Title: High-frequency direct current bulk capacitors with interleaved busbar packages

Abstract

Presented are electrical capacitors with interleaved busbar architectures, methods for making/operating such capacitors, and electric-drive vehicles equipped with such capacitors. A bulk capacitor includes multiple capacitor devices disposed within an outer housing and operable to modify electric current transmitted between a power source and an electrical load. An interleaved busbar package is interposed between the capacitor devices and outer housing. The interleaved busbar package includes a first busbar plate that electrically connects to first terminals of the capacitor devices and defines a busbar pocket. A second busbar plate is seated within the busbar pocket and electrically connects to second terminals of the capacitor devices. The second busbar plate includes a capacitor basin that seats therein the capacitor devices. An isolator sheet is interleaved between and electrically insulates the first and second busbar plates. The capacitor devices and interleaved busbar package may be partially submerged in an epoxy endfill composition.

Inventors:

Jaksic, Marko; Stancu, Constantin C.; Abu-Zama, Dawud S.

Issue Date:

2020-07-21

Research Org.:

GM Global Technology Operations LLC, Detroit, MI (United States)

Sponsoring Org.:

USDOE

OSTI Identifier:

1735039

Patent Number(s):

10717366

Application Number:

16/405,491

Assignee:

GM Global Technology Operations LLC (Detroit, MI)

Patent Classifications (CPCs):

H - ELECTRICITY H01 - BASIC ELECTRIC ELEMENTS H01M - PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02T - CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

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H - ELECTRICITY H01 - BASIC ELECTRIC ELEMENTS H01M - PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY

H01M10/4264 - {with capacitors}

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02T - CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

Y02T10/62 - Hybrid vehicles

B - PERFORMING OPERATIONS B60 - VEHICLES IN GENERAL B60M - POWER SUPPLY LINES, AND DEVICES ALONG RAILS, FOR ELECTRICALLY- PROPELLED VEHICLES

B60M1/30 - Power rails

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02E - REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

Y02E60/10 - Energy storage

H - ELECTRICITY H02 - GENERATION H02M - APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS

H02M7/5387 - in a bridge configuration

H - ELECTRICITY H01 - BASIC ELECTRIC ELEMENTS H01M - PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY

H01M10/625 - Vehicles
H01M2220/20 - Batteries in motive systems, e.g. vehicle, ship, plane

B - PERFORMING OPERATIONS B60 - VEHICLES IN GENERAL B60M - POWER SUPPLY LINES, AND DEVICES ALONG RAILS, FOR ELECTRICALLY- PROPELLED VEHICLES

B60M7/003 - {for vehicles using stored power

B - PERFORMING OPERATIONS B60 - VEHICLES IN GENERAL B60L - PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES

B60L50/64 - Constructional details of batteries specially adapted for electric vehicles

H - ELECTRICITY H02 - GENERATION H02M - APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS

H02M7/003 - {Constructional details, e.g. physical layout, assembly, wiring, busbar connections}

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02T - CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

Y02T10/70 - Energy storage for electromobility

H - ELECTRICITY H05 - ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR H05K - PRINTED CIRCUITS

H05K7/1432 - {for power drive units}

B - PERFORMING OPERATIONS B60 - VEHICLES IN GENERAL B60L - PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES

B60L50/61 - by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
B60L15/007 - {Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles}

H - ELECTRICITY H02 - GENERATION H02M - APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS

H02M1/32 - Means for protecting converters other than automatic disconnection

B - PERFORMING OPERATIONS B60 - VEHICLES IN GENERAL B60L - PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES

B60L50/16 - with provision for separate direct mechanical propulsion

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02T - CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

Y02T10/7072 - Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors

B - PERFORMING OPERATIONS B60 - VEHICLES IN GENERAL B60L - PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES

B60L58/19 - Switching between serial connection and parallel connection of battery modules
B60L50/40 - using propulsion power supplied by capacitors

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DOE Contract Number:  

EE0007285

Resource Type:

Patent

Resource Relation:

Patent File Date: 05/07/2019

Country of Publication:

United States

Language:

English