xEVCap Next Level: Capacitor Bank and Thermo-Mechanical Evaluation of a Powertrain Inverter

Building on prior studies introducing the modular xEVCap DC‑link solution and its system‑level electro‑thermal evaluation, this paper presents a validated thermo‑mechanical model of a traction‑inverter DC‑link using four xEVCap in parallel. The model, calibrated against a hardware demonstrator, predicts internal hot‑spot temperatures and informs lifetime estimation. We assess a busbar design and fixation strategy (adhesives/gap fillers) that withstand automotive vