Issue link: https://resources.mouser.com/i/1538715
As a result, common-mode chokes must carry more of the filtering burden in high-voltage systems. This shift places additional performance requirements on magnetic components, which must now provide greater attenuation across wide frequency ranges without introducing thermal or insertion loss penalties. The reliability implications of these voltage levels extend beyond filtering. In traction inverters and power modules, capacitors are exposed to continuous ripple current and voltage stress. Brick- style polypropylene film capacitors are commonly used in DC link stages in traction inverters, where they must handle hundreds of amps of ripple current while maintaining stable capacitance and minimal temperature rise. These capacitors often feature custom shapes and internal geometries to fit tightly constrained inverter housings, and their behavior is heavily modeled and simulated to ensure C h a p t e r 3 | A r c h i t e c t i n g t h e E l e c t r i f i e d Po w e r t r a i n When you shift to 800V powertrains, you're doubling the voltage from 400V. That's a big challenge that requires higher dielectric strength components, tighter creepage tolerances, less space, and improved insulation capabilities." Peter Blais Senior Director, Head of Technical Marketing & Digital Development, YAGEO Group electrical and thermal performance over the full life of the vehicle. For aluminum electrolytics, the move to 800V poses particular challenges. Suitable single-part voltage ratings are rare or nonexistent, forcing designers to place capacitors in series. As a result, active or passive balancing networks are now needed to equalize voltage across each part and prevent premature failure due to leakage current mismatch. Manufacturers are now expected to guarantee tight leakage current tolerances over the service life of the component. And, of course, thermal integration is tantamount to powertrain reliability. Passive components in high-current paths must dissipate significant amounts of heat without external airflow. This constraint has prompted new packaging approaches that enable thermal transfer directly to the vehicle chassis or to liquid-cooled cold plates. 18 Powering the New Automotive Era with Smart Passive Solutions