Integrated DC-Link Capacitor Assembly With Dual-Side Cooling
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Solution Overview
Problem
Existing power conversion units (PTUs) in hydrogen vehicles face challenges with large PCB sizes due to multiple separately soldered capacitors and inadequate cooling of DC-link capacitors, which hinder efficient operation and meet customer needs.
Innovation Solution
A DC-link capacitor assembly integrating input and output capacitors within a box body, combined with a dual cooler system comprising an upper and lower cooler, to enhance current capacity and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple capacitors are soldered separately on a PCB, then the current capacity is sufficient, but the PCB size and PTU size become larger
Solution Approach 1:
The patent merges multiple capacitors (input capacitor and output capacitor) into a single integrated DC-link capacitor assembly with a common housing and shared bus duct. This consolidation reduces the number of separate PCB mounting locations needed and decreases the overall PTU size while maintaining the required current capacity through the combined capacitance of multiple capacitors working together in one unit.
Solution Approach 2:
The integrated DC-link capacitor assembly serves multiple functions within a single component: it provides both input filtering and output filtering capabilities, houses multiple capacitors with different capacitance values, and includes integrated bus ducts for electrical connections. This multi-functionality eliminates the need for separate PCB-mounted capacitors and reduces the overall system footprint.
2Power
If DC-link capacitors generate large amounts of heat, then the power conversion capability is enhanced, but the cooling requirements increase
Solution Approach 1:
The patent introduces a cooling plate as an intermediary thermal management component that interfaces directly with the DC-link capacitor assembly. The cooling plate serves as a heat transfer mediator, conducting heat away from the capacitors and providing a mounting surface for the cooler, thereby enabling efficient thermal management while maintaining high power conversion capability.
Solution Approach 2:
The patent employs a liquid cooling system with coolers that circulate coolant through channels to remove heat from the DC-link capacitors. This hydraulic cooling approach efficiently manages the large amounts of heat generated during high-power operation, maintaining operational temperatures within safe limits while enabling sustained high power conversion capability.
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 integrated capacitor assembly reduces PTU size and effectively dissipates heat, enabling stable operation under high current and pressure conditions.
Implementation Method 1
the bus duct housing the input capacitor and the output capacitor is bonded to the box body by a thermal adhesive
Implementation Method 2
The cooling device includes at least one of an upper cooler mounted abutting a bus duct of the DC-link capacitor assembly from above and a lower cooler mounted abutting a box body of the DC-link capacitor assembly from below
Data Source
AI summary
A DC-link capacitor assembly for a power conversion unit is disclosed. The DC-link capacitor assembly includes an input capacitor, an output capacitor, a bus duct, and a box body. The input capacitor and the output capacitor are housed in the bus duct and are in electrical connection with a terminal on the bus duct. The input capacitor, the output capacitor and the bus duct are housed together and fixed within the box body and formed as an independent component together with the box, the independent component being capable of being mounted directly to the power conversion unit and electrically connected to an external component through a terminal on the bus duct. By way of the above, the DC-link capacitor is allowed to withstand large currents and helps reduce the total size of PTU. Also disclosed is a cooling device for the above-mentioned DC-link capacitor assembly, which effectively solves the problem of high heat generation of DC-link capacitors.