New Yorker adds Cornell Dubilier’s custom capacitors for EV chargers

Cornell Dubilier Electronics (CDE) has added custom capacitor capabilities for higher performance DC link capacitors for EV chargers which are now available from New Yorker Electronics. 

The inverter circuitry at the heart of EV charging stations may seem familiar to design engineers but there are operational, environmental and mechanical demands that make Level 3 EV charging stations unique, said New Yorker Electronics. The latest designs are pushing voltages and current handling to higher levels to shorten recharge times.

According to Bob Kropiewnicki, director of applications engineering of CDE, “We’ve found that design engineers engaged in Level 3 charger projects are faced with a balancing act to mitigate significant circuit harmonics that cause heating problems. Adequate input and output filtering, strategic current paths, and reducing inductance and ESR are all concerns.” Kropiewnicki continued, “All too often, the DC link capacitor is an afterthought which forces those problems to be dealt with in ways that are more complex than necessary. A better solution is to focus on the requirements of the DC link as early as possible in the design process,” he said. “We are able to predict performance by using our advanced capacitor modelling based on project application conditions.”

CDE has been involved in the design and manufacture of DC link and pulse power capacitors for high power applications in military and green energy fields and acquired the custom film capacitor division of NWL in 2021. 

Components available include screw terminal and snap-in aluminium electrolytics as well as polypropylene film capacitors, air or water-cooled types, with oil-impregnated or dry-epoxy construction. Constructions include multiple terminal options in metal or plastic cases. CDE’s process begins with the customer providing the required specifications, including life and other application requirements. These specifications help determine if a standard or custom solution is recommended. To validate the recommendation, CDE utilises advanced in-house thermal modelling and product testing capabilities. CDE has dedicated engineering resources to design custom DC link capacitors that meet the exact power requirements and unique mechanical packaging to fit complex applications. The company has multiple North American manufacturing facilities.

CDE’s custom-engineered DC Link capacitors are designed specifically for Level 3 EV charging applications. The high power demands of Level 3 charging require robust DC link capacitors, having exceptional life and reliability over a broad range of operating conditions. CDE offers high capacitance values with low inductance (less than 5nH), high ripple current (100s of Amps), self-healing and low loss dielectrics. The voltage range is 450V DC to 3,800V DC. The operating temperature range is -40 to +135 degrees C, with life expectancies of 200,000 hours typical.

New Yorker Electronics is franchise distributor of Exxelia Magnetics (ex-Microspire), part of Exxelia Group, and supplies its full line of film, mica, tantalum, aluminium electrolytics and ceramic capacitors as well as its EMI/RFI filters, magnetics, position sensors, slip rings and rotary joints. 

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