Shanghai Yongming Electronic Co., Ltd.

Evaluate how YMIN’s solid-liquid hybrid aluminum electrolytic capacitors reduce high power consumption in vehicle On-Board Charger (OBC) and DCDC converter units, particularly under high-voltage EV architectures up to 800 V.

Background

Modern OBC/DCDC designs must handle high-frequency ripple currents, voltage spikes, elevated temperatures, and bidirectional power flow while minimizing size, weight, and power losses. Capacitor choice critically impacts efficiency, reliability, power density, and thermal performance.

Capacitor Technologies Compared

• Liquid horn-type aluminum electrolytics (CW3H series): Designed for high voltage margin, surge-current capability at 1.3× ripple current, robust high-voltage aging tests. Offers ~20 % greater capacitance density vs. industry standard, enabling compact installation space.
• Liquid plug-in aluminum electrolytics (LKD series): Compact form factor suitable for limited space, withstands 105 °C ambient, rated for 12,000 h at 105 °C, ~20 % smaller diameter and height (~40 % lower height) than comparable horn types; high sealing integrity and stable electrical performance under temperature stress.
• Solid-liquid hybrid capacitors: Combine liquid and solid dielectric characteristics to deliver >30 % higher capacitance density at equal volume; capacitance stability within ±5 % over wide operating temperature; long-term capacitance retention >90 %. Extremely low ESR (~8 mΩ) and leakage current ≤20 µA, with consistent performance maintained post 260 °C reflow soldering.
• Film capacitors: High dielectric withstand (>1200 V), ultra-low ESR, non-polar design, rated >100,000 h life cycle, ripple tolerance ~3 µF/A (≈50× electrolytic), dry type, shelf-stable; ideal safety/reliability barrier in long-life systems .

Measured Results: Hybrid Capacitor Performance

In EV OBC/DCDC applications, YMIN’s hybrid capacitors reduced overall power losses by approximately 30 % compared to conventional electrolytic-only designs. The significant drop in ESR and leakage current enables improved filtering efficiency and reduced PFC ripple energy dissipation. High capacitance density enabled compact board-level integration, improving overall power density. Components retained key performance metrics after thermal shock (260 °C reflow) and sustained high-temperature operation. No significant drift in ESR or leakage was observed across extended thermal cycling, confirming manufacturing quality and reliability consistency.

Conclusion

YMIN's solid-liquid hybrid capacitors provide an optimal balance for EV OBC/DCDC systems:

• Higher energy & capacitance density than liquid or solid-only capacitors
• Very low ESR and leakage current reduce conduction and switching-related power loss
• Stability under high thermal stress and during board-level reflow support modern assembly processes
• Compact design supports miniaturized, high-voltage, high-power platforms

Engineers may apply these components to reduce DC-link losses, improve ripple attenuation, downsize capacitor bank volume, and increase overall system thermal-efficiency and reliability.

Quellenlink: https://www.ymin.cn/news/solving-the-problem-of-high-power-consumption-of-obcdcdc-units-unveiling-the-measured-data-of-ymins-solid-liquid-hybrid-capacitors/

Autor: Shanghai Yongming Electronic Co., Ltd. （https://www.ymin.cn/)

Kontakt: ymin-sale@ymin.com