82. This results in the external input bus 831 and the external output bus 832 of the PM unit 83, which are used to transfer current between the PM 830 and the capacitor unit 82, having a larger dimension in at least one direction. That is, the distance between the PM 830 and the capacitor terminals (including the capacitor input terminal 820 and the capacitor output terminal 821), i.e., the path traveled by the current, is relatively large. This leads to a higher inductance of the PTU, which significantly impairs the flow of the ripple current into the PTU 80.

[0024] As from Fig. As is most clearly evident in Figure 2, the external input bus 831, taking into account the specific arrangement of the PTU 80, is essentially H-shaped, having one end A1 and one end A2 for connection to the capacitor input terminal 820. This configuration of the external input bus 831 results in a current from the PM 830 (as indicated by the arrow in Figure 2) being able to flow through the PTU 80. Fig. (2 shown) travels unequal distances to the ends A1 and A2. Particularly at high frequencies, this results in the current reaching the more distant end A2 being smaller than the current reaching the closer end A1. This, in turn, leads to an uneven distribution of the currents flowing into the capacitor unit 820 via the various capacitor input terminals, ultimately resulting in an uneven distribution of the currents flowing into the individual cores of the capacitor unit 82. This uneven current distribution leads to a higher equivalent series resistance (ESR) of the capacitor unit, which is the root cause of problems related to heat and loss concentration in the cores of the capacitor unit.

[0025] To solve the aforementioned problem of uneven current distribution, the integrated PTU according to the present utility model has an improved arrangement of the capacitor terminals.

[0026] Fig. Figures 4 and 5 each show a spatial view from below and a view from below, respectively, of a PTU according to an embodiment of the present utility model. As in Fig. 4 and Fig. As shown in Figure 5, the PTU 10 according to the present utility model comprises a housing 11, a capacitor unit 12 and a PM unit 13. This is most clearly evident from Fig. 6 can be seen. The housing 11 has a similar structure to the housing 81 of the PTU 80 according to the state of the art and also serves to accommodate the capacitor unit and the PM unit.

[0027] As in Fig. 4 and Fig. As shown in Figure 5, the capacitor input terminal 120 and the capacitor output terminal 121 of the capacitor unit 12 of the PTU 10, according to the present utility model, are arranged in a straight line (in a column) directly below and approximately in the center of the PM unit 13, as viewed from above, thus forming a capacitor terminal column. Hereinafter, the plane in which the capacitor terminal column is located is referred to as the capacitor terminal plane. Furthermore, the capacitor input terminal 120 and the capacitor output terminal 121 are arranged alternately to ensure an even distribution of the (in Fig. 5 (shown by arrows) to promote the current between the individual capacitor terminals. In other words, the PM unit 13 comprises an even number of PM 130 (in Fig. 4 to 5 (shown as two), which are arranged in a mirror-symmetrical manner to the capacitor terminal plane, contributing to a uniform distribution of the currents flowing from the individual PM 130 into the capacitor input terminal 120 of the capacitor unit 12.

[0028] Fig. Figure 6 shows an exploded partial view from below of the PTU. Fig. 4. As in Fig. As shown in Figure 6, the capacitor unit 12 is divided into two parts: the capacitor core and the input / output buses.

[0029] Apart from a modified arrangement of the capacitor terminals, the capacitor core has a structure that is essentially identical to that of capacitor cores according to the prior art and is known to experts in the field, which is why it will not be discussed in more detail here.

[0030] Although the capacitor unit 12 shown here comprises two capacitor groups (i.e., an upper capacitor group and a lower capacitor group, the directional indications referring to the respective figures), the present utility model is not limited thereto. Rather, it is provided that at least one capacitor group may be located in a capacitor unit of a PTU. Although only one capacitor group (i.e., the lower capacitor group) is distinct from the capacitor groups of the in Fig. The present utility model does not limit the use of the improved input and output buses in the capacitor unit 12 shown in Figure 6 to that unit. Rather, it is provided that each capacitor group of the capacitor unit can use the improved input and output buses according to the present utility model.

[0031] Fig. Figure 7 shows an exploded spatial view from below of an internal input bus and an internal output bus of a (lower) capacitor group located in the PTU. Fig. 4 is used. Fig. Figure 8 shows a spatial magnification view from below of the internal input bus. Fig. 7.

[0032] In contrast to the internal input and output buses used in the capacitor unit 82 according to the prior art, the internal input and output buses used in the capacitor unit 12 of the PTU according to the present utility model have a simpler structure. The following description is given using the internal output bus 122 as an example.

[0033] As in Fig. As shown in Figure 7, the internal output bus 122 comprises two extension sections 122A and 122B and a bridging section 122C, wherein the bridging section 122C connects the extension sections 122A and 122B such that the extension sections 122A and 122B are essentially coplanar and extend away from each other. The bridging section 122C is configured to form a recess with respect to an extension plane in which the extension sections 122A and 122B are located, the recess being configured to accommodate and be electrically coupled to the capacitor terminal of the capacitor unit 12. The height H of the bridging section 122C (i.e., the maximum depth of the bottom wall of the recess with respect to the extension plane in which the extension sections are located) can be selected depending on the application.The two extension sections 122A and 122B are configured to be mirror images of the bridging section 122C and are each in electrical contact with the output side of the core of the capacitor unit 12. Although the extension sections 122A and 122B and the bridging section 122C are in . Fig. Although the components shown in Figure 7 are depicted as a single, one-piece component, the present utility model is not limited to this. Rather, these components can initially be separated from one another and then joined together.

