Capacitor Block Fluid Channel Heat Transfer Design

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Solution Overview

Problem

Existing capacitor blocks face challenges in efficiently transferring heat from electrolytic capacitors, leading to overheating and reduced lifespan, and are not easily extensible to vary the number of capacitors.

Innovation Solution

A capacitor block design with a system that utilizes fluid channels for heat transfer, allowing 90-100% of the capacitor bases to be in contact with a cooling medium, and can be extended by adding spacers and wall elements to increase the number of capacitors, with controlled cooling gas flow to manage temperature.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a cooling plate is used to transfer heat from the capacitor base, then heat transfer efficiency is improved, but the terminal contact occupies space and reduces the contact area between the cooling plate and capacitor base

Engineering Contradiction:

Improvecapacitor temperatureVSAvoidcontact area between cooling plate and capacitor base

Core Design Contradiction:

TemperatureVSArea of stationary object

Solution Approach 1:

The patent introduces fluid channels with cooling medium flow to replace or supplement solid cooling plate contact. The fluid channels are formed between the capacitor base and the housing base, allowing cooling medium (gas or liquid) to flow directly over the capacitor base surface, thereby achieving heat transfer without occupying space with a solid cooling plate structure.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Temperature

If a pipe or cooling duct travels through the capacitor, then heat transfer is improved, but the capacitor cover structure must be changed with openings

Engineering Contradiction:

Improvecapacitor temperatureVSAvoidcapacitor cover structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

Instead of having cooling ducts travel vertically through the capacitor from top to bottom (requiring cover openings), the patent forms fluid channels in the horizontal plane between the capacitor base and housing base. This dimensional change eliminates the need for cover modifications while maintaining effective heat transfer pathways.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Quantity of substance

If electrolytic capacitors are arranged in a capacitor block, then space utilization is improved, but heat transfer becomes more difficult and requires complex cooling systems

Engineering Contradiction:

Improvenumber of capacitorsVSAvoidheat transfer efficiency

Core Design Contradiction:

Quantity of substanceVSTemperature

Solution Approach 1:

The housing base serves multiple functions: it provides structural support for the capacitor block and simultaneously forms fluid channels with the capacitor bases for heat transfer. This multi-functional design integrates the cooling system into the existing housing structure, avoiding the need for separate complex cooling systems when multiple capacitors are arranged in a block.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of manufacture

If the capacitor block is designed with fixed number of capacitors, then manufacturing is simplified, but adaptability to vary the number of capacitors is reduced

Engineering Contradiction:

Improvecapacitor block manufacturingVSAvoidextensibility of capacitor block

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The capacitor block is designed as a modular assembly where capacitors are arranged in rows with fluid channels formed between them. The housing and spacers create standardized slots that can accommodate different numbers of capacitors. This segmented, modular design allows the capacitor block to be manufactured with standard components while maintaining adaptability to configure different numbers of capacitors in rows.

Inventive Principle:

Principle #1Segmentation

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

This design effectively reduces hotspot temperatures by 7-10°C, doubles capacitor lifespan, allows for a 25% increase in current load without temperature elevation, and enables easy expansion of the capacitor block, reducing investment costs and improving packaging density.

Implementation Method 1

A fluid medium can flow through the fluid channels formed between the electrolytic capacitors in order to transfer heat from the bases of the capacitors

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

Heat conduction is most effective through the bottom of an electrolytic capacitor

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3093860B1Capacitor block and method for transferring heat from a capacitor block

Publication Date: 2020.12.16 ABB (SCHWEIZ) AG

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AI summary

According to an example aspect of the present invention, there is provided a capacitor block (1) comprising - a plurality of electrolytic capacitors (2) arranged in at least one row, each capacitor (2) comprising a support (14) protruding from a casing of the capacitor (2) in a direction radially outwards relative to a center axis (15) of the capacitor (2), a capacitor holder (4), wherein each capacitor (2) is mechanically connected to the capacitor holder (4) via the support (14), and wherein between at least two capacitors (2) a fluid channel (6) is arranged in each row.