Wound Capacitor Cooling Channels for Internal Hot Spot Reduction
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Solution Overview
Problem
Conventional wound capacitors in electric vehicles experience overheating due to hot spots, limiting their performance and that of the connected pulse-controlled inverters, despite existing solutions like duromer cooling channels.
Innovation Solution
Incorporating cooling channels made of electrically non-conductive, thermally conductive materials such as fiber-reinforced duromer plastics, which are resistant to coolants, to enhance heat dissipation within the capacitors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods are used for wound capacitors, then the capacitor structure remains simple, but hot spots form in the interior limiting performance
Solution Approach 1:
The cooling channels are integrated directly into the capacitor winding structure by incorporating them into the plastic film layers during the winding process. This merging of cooling functionality with the capacitor structure enables effective internal heat dissipation without adding separate cooling components, thus improving temperature distribution while avoiding increased device complexity
Solution Approach 2:
Cooling channels are strategically positioned at specific locations within the capacitor winding where heat generation is highest. The cooling structure is not uniformly distributed but rather localized to critical hot spot regions, enabling targeted heat dissipation where most needed while maintaining overall structural simplicity
2Reliability
If cooling channels are added to dissipate heat, then hot spots are reduced, but the capacitor structure becomes more complex
Solution Approach 1:
The cooling channels are formed as integral parts of the plastic film layers used in the capacitor winding. By combining the cooling channel formation with the existing film layer structure during manufacturing, the cooling functionality is added without requiring separate complex cooling components, thus improving reliability while minimizing structural complexity
Solution Approach 2:
The plastic film layers serve dual functions: as dielectric insulation layers for electrical isolation and as structural components containing integrated cooling channels. This multi-functionality allows the same material layers to perform both electrical and thermal management roles, improving capacitor reliability without adding dedicated cooling structures
3Productivity
If the capacitor structure is simplified without cooling channels, then manufacturing is easier, but heat dissipation is insufficient limiting performance improvement
Solution Approach 1:
The cooling channels are incorporated into the plastic film layers during the standard winding and lamination process. By merging cooling channel formation with existing manufacturing steps, no additional complex manufacturing processes are required, enabling effective heat dissipation for performance improvement while maintaining ease of manufacture
Solution Approach 2:
The plastic film material properties are modified to include thermally conductive fillers or compounds during manufacturing. By changing the material parameters of the existing plastic film to enhance thermal conductivity, effective heat dissipation is achieved through the same manufacturing process without requiring separate cooling channel fabrication steps
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 effectively dissipates heat, optimizing coolant flow control and reducing hot spots, thereby enhancing the performance of wound capacitors and associated inverters.
Implementation Method 1
the cooling channel comprising an electrically non-conductive and thermally conductive material
Implementation Method 2
coolant flow control
Implementation Method 3
the cooling channel comprising an electrically non-conductive and thermally conductive material
Implementation Method 4
the cooling channel comprising an electrically non-conductive and thermally conductive material
Data Source
AI summary
A wound capacitor is provided, the wound capacitor including a cooling channel for conducting coolant. The provided cooling channel includes an electrically non-conductive and thermally conductive material. A pulse-controlled inverter including the wound capacitor is provided. A motor vehicle including the pulse-controlled inverter and the wound capacitor are also provided.