A capacitor

Abstract

The present invention relates to a capacitor (1) which is included in a motor drive that enables the electric motor to be operated by converting the energy stored as DC in the vehicle battery into AC current.

Description

[0001] DESCRIPTION

[0002] A CAPACITOR

[0003] Technical Field

[0004] The present invention relates to a capacitor which is included in a motor drive that enables the electric motor to be operated by converting the energy stored as DC in the vehicle battery into AC current.

[0005] Background of the Invention

[0006] Energy is stored as DC in vehicle batteries; however, AC current is required for the electric motor to operate. Therefore, the energy stored in the battery needs to go through a cycle in order to drive the electric motor. A motor drive unit is used for the cycle. High-speed electronic load switching is performed inside the motor drive. In the absence of a capacitor between the motor and the battery, these currents will be drawn from the battery and therefore generate an intense electromagnetic noise. For this reason, today, there is a need for a DC link capacitor which is compatible with the mechanical design of the inverter in order for the high amplitude currents in the motor drive to be drawn from an intermediate component instead of the battery so as to avoid the said noise.

[0007] On the other hand, the capacitor needs cooling as it heats up during operation. Each company defines a cooling surface specific to their systems in order to provide cooling. The HV lines included in the capacitor, the unit cooling channel, the mechanical design of the unit should be taken into consideration during the creation of this surface and a thermal analysis should be performed according to the unit operating conditions. Furthermore, the most common method during capacitor production is to place capacitor elements and busbars in the mold and to apply epoxy filler over the large surface. In order for the capacitors produced by this method to have the desired flatness and tolerance of the epoxy filling surface, the production process must be in 2 stages, which adversely affects the production time and cost. Therefore, today, a method which will both enable the formation of a flat surface and will not adversely affect production time and cost is required.

[0008] The Turkish patent document no. TR2016 / 04596, an application included in the state of the art, discloses the use of capacitors as a primary source of electrical energy in vehicles. In the said invention, it is aimed to feed the electric motors, which are used to move the vehicle in electric and hybrid vehicles, with electrical energy stored in capacitors instead of electrical energy stored in batteries. In this way, vehicles are lightened and performance is increased, vehicle costs are reduced and the environment is protected. In the invention, the capacitors placed in the vehicle will be charged continuously and in an efficient charge / discharge cycle via the electrical circuits that will be applied to the vehicle and will be discharged upon operating the electric motors in the vehicle. It is aimed to use capacitors instead of heavy, expensive and dangerous batteries with up to one million charge / discharge cycles in the lifespan of the vehicle.

[0009] The International patent document no. WO2023031393, an application included in the state of the art, discloses an inverter arrangement for a vehicle. The problem addressed by the said invention is to provide an inverter arrangement for a vehicle with a particularly compact design. This problem is solved by an inverter arrangement for a vehicle, having a plurality of switch modules, each of the switch modules comprising at least one switching device, some of the switching devices being in the form of high- side switching devices and some of the switching devices being in the form of low-side switching devices, having a DC-link capacitor device and having at least one phase output, wherein the input side of the switching devices is connected to the DC-link capacitor device and the output side of said switching devices is connected to the at least one phase output, wherein the switch modules each have at least one module main side, the module main side being in the form of the side of the switch module having the largest surface area, wherein several of the switch modules are arranged in the inverter arrangement in series with parallel- oriented module main sides.

[0010] Summary of the Invention

[0011] An object of the present invention is to realize a capacitor wherein the instantaneous currents are drawn by instead of the battery and wherein the stray inductances occurring in the transistor and interconnections and the stray resistances occurring in the connection path are minimized via the busbar structure thereof.

[0012] Another object of the present invention is to realize a capacitor which has input busbars designed for minimum cost and optimum cooling, wherein one of the high voltage (HV-High voltage) busbars is not used as a cooling surface.

[0013] A further object of the present invention is to realize a capacitor wherein the process of filling the inner volume with epoxy material is not carried out on its large surface and wherein one of the high voltage (HV-High voltage) busbars does not protrude from the center of the epoxy material.

[0014] Detailed Description of the Invention

[0015] “A Capacitor” realized to fulfd the objectives of the present invention is shown in the figures attached, in which:

[0016] Figure 1 is a perspective view of an inventive capacitor.

[0017] Figure 2 is a view wherein the epoxy material filling surface of an inventive capacitor is shown.

[0018] The components illustrated in the figures are individually numbered, where the numbers refer to the following: 1. Capacitor

[0019] 2. Body

[0020] 3. Busbar

[0021] 31. First Lug

[0022] 32. Second Lugs

[0023] 33. Connection Hole

[0024] 4. Lug

[0025] 5. Epoxy Layer

[0026] 6. Tab

[0027] 7. Gap

[0028] An inventive capacitor (1) which enables the electric motor to be operated by converting the energy stored as DC in the vehicle batteries of electric vehicles into AC current and the stray inductors and stray resistances in the connection path to be minimized during operation comprises at least one body (2) which has a rectangular prism shape and has an internal volume wherein the capacitor elements are positioned; at least two busbars (3) which are located on the body (2) on any surface of the body (2) that is narrower than the other surfaces thereof and comprise a first lug (31) protruding outward from the body (2) when positioned on the body (2) and a plurality of second lugs (32) extending toward the body (2) and shorter than the first lug (31); at least one epoxy layer (5) which is formed by filling the epoxy material from the surface of the body (2) wherein the busbars (3) are located and is located on the surface of the body (2) wherein the busbars are located.

