Condensing exclusive technology - Nichicon's on-board charger solution

Latest update time：2019-11-16

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In July 2009, Mitsubishi Motors Corporation's electric vehicle "i-MiEV" was equipped with Nichicon's "charger-integrated DC-DC converter", which is a device for charging the high-voltage and low-voltage batteries that are indispensable for driving electric vehicles, and can be easily charged through a household socket.

In addition, in December 2010, Nissan Motor Company also adopted the "on-board charger" on its first-generation electric vehicle "LEAF".

These products are the result of cutting-edge technologies such as power control circuit technology, power control software technology, processing technology, and analysis technology. Nichicon has unique technologies related to "on-board chargers" and "DC-DC converters." By combining these technologies, integrated products can be manufactured.

Because these electric and fuel cell vehicles are environmentally friendly and affordable, they are gradually becoming popular. As long as enough infrastructure is built in the future, the popularity of electric vehicles will soar.

To achieve technological innovation in the automotive/vehicle-related fields, it is essential to improve the performance and functionality of the components installed, such as "downsizing", "high efficiency", "responsibility for harsh environments", and "extended life". In particular, it is necessary to cope with space saving and high temperature harsh environments in order to ensure a comfortable interior space.

Large-capacity DC-DC converters for electric vehicles (EVs)

Car charger application

Nichicon has launched the "LGX Series" product lineup to meet the needs for miniaturization, space saving, and longer life of large aluminum electrolytic capacitors used in automotive chargers.

The LGX series has a maximum rated voltage of 500V, and has achieved a higher withstand voltage by adopting a uniquely developed high withstand voltage electrode foil and optimizing the electrode foil winding method that has been cultivated so far. In addition, it has the same size system as the LGN series and has achieved a longer life.

Comparison of the same rated specifications between the LGX series and the LGN series

LGX" substrate self-supporting aluminum electrolytic capacitor

DC-DC converter applications

Nichicon has also launched a variety of series products for DC-DC converter applications. This time, we are focusing on the development of "miniaturization" and introducing the "UCV" series products, which have the highest capacitance per unit volume in the industry.

This product successfully commercialized the high-capacity technologies that Nichicon has cultivated so far. The main high-capacity technologies include thinning the components, increasing the power of the electrode foil, and optimizing the internal structure.

105℃ Small/High Capacity "UCV"

① Thinning of electrode foil and electrolytic paper

The capacitor element has a cylindrical structure with wound electrode foil and electrolytic paper. By making the electrode foil and electrolytic paper thinner, the element volume can be reduced. In other words, the same element volume can ensure more electrode foil surface area and achieve higher capacity.

②Applicable to high rate anode foil

The larger the foil surface area, the greater the foil capacity of the anode foil. By applying the latest etching technology, the capacitance per unit volume of the foil is increased.

③Optimize internal structure

By enhancing the assembly technology, it is possible to accommodate capacitor elements with a larger volume than existing products, thereby further expanding the surface area of the electrode foil.

By adopting the above technology, we have achieved a higher capacity than the existing "UCM" series.

Comparison of the size of "UCM" and "UCV"

The launch of the "UCV" product lineup will contribute to the miniaturization, weight reduction, and reduction in the number of parts of machines, which are in high demand regardless of their application.

The size system consists of three sizes: Φ6.3×7.7L, Φ8×10L, and Φ10×10L. The rated voltage range is 25 V and 35 V, and the rated capacitance range covers 220~1,000μF.

125℃ low temperature ESR specified products: UCH series

In the automotive/vehicle-related fields, in order to ensure a comfortable interior space and high efficiency, electronic circuits are often configured in and around the engine room, so the components are required to be able to cope with harsh high-temperature environments. In addition, products are required to be used in low-temperature environments such as cold regions, so the temperature range that needs to be coped with is large. In addition, products are also required to have high reliability such as long-term stability. In particular, the equivalent series resistance (ESR) of the product is valued. In order to know the specified peak value of the ESR at the design stage, Nichicon has launched a low-temperature ESR specified product after durability testing to meet market demand. The market also requires further miniaturization and low ESR, and the industry's top "UCH" has been developed as a low-temperature ESR specified product after durability testing.

125℃ Low temperature ESR standard product "UCH"

The Φ6.3×7.7L size features a 75% reduction in ESR compared to existing products.

This product uses a low-emission, low-resistance electrolyte and optimizes internal specifications to significantly suppress the degradation of the product's ESR over time.

①Use low-emission and low-resistance electrolyte

The existing electrolyte is easy to emit in high temperature environment, and the product characteristics will deteriorate significantly after a certain amount of emission. "UCH" achieves stable product characteristics for a long time by adopting low-emission electrolyte. In addition, by reducing the resistance of the electrolyte, we strive to reduce the ESR value.

②Optimize internal structure

By changing the existing design concept and optimizing the internal structure, we can contribute to strengthening the product characteristics. Through the "UCH" product lineup, we can contribute to the vehicle environment, power saving and long life of the whole machine. The size system is Φ6.3×7.7L, the rated voltage range is 35V, and the rated capacitance range is 47μF and 100μF. In addition, Nichicon promotes the development of environmentally friendly products, and both "UCV" and "UCH" are in compliance with the RoHS directive.

Comparison of ESR degradation over time between "UCZ" and "UCH"

The electric vehicle market is expected to expand worldwide. Each series introduced this time will need to achieve further advanced functions. Nichicon will further strengthen its technological capabilities and develop products that meet future market needs, thereby contributing to the development of China's automobile society.

Click to read the original article and browse the Nichicon Technology Subsite, which includes EV/In-Vehicle Solutions (Capacitors), Small Li-ion Rechargeable Batteries, and the "Capacitor Doctor" series of short films. The content is rich and detailed, and I believe it will definitely meet your needs and benefit you a lot.

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