The increasing voltage and power density demands of electric vehicles pose notable challenges to the high-temperature resistance performance of film capacitors within motor controllers. Existing methods primarily focus on material modifications and conventional thermal management designs, often tested at 85 °C, which fail to meet the escalating demands for high-temperature operations. This paper presents the design and optimization of a thermal management system for film capacitors through simulations and experiments under ultra-high temperatures. ANSYS electro-thermal coupled simulation was used to analyze the temperature distribution of the capacitor under different ripple currents, leading to the development of a thermal management system based on internal micro-channel cold plates (IMCPs). These IMCPs were optimized using response surface and genetic algorithms to enhance cooling performance. Experimental and simulation comparisons were made between standard capacitors and those with IMCPs under ripple currents of 120 A and 180 A at 85 °C. Further examinations were conducted at ultra-high temperatures of 125 °C and 140 °C with a ripple current of 180 A. The findings show that capacitors with IMCPs had average temperature reductions of 45.50 °C and 48.45 °C at 85 °C under 120 A and 180 A ripple currents, respectively. Additionally, standard capacitors developed cracks or exploded at 125 °C and 140 °C under 180 A ripple current, while capacitors with IMCPs maintained normal functionality. These results indicate that capacitors integrated with IMCPs meet the rigorous high-temperature operational standards required for motor controllers in high-voltage electric vehicles.
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