[0034] In one example, the bridging section 123C is configured as several discrete strips extending in the same direction as the extension sections 122A, 122B, with these several discrete strips arranged substantially parallel to each other with a gap between them. Each of these gaps is configured to interact with the associated configuration of the associated bridging section 123C of the internal input bus 123. The discrete strips are each configured to interact with the associated capacitor input terminal 120. Therefore, the number of discrete strips is preferably the same as the number of capacitor input terminals 120. Fig. Figure 7 shows an example of a bridging section 122C with two discrete strips. However, the present utility model is not limited to this. Fig. 8 shows the external output bus Fig. 7 from a different perspective to better understand its structure.

[0035] Although the specific structures of extension sections 122A and 122B in Fig. The present utility model is not limited to the representations shown in Figure 7. Rather, it is intended that these can be adapted according to the specific structure of the core of the capacitor unit 12, provided that electrical coupling between them can be achieved. Depending on the specific arrangement of the core of the capacitor unit, the extension sections 122A and 122B can be configured such that they are not coplanar and extend parallel to each other in opposite directions. Alternatively, they can be non-planar, or they can be positioned at an angle other than 180° to each other. Although the side wall of the recess of the bridging section 122C is shown perpendicular to the plane of extension in which the extension sections are located, the present utility model is not limited to this.For example, the side wall can be configured as needed to be positioned at an acute angle or curved relative to the plane of extension.

[0036] The internal input bus 123 and the internal output bus 122 from Fig. The 7 components have similar structures. The only difference is that the sum of the height of the bridging section 122C of the internal output bus 122 and the thickness of the core of the capacitor unit 12 (i.e., the size of the core between the input and output buses) is not equal to the height of the bridging section 123C of the internal output bus 123. In other words, the bottom walls of the recesses of the bridging sections 122C and 123C are arranged parallel to each other, perpendicular to the capacitor terminal plane, after the internal output bus 122 and the internal input bus 123 have been placed on either side of the core of the capacitor unit 12. The plane in which the bottom wall of the recess of the bridging section 122C is located is not coplanar with the plane in which the bottom wall of the recess of the bridging section 123C is located (i.e., there is a height difference relative to the plane of extension).This arrangement contributes to an even distribution of the current between the individual capacitor terminals and thus to an electrical connection between the PM unit 13 and the capacitor unit 12.

[0037] As in Fig. As shown in Figure 6, the PM unit 13 comprises an external input bus 131 and an external output bus 132. The external input bus 131 is configured to receive current from the PM 130 and direct it to the capacitor input terminal 120 of the capacitor unit 12, while the external output bus 132 is configured to receive current from the individual capacitor output terminals 121 of the capacitor unit 12 and direct it back to the PM 130. Preferably, but not exclusively, each of the external input bus 131 and the external output bus 132 is mirror-symmetrical about its own centerline (not shown), with its own centerline being located within the capacitor terminal plane during assembly.

[0038] Fig. Figure 9 shows a bottom view of a PTU according to another embodiment of the present utility model. The difference to the PTU from Fig. 5 lies mainly in the orientation of the capacitor connection plane. In the exemplary embodiment according to Fig. 5 the capacitor connection plane runs parallel to the longitudinal axis of the elliptical core of the capacitor unit 12 (i.e. the one in Fig. 5 (xx direction shown). In contrast, the capacitor connection plane in the exemplary embodiment runs according to Fig. 9 parallel to the short axis of the elliptical nucleus (i.e., the one in Fig. 9 (yy direction shown). This results in the extension sections of the internal input and output buses of the capacitor unit having different extension directions (perpendicular to the capacitor connection plane) in the two embodiments. In the Fig. In the embodiment shown in Figure 9, the width of the bridging section of the internal input or output bus (i.e., the size along the yy direction) differs from the width of the extension section (i.e., larger or smaller than this), with the width of the extension section being able to vary along the direction away from the bridging section.

[0039] Furthermore, it shows Fig. 9. By way of example, the upper and lower capacitor groups, both of which use the improved internal input and output buses according to the present utility model. In actual use, the two capacitor groups can operate independently of each other.

[0040] Although several embodiments of the present utility model have been described with reference to the accompanying figures, it is clear to those skilled in the art that various modifications are possible within the scope limited by the attached claims. For example, although the PMs in the figures are shown as mirror-symmetrical to the connection plane of the capacitor cabinet, this is not strictly necessary. If, for example, two PMs are mounted on either side of the capacitor connection plane, the two PMs need not be arranged symmetrically to this plane. It is sufficient if the distances from the electrical interfaces to the respective associated capacitor terminals (i.e., the current paths) are of equal length. The foregoing embodiments do not constitute a limitation of the scope of the present utility model but serve as examples to illustrate it.Features or elements described in one embodiment also apply to another embodiment, provided they do not conflict with existing features or elements of that embodiment.

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