Heat conductor for use with an inverter in an electric vehicle (EV) or a hybrid-electric vehicle (HEV)
First Claim
1. A heat conductor for use with an inverter in an electric vehicle (EV) or a hybrid-electric vehicle (HEV), the inverter including a direct current (DC) link capacitor comprising a plurality of film capacitors configured in a stack to form a substantially polygonal prism, wherein each film capacitor has orthotropic characteristics such that a thermal conductivity across a thickness of each film capacitor differs from a thermal conductivity across another dimension of the film capacitor, and such that a stiffness across the thickness of each film capacitor is less than a stiffness across another dimension of the film capacitor, the heat conductor comprising:
- a first substantially planar member configured to contact a first side of the polygonal prism formed by a single one of the film capacitors, the first substantially planar member comprising a thermally conductive material for dissipating heat generated by the plurality of film capacitors;
a second substantially planar member configured to contact a second side of the polygonal prism opposite the first side of the polygonal prism, the second side of the polygonal prism formed by another single one of the film capacitors, the second substantially planar member comprising a thermally conductive material for dissipating heat generated by the plurality of film capacitors; and
an interconnect for fixedly attaching the first and second substantially planar members, wherein the interconnect comprises a third substantially planar member comprising a thermally conductive material, the third planar member substantially coextensive with a third side of the substantially polygonal prism oriented between the first and second sides of the prism, wherein the third substantially planar member comprises a first piece extending from the first substantially planar member and a second piece extending from the second substantially planar member, the first and second pieces each having an attachment feature, the attachment features of the first and second pieces configured to cooperate for attachment of the first and second pieces, and wherein the attachment features of the first and second pieces are further configured to operate as heat dissipating features by increasing a surface area of the third substantially planar member;
wherein the first and second substantially planar members have sufficient rigidity to confine expansion of the plurality of film capacitors across the thicknesses thereof.
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Accused Products
Abstract
A heat conductor for use with an inverter in an electric or hybrid-electric vehicle, the inverter including a direct current link capacitor having multiple film capacitors configured in a stack to form a substantially polygonal prism. Each film capacitor has orthotropic characteristics. The heat conductor has a first substantially planar member configured to contact a first side of the polygonal prism formed by one of the film capacitors, and a second substantially planar member configured to contact a second side of the polygonal prism opposite the first side of the rectangular prism, the second side of the rectangular prism formed by another one of the film capacitors. The first and second planar member are thermally conductive for dissipating heat generated by the film capacitors, are attached by an interconnect, and have sufficient rigidity to confine expansion of the film capacitors across the thicknesses thereof.
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Citations
13 Claims
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1. A heat conductor for use with an inverter in an electric vehicle (EV) or a hybrid-electric vehicle (HEV), the inverter including a direct current (DC) link capacitor comprising a plurality of film capacitors configured in a stack to form a substantially polygonal prism, wherein each film capacitor has orthotropic characteristics such that a thermal conductivity across a thickness of each film capacitor differs from a thermal conductivity across another dimension of the film capacitor, and such that a stiffness across the thickness of each film capacitor is less than a stiffness across another dimension of the film capacitor, the heat conductor comprising:
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a first substantially planar member configured to contact a first side of the polygonal prism formed by a single one of the film capacitors, the first substantially planar member comprising a thermally conductive material for dissipating heat generated by the plurality of film capacitors; a second substantially planar member configured to contact a second side of the polygonal prism opposite the first side of the polygonal prism, the second side of the polygonal prism formed by another single one of the film capacitors, the second substantially planar member comprising a thermally conductive material for dissipating heat generated by the plurality of film capacitors; and an interconnect for fixedly attaching the first and second substantially planar members, wherein the interconnect comprises a third substantially planar member comprising a thermally conductive material, the third planar member substantially coextensive with a third side of the substantially polygonal prism oriented between the first and second sides of the prism, wherein the third substantially planar member comprises a first piece extending from the first substantially planar member and a second piece extending from the second substantially planar member, the first and second pieces each having an attachment feature, the attachment features of the first and second pieces configured to cooperate for attachment of the first and second pieces, and wherein the attachment features of the first and second pieces are further configured to operate as heat dissipating features by increasing a surface area of the third substantially planar member; wherein the first and second substantially planar members have sufficient rigidity to confine expansion of the plurality of film capacitors across the thicknesses thereof. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A heat conductor for use with an inverter in an electric vehicle (EV) or a hybrid-electric vehicle (HEV), the inverter including a direct current (DC) link capacitor comprising a plurality of film capacitors configured in a stack to form a substantially polygonal prism, wherein each film capacitor has orthotropic characteristics such that a thermal conductivity across the thickness of each film capacitor differs from a thermal conductivity across another dimension of the film capacitor, and such that a stiffness across the thickness of each film capacitor is less than a stiffness across another dimension of the film capacitor, the heat conductor comprising:
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a first plate configured to contact a first side of the polygonal prism formed by a single one of the film capacitors, the first plate substantially coextensive with the first side of the prism and comprising a thermally conductive material for dissipating heat generated by the plurality of film capacitors; a second plate configured to contact a second side of the polygonal prism opposite the first side of the polygonal prism, the second side of the prism formed by another single one of the film capacitors, the second plate substantially coextensive with the second side of the prism and comprising a thermally conductive material for dissipating heat generated by the plurality of film capacitors; and a third plate fixedly connecting the first and second plates, wherein the third plate comprises a thermally conductive material and is substantially coextensive with a third side of the polygonal prism between the first and second sides of the prism, wherein the third plate comprises a first piece extending from the first plate and a second piece extending from the second plate, the first and second pieces each having an attachment feature, the attachment features of the first and second pieces configured to cooperate for attachment of the first and second pieces, wherein the attachment feature of the first and second pieces are further configured to operate as heat dissipating features by increasing the surface area of the third plate; wherein the first and second plates have sufficient rigidity to confine expansion of the plurality of film capacitors across the thicknesses thereof. - View Dependent Claims (8, 9, 10, 11)
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12. An inverter in an electric vehicle (EV) or a hybrid-electric vehicle (HEV), the inverter comprising:
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a direct current (DC) link capacitor comprising a plurality of film capacitors configured in a stack to form a substantially polygonal prism, wherein each film capacitor has orthotropic characteristics such that a thermal conductivity across the thickness of each film capacitor differs from a thermal conductivity across another dimension of the film capacitor, and such that a stiffness across the thickness of each film capacitor is less than a stiffness across another dimension of the film capacitor; a heat conductor comprising a first substantially planar member configured to contact a first side of the polygonal prism formed by a single one of the film capacitors, and a second substantially planar member configured to contact a second side of the polygonal prism opposite the first side of the polygonal prism, the second side of the prism formed by another single one of the film capacitors, the first and second substantially planar members comprising a thermally conductive material for dissipating heat generated by the plurality of film capacitors; and an interconnect for fixedly attaching the first and second substantially planar members, wherein the interconnect comprises a third substantially planar member comprising a thermally conductive material, the third planar member substantially coextensive with a third side of the substantially polygonal prism oriented between the first and second sides of the prism, wherein the third substantially planar member comprises a first piece extending from the first substantially planar member and a second piece extending from the second substantially planar member, the first and second pieces each having an attachment feature, the attachment features of the first and second pieces configured to cooperate for attachment of the first and second pieces, and wherein the attachment features of the first and second pieces are further configured to operate as heat dissipating features by increasing a surface area of the third substantially planar member; wherein the first and second substantially planar members have sufficient rigidity to confine expansion of the plurality of film capacitors across the thicknesses thereof. - View Dependent Claims (13)
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Specification