Low-Inductance Capacitor Assembly for High-Power Switching
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Solution Overview
Problem
Conventional capacitors in high-power switching circuits are bulky, leading to large packaging envelopes, which is undesirable in aerospace applications where minimizing size, weight, and drag is crucial, while also requiring improved control of switching speeds and pulse rise times.
Innovation Solution
A low-inductance capacitor assembly comprising a positive and negative terminal plate with an array of capacitors disposed between them, where the capacitors are electrically coupled and mechanically secured, and optionally positioned within a non-conductive matrix with sockets, allowing for flexible packaging and reduced inductance through the use of conductive epoxy for electrical coupling and mechanical connectors for structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional capacitors are used in high-power switching circuits, then the circuit can achieve required capacitance, but the packaging envelope becomes large and bulky
Solution Approach 1:
The capacitor assembly is segmented into multiple individual capacitors arranged in an array between terminal plates. This segmentation allows the total capacitance to be distributed across multiple smaller units, achieving the required electrical capacity while reducing the overall packaging volume compared to a single conventional capacitor of equivalent capacitance.
Solution Approach 2:
The invention transitions from a single-volume capacitor design to a multi-dimensional array configuration. Multiple capacitors are arranged in spatial arrays between parallel terminal plates, utilizing three-dimensional space efficiently. This dimensional arrangement achieves high capacitance in a compact envelope by distributing capacitive elements across multiple positions rather than concentrating them in a single bulky unit.
2Speed
If conventional capacitors are used, then the circuit can operate, but the inductance is high which affects switching speeds and pulse rise times
Solution Approach 1:
The segmentation of capacitance into multiple distributed capacitors reduces the equivalent series inductance (ESL) of the assembly. By distributing the capacitive load across multiple parallel elements with shorter current paths, the overall inductance is reduced, enabling faster switching speeds and improved pulse rise times compared to conventional single-capacitor designs.
Solution Approach 2:
Multiple capacitors are merged in parallel between the terminal plates to achieve the required total capacitance. This merging of multiple low-inductance capacitor elements results in an assembly with lower overall inductance than a single conventional capacitor of equivalent capacitance, thereby improving switching performance.
3Volume of moving object
If multiple capacitors are arranged in an array, then the packaging envelope is reduced, but the assembly complexity increases
Solution Approach 1:
The terminal plates serve multiple functions simultaneously: they provide electrical connections to all capacitors in the array, provide mechanical support and spacing for the capacitor elements, and define the packaging envelope. This multi-functionality reduces assembly complexity despite the increased number of capacitor elements, as the terminal plates integrate several structural and electrical roles into single components.
Solution Approach 2:
A non-conductive matrix is introduced as an intermediary structure to hold and position the capacitors within the assembly. This matrix provides a standardized framework that simplifies the arrangement of multiple capacitors, ensuring proper spacing and alignment while reducing the complexity of direct capacitor-to-terminal-plate mounting for each element.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a compact, high-capacitance capacitor assembly with excellent response characteristics and low inductance, suitable for high-current and high-frequency applications, such as in gas turbine starter-generators, while allowing for efficient heat dissipation and flexible routing of components.
Implementation Method 1
electrically coupled to the positive terminal plate and the negative terminal plate
Implementation Method 2
an array of capacitors disposed between and electrically coupled to the positive terminal plate and the negative terminal plate
Data Source
AI summary
A method of assembling a capacitor assembly is provided. The method comprises positioning a plurality of capacitors in respective sockets formed within a non-conductive matrix and electrically coupling the capacitors to a positive terminal plate and to a negative terminal plate.