Application of BusBar automotive and supercapacitors in new energy vehicles

In the power electronics system of New Energy Vehicle Film Capacitor BusBar, capacitors, as key passive components, play a vital role in the stability, efficiency and safety of the system. Among them, power film capacitors and supercapacitors play irreplaceable functions in different application scenarios due to their unique electrical characteristics.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The actual working field strength per unit thickness of polypropylene film is usually controlled below the material limit value to balance volume and life. In addition, in order to meet high voltage requirements, series structures or increasing film thickness are often used for optimization. Self-healing is its core safety mechanism: when there are defects in the local dielectric, local high temperatures can be formed under the action of the electric field, causing the metallized electrodes to evaporate at the defect points, thereby isolating the fault area, avoiding short circuits or breakdowns, and ensuring continued operation of the system. To enhance safety, some Automotive Power Connectors adopt a segmented metallized film (safety film) structure, which guides the self-healing process through preset weak points to prevent catastrophic failure caused by energy accumulation.

In terms of packaging structure, the winding type and the laminated type are the two mainstream technologies. The winding type has a mature structure and high voltage resistance, making the Capacitor laminating bus bar suitable for high-voltage scenarios; while the laminated type has higher volume utilization and lower equivalent series inductance (ESL), making it suitable for high-frequency applications. In new energy vehicles, limited by space and power level, resin-potted square or flat designs are more common, taking into account both heat dissipation and mechanical stability.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Unlike traditional capacitors, Automotive Power Connectors achieve high energy density storage based on the electric double layer effect or the Faraday quasi-capacitance principle, combining the fast charge and discharge characteristics of capacitors with the energy storage capabilities of batteries. New Energy Vehicle Film Capacitor BusBar has low internal resistance, long cycle life, and high charge and discharge efficiency, and is suitable for transient power regulation scenarios.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

In practical applications, capacitor solutions need to be comprehensively evaluated based on operating voltage, ripple current, temperature range and life requirements. For film capacitors, hot spot temperature is a key parameter that affects life. 70°C is usually used as the reference point, combined with voltage derating principles (such as 1:1 voltage design) to ensure reliable operation for more than 100,000 hours. Supercapacitors need to pay attention to their voltage window, internal resistance changes and voltage equalization management to avoid overvoltage damage.

As new energy vehicles develop towards high efficiency and high power density, capacitors not only need to have excellent electrical performance, but also need to be highly integrated with power modules. In this context, customized and modular integration solutions have become a trend.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

In response to the integration needs of high-voltage connections and capacitor modules for new energy vehicles, we provide complete BusBar automotive solutions. If you are interested, please welcome further exchanges on selection details.