Capacitor Block With Waterproof-Breathable Membrane for Outgassing
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Solution Overview
Problem
Existing capacitor blocks for motor vehicle power modules face challenges in withstanding high temperatures, corrosive atmospheres, and fluid exposure, particularly in 'mild-hybrid' architectures, where high currents and salt bridge formation are concerns, and they fail to adequately manage outgassing for sealing requirements.
Innovation Solution
A capacitor block comprising multiple electrochemical capacitors in a metal tank with cooling fins, partially filled with a thermally conductive and electrically insulating material, and featuring a waterproof-breathable membrane for sealing and degassing, along with busbars that prevent electrical contact and allow for pin alignment without contact, ensuring thermal management and environmental resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If capacitors are sealed in a metal tank to withstand harsh environments, then environmental resistance is improved, but outgassing management becomes problematic
Solution Approach 1:
The patent employs a waterproof-breathable membrane as the tank material that allows hydrogen gas to permeate through while blocking liquid water. This flexible film approach resolves the contradiction by enabling outgassing management while maintaining environmental sealing, as the membrane selectively permits gas transmission while preventing liquid ingress.
Solution Approach 2:
The waterproof-breathable membrane utilized in the tank is a porous material with controlled permeability properties. The membrane's porous structure allows small hydrogen molecules to pass through while blocking larger water molecules, thus managing outgassing from electrochemical capacitors while maintaining environmental protection.
2Power
If busbars are used to connect capacitors for high current applications, then current handling is improved, but electrical contact between positive and negative busbars must be prevented
Solution Approach 1:
The patent introduces an insulating support as an intermediary element positioned between the positive and negative busbars. This mediator prevents direct electrical contact between the oppositely charged busbars while allowing both to be mounted on the same structural component, thus enabling high current handling while maintaining electrical isolation.
Solution Approach 2:
The busbars are arranged in different spatial dimensions with the insulating support providing separation in the vertical dimension. The positive busbar extends in one direction while the negative busbar extends perpendicular to it, with the insulating support preventing contact in the third dimension, thus achieving both high power capability and electrical isolation.
3Volume of moving object
If capacitors are assembled into a compact block, then space efficiency is improved, but thermal management becomes more challenging
Solution Approach 1:
The patent utilizes a liquid cooling circuit that circulates coolant through channels in the metal tank to remove heat from the compact capacitor assembly. This hydraulic cooling system enables effective thermal management in the compact block configuration by providing direct thermal contact between the cooling fluid and the capacitor components through the conductive metal tank.
Solution Approach 2:
The metal tank serves as both the structural housing and the thermal management component, creating a homogeneous structure that combines mechanical support with heat dissipation functions. The uniform thermal conductivity of the metal tank ensures even heat distribution and efficient heat transfer to the circulating coolant.
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, environmentally resistant capacitor block that stabilizes voltage and reduces disturbances, capable of operating in harsh conditions while preventing salt bridge formation and managing outgassing, thus enhancing the integration of capacitors in motor vehicle power modules.
Implementation Method 1
partially filled with a thermally conductive and electrically insulating material
Implementation Method 2
partially filled with a thermally conductive and electrically insulating material
Implementation Method 3
metal tank with cooling fins
Implementation Method 4
metal tank with cooling fins
Implementation Method 5
waterproof-breathable membrane for sealing and degassing
Data Source
Figure 1~2
Figure 3
Figure 4a~4b
AI summary
A capacitor block comprising electrochemical capacitors (11) housed in a metal vessel (9) provided with cooling fins (2). The vessel is filled with a thermally conductive and electrically insulating material (21). The capacitors are arranged by means of a bus bar (15) with positive polarity and a bus bar (16) with negative polarity kept separated by an insulating support (10). The positive bus bar comprises first holes (17) receiving positive pins (12) of the electrochemical capacitors (11) and the negative bus bar comprises second holes (18) receiving negative pins (13) of the electrochemical capacitors. The positive bus bar also comprises first release holes (19) allowing the negative pins to pass through the positive bus bar without making electrical contact and the negative bus bar also comprises second release holes (20) allowing the positive pins to pass through the negative bus bar without making electrical contact. According to the invention, the vessel comprises sealing means (10, 24) and degassing means (25).