Wrapped Capacitor Inverter Layout for Space and Heat Limits
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Solution Overview
Problem
Power conversion devices, such as those for hybrid and electric vehicles, face challenges due to the large space requirements of cylindrical electrolytic capacitors and heat generation, which limits inverter performance and leads to early degradation.
Innovation Solution
A power conversion device design featuring a capacitor module wound around a support frame, which reduces space usage and incorporates a cooling element to manage heat, allowing for efficient heat dissipation and improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If cylindrical electrolytic capacitors are used in power conversion devices, then the capacitors can store electrical energy, but they occupy large installation space
Solution Approach 1:
The capacitor is transformed from a cylindrical 3D object occupying significant volume into a flat layered structure that wraps around the support frame. This dimensional transformation allows the capacitor to utilize the surface area of the support frame rather than consuming internal volume, thereby reducing the overall space required in the power conversion device while maintaining the necessary energy storage capacity.
Solution Approach 2:
The capacitor is designed to wrap around and conform to the exterior surface of the support frame, effectively nesting the capacitor structure within the available external surface area. This nesting approach allows the capacitor to utilize the support frame's surface as its mounting substrate, eliminating the need for separate dedicated capacitor mounting space and reducing the total device volume.
2Power
If high current-ripples are handled by capacitors, then power conversion is enabled, but capacitor temperature increases causing derating and limited inverter power
Solution Approach 1:
The cooling element is integrated directly with the support frame structure, merging the mechanical support function with the thermal management function. The cooling element's first cooling surface is positioned adjacent to the power module for heat dissipation, while the second cooling surface contacts the capacitor to cool it during high current-ripple operation. This combined structure eliminates the need for separate cooling systems and enables effective thermal management of both high-power components and capacitors simultaneously.
3Reliability
If heat is extracted from power conversion devices, then performance is improved and degradation is prevented, but additional cooling components are required
Solution Approach 1:
The support frame is designed to serve multiple functions simultaneously: it provides mechanical support for the power module, serves as the mounting structure for the capacitor by having the capacitor wrap around it, and incorporates an integrated cooling element for thermal management. This multi-functional design eliminates the need for separate dedicated cooling components and structural supports, thereby improving reliability through effective heat extraction without increasing device complexity.
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 design minimizes space requirements and enhances performance by effectively managing heat, thereby preventing early degradation and improving power conversion efficiency.
Implementation Method 1
a second cooling surface adjacent to the capacitor such that the cooling element may absorb heat dissipated by the power module and/or the capacitor
Implementation Method 2
The cooling element may comprise a heat sink and/or cooling channels
Data Source
AI summary
Disclosed herein are power conversion devices comprising power modules, capacitor modules, and support frames. The power modules may be operable to convert direct current (DC) electricity to alternating current (AC) electricity. The capacitor modules may be electrically connected to the power modules. The support frames may house the power modules and conductor plates, and the capacitor modules may be at least partially wound around exterior sides of the support frames. Such arrangements may advantageously take up less installation space and/or have better form factors than power conversion devices with cylindrical capacitors.