TDK Electronics · TDK Europe

ModCap – the new modular capacitor concept


TDK has implemented a modular and versatile power capacitor concept for DC link applications. This, combined with the latest-generation of IGBT modules, allows compact converters for applications in traction, renewable energies and industrial to be brought swiftly to market readiness.


ModCap is constructed from parallel interconnected flat windings filled with polyurethane resin. Thanks to this design, the capacitors can be fitted very near to the IGBT modules, thus producing very short lead lengths. This, combined with a very low 14 nH self-inductance of the capacitors, stops any substantial voltage overshoot at the IGBT modules when the current is shut off. As a result, generally, no snubber capacitors are needed. This in turn, reduces the space requirement and costs of new converter designs.

Biaxial oriented polypropylene (BOPP) is deployed as dielectric allowing for a constant 90 °C hot spot temperature. Furthermore, considerably enhanced self-healing properties are achieved. Thanks to the use of simulation software, TDK calculates capacitor thermal reactions based on parameters such as frequency spectrum, maximum current and installation circumstances specified by the customer.


ModCap at a glance

Features & Benefits

 ModCap

Features

  • Capacity range from 365 up to 2525 µF 
  • Voltages from 1100 up to 2300 V
  • Low ESL <14 nH
  • Temperature range up to 90 °C hot spot
  • IEC 61071, IEC 61881-1, EN 45545-2 HL3 R23 (fire and smoke)
  • Filled with polyurethane resin (dry technology)
  • Plastic case (opened)
  • Flat windings

Benefits

  • High energy density, ultra compact solution
  • Modular concept for parallelization
  • Low voltage overshoot
  • Generally no snubber capacitors are needed
  • Lifetime up to 200,000 hours
  • Simulation software available for the whole series
  • Cost optimization
  • Reduced time to market & lead time

Applications

 Applications

Simulations

Thermal simulation

Thermal model available for specific simulation according to spectrum and boundary conditions defined by the customer.

 Simulations Thermal Map

Electromagnetic simulation

Electromagnetic model available for specific simulation according to spectrum and boundary conditions defined by the customer.

 Simulations Electromagnetic

ModCap solves design problems

Why are snubber capacitors generally not required?

ModCap has been designed to minimize the stray inductance; values below 14 nH are achieved for the whole series. Thanks to its design, the capacitors can be fitted very near to the IGBT modules, thus producing very short lead lengths. This stops any substantial voltage overshoot at the IGBT modules when the current is shut off. As a result, generally, no snubber capacitors are needed.

Why does ModCap have higher energy and power density than other solutions?

ModCap is based on long experience designing resin filled capacitors. The unique metallization of the films maximizes self-healing capability while withstanding high current densities, thus reducing losses. The capacitor dimensions have been designed for current and future IGBT power modules to optimize the DC link unit's space requirements in terms of dimensions and power.

What are the advantages of a modular DC link capacitor concept?

The main advantages of a modular capacitor are reduced volume, low cost, standard design, low stray inductance and high current and energy density. Additionally, ModCap enables the plug-and-play philosophy through its special mechanical design, matched to existing SiC/IGBT power modules.

As a standardized product, the ModCap is compliant with most of the industry standards: EN 45545-2, IEC 61071, IEC61881-1, UL, and others. Since the moment of purchasing, our customers receive a fully validated product with all the necessary documentation.

Despite of being a standard design, TDK is also able to offer customized solutions. Thanks to our broad catalog and technical support, SPICE models and electromagnetic and thermal FEA simulations; TDK delivers excellent solutions for customer-specific requirements.

What is the maximum hot spot temperature of this series?

Up to 90 ºC of hot-spot temperature can be achieved during operation thanks to the use of high crystallinity BOPP and our fine-tuned automated process parameters. Furthermore, considerably enhanced self-healing properties are achieved.

For precise heat distribution in the capacitor, TDK also offers FEA simulations tailored to your specific electrical and mechanical conditions. TDK can simulate ModCap in customer setup, taking into account the electrical conditions and all other aspects that may have an influence, such as external electromagnetic interference, the cooling system, the mechanical assembly, etc.

Is ModCap compliant with fire and smoke regulations?

All materials used in rail vehicles for passenger transport must meet the EN45545-2 standard in order to achieve the highest level of safety possible in the event of a fire. Railway vehicles are classified in accordance with the fire hazard level associated with their design and operation.

The three hazard levels are: HL1, HL2 and HL3 with HL1 being the lowest requirement and HL3 being the highest. ModCapTM/ New modular Standard Series meet the high requirements of the new European fire protection standard EN45545-2, reaching safety levels up to HL3 in the requirement set applicable to power capacitors (R22, R23 and/or R24).

Therefore, ModCap can even be installed in bunks and bed wagons that cross long tunnels and railway vehicles operating on the underground tracks.

Why ModCap is able to handle harmonics up to 100 kHz?

The basis for the use with high harmonics is the internal mechanical construction of the ModCap, i.e., the even distribution of the flat windings used and their short lead lengths. Also, by using special FAE software, external and self-induced electromagnetic fields can be detected, and appropriate countermeasures can be taken. TDK also supports its customers in designing the mechanical interface to the capacitor.

Product presentation

TDK has implemented a modular and versatile power capacitor concept for DC link applications. This, combined with the latest-generation of IGBT modules, allows compact converters for applications in traction, renewable energies and industrial to be brought swiftly to market readiness.


Get data sheets

PDF Type Application Style Number of phases Rated capacitance (µF)
file_pdf_box new
B25645 DC link MKK DC-R unknown 365 - 2525

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