[0029] The body (2) included in the inventive capacitor (1) is in the shape of a rectangular prism and wherein the busbars (3) are located on one of its narrow surfaces and on which there are tabs used for connection to the motor driver with holes. The body

[0030] (2) comprises an epoxy layer (5) that is located on the surface wherein the busbars

[0031] (3) are present and that is obtained by filling an epoxy material inside. Due to the fact that the epoxy layer (5) is located on the narrower one of the body (2) surfaces enables the wider surfaces to be used more efficiently for cooling. The body (2) comprises a gap (7) on the narrow surface wherein only the epoxy is filled. In the body (2), both the epoxy material and the capacitor elements are placed in the inner volume through the said gap (7). (Figure 2)

[0032] The busbar (3) included in an inventive capacitor (1) comprises a first lug (31) and four second lugs (32) that are shorter than the first lug (31) facing in opposite directions with respect to each other for minimum cost and optimum cooling. When the busbar (3) is positioned on the body (2), the second lugs (32) extend towards one of the large surfaces of the body (2). And the first lug (31) extends upwards from the body (2). The busbar (3) is located on one of the narrow surfaces of the body (2) and does not exit from any of the large surfaces of the body. In this way, it is not needed to use one of the busbars (3) as a cooling surface.

[0033] The epoxy layer (5) included in an inventive capacitor (1) is located on the narrow surface of the body (2) wherein the busbars (3) are received. The epoxy layer (5) is formed by filling epoxy from the surface of the body (2) to the inside wherein the busbars (3) are present. The large surfaces can be used for cooling more efficiently due to the fact that the epoxy layer (5) is located on the narrow surface of the rectangular prism- shaped body (2).

[0034] Industrial Application of the Invention

[0035] The inventive capacitor (1) meets the instantaneous high current requirement between the electric motor and the battery in electric vehicles by being used in the motor drive. In this way, less electromagnetic noise is generated than in applications wherein the capacitor (1) is not used. On the other hand, the stray inductance that occurs in the interconnections and the transistor used and the stray resistances that occur in the connection path are minimized due to the busbar (3) structure. Within these basic concepts; it is possible to develop various embodiments of the inventive “A Capacitor (1)”; the invention cannot be limited to examples disclosed herein and it is essentially according to claims.

Claims

CLAIMS1. A capacitor (1) which enables the electric motor to be operated by converting the energy stored as DC in the vehicle batteries of electric vehicles into AC current and the stray inductors and stray resistances in the connection path to be minimized during operation; characterized by at least one body (2) which has a rectangular prism shape and has an internal volume wherein the capacitor elements are positioned; at least two busbars (3) which are located on the body (2) on any surface of the body (2) that is narrower than the other surfaces thereof and comprise a first lug (31) protruding outward from the body (2) when positioned on the body (2) and a plurality of second lugs (32) extending toward the body (2) and shorter than the first lug (31); at least one epoxy layer (5) which is formed by filling the epoxy material from the surface of the body (2) wherein the busbars (3) are located and is located on the surface of the body (2) wherein the busbars are located.

2. A capacitor (1) according to Claim 1; characterized by the body (2) which is in the shape of a rectangular prism and wherein the busbars (3) are located on one of its narrow surfaces and on which there are tabs used for connection to the motor driver with holes.

3. A capacitor (1) according to Claim 1 or 2; characterized by the body (2) which comprises an epoxy layer (5) that is located on the surface wherein the busbars (3) are present and that is obtained by filling an epoxy material inside.

4. A capacitor (1) according to any one of the preceding claims; characterized by the busbar (3) which comprises a first lug (31) and four second lugs (32) that are shorter than the first lug (31) facing in opposite directions with respect to each other for minimum cost and optimum cooling.

5. A capacitor ( 1 ) according to any one of the preceding claims ; characterized by the busbar (3) the second lugs (32) of which extend towards one of the large surfaces of the body (2) when it is positioned on the body (2).

6. A capacitor ( 1 ) according to any one of the preceding claims ; characterized by the first lug (31) which extends upwards from the body (2).

7. A capacitor ( 1 ) according to any one of the preceding claims ; characterized by the busbar (3) which is located on one of the narrow surfaces of the body (2) and does not exit from any of the large surfaces of the body (2).

8. A capacitor ( 1 ) according to any one of the preceding claims ; characterized by the body (2) which comprises a gap (7) on the narrow surface wherein only the epoxy is filled.

9. A capacitor ( 1 ) according to any one of the preceding claims ; characterized by the body (2) wherein both the epoxy material and the capacitor elements are placed in the inner volume through the gap (7).

10. A capacitor (1) according to any one of the preceding claims; which meets the instantaneous high current requirement between the electric motor and the battery in electric vehicles by being used in the motor drive.

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