POWER CONVERSION DEVICE

Abstract

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.

Claims

1. A power conversion device for a vehicle comprising: a power module operable to convert direct current (DC) to alternating current (AC); a capacitor module electrically connected to the power module; and a support frame that houses the power module and a conductor plate, wherein the capacitor module is at least partially wound around an exterior side of the support frame.

2. The power conversion device according to claim 1, wherein the power conversion device has an axis, and the capacitor module is wound at least partially around the axis.

3. The power conversion device according to claim 2, wherein the axis is a longitudinal axis.

4. The power conversion device according to claim 1, wherein the capacitor module is wound around the support frame at least once.

5. The power conversion device according to claim 1, wherein the capacitor module is wound around the support frame at least twice.

6. The power conversion device according to claim 1, wherein the capacitor module is wound around the support frame at least three times.

7. The power conversion device according to claim 1, wherein the capacitor module is wound to form a capacitor having overlying layers.

8. The power conversion device according to claim 1, wherein the capacitor module comprises: a first metal foil having a first side and a second side; a second metal foil having a first side and a second side; and a dielectric layer, wherein the first metal foil and the second metal foil are arranged such that the first sides of the first metal foil and the second metal foil are facing each other; and wherein the dielectric is arranged between the first metal foil and the second metal foil and separates the first metal foil and the second metal foil.

9. The power conversion device according to claim 1, further comprising a cooling plate.

10. The power conversion device according to claim 9, wherein the support frame further houses the cooling plate.

11. The power conversion device according to claim 9, wherein the cooling plate has an upper side arranged adjacent to the power module.

12. The power conversion device according to claim 9, wherein the cooling plate has a lower side arranged adjacent to at least one of: the support frame, and the capacitor.

13. The power conversion device according to claim 1, wherein the support frame is a metal support frame.

14. The power conversion device according to claim 13, wherein the support frame comprises at least one of: steel, and aluminium.

15. The power conversion device according to claim 1, further comprising a housing.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0043] FIG. 1 is a schematic cross-sectional view of a power conversion device, perpendicular to a longitudinal axis, in accordance with various embodiments.

[0044] FIG. 2 is a schematic sectional top view along line AA onto the power conversion device according to FIG. 1.

DETAILED DESCRIPTION

[0045] In FIG. 1, a power conversion device 1 is illustrated. The power conversion device 1 comprises a power module 3, a cooling plate 2, a gate driver and controller logic 4, a capacitor 5, a support frame 6, and a housing 7. The power module 3 is arranged on top of the cooling plate 2 such that the cooling plate 2 may absorb heat dissipated by the power module 3.

[0046] The support frame 6 is made of aluminum and houses the cooling plate 2, the power module 3, and the gate driver and controller logic 4. The gate driver and controller logic 4 are electrically connected to the power module 3. The support frame 6 has rectangular shape defining the edges of a box. Further, the support frame 6 has a base plate. The support frame 6 has a length of 0.22 m, a width of 0.22 m, and a height 0.1 m. The values are approximate, such as with a tolerance of 1 to 3 centimetres.

[0047] The power module comprises an AC terminal and a DC terminal.

[0048] The capacitor 5 is a PP-film capacitor of 550 microfarads (μF) with a film thickness of 7 microns (μm). In some embodiments the film capacitor may have another thickness, for example at least 2 μm, at least 3 μm, at most 10 μm, and/or at most 8 μm. The shown capacitor has a width of 0.22 m and a length (in unwound state) of 450 m. The capacitor 5 comprises a first metal foil and a second metal foil arranged on top of each other and separated by a dielectric layer. The capacitor 5 is wrapped around an exterior side of the support frame 6 and electrically connected to the DC terminal of the power module 3. The capacitor 5 operates to smooth out ripple voltage and ripple current for the DC circuit sections and to supply stable electric power to the power module 3.

[0049] When wound around the support frame 6 as shown in FIG. 1, the capacitor 5 comprises 660 turns. In the illustrated example, the capacitor forms a total layer of 0.01 m thickness which is wound around the support frame 6.

[0050] The capacitor 5 is arranged adjacent to the cooling plate 2 such that a coolant passing through conduits provided in the cooling plate 2 may absorb heat emitted by the capacitor 5.

[0051] The support frame 6 with the capacitor 5 wrapped around is disposed in the housing 7. The housing 7 is a metal box with a removable lid. The lid may be screwed or clamped to the side walls of the box. The housing 7 may comprise openings to receive connectors for coolant or electricity, for example. The housing has a length L of 0.22 m, a width W of 0.25 m, and a height H of 0.13 m. The values are approximate, such as with a tolerance of 1 to 3 centimetres.

[0052] In FIG. 2, the power conversion device 1 of FIG. 1 is illustrated in a schematic cross-section along line AA, shown in FIG. 1.

[0053] The cooling plate 2 has a receiving port 2a and a discharge port 2b for receiving and discharging coolant. The receiving port 2a and the discharge port 2b are each arranged in an opening of the housing 7, and fluidly connected to the cooling plate 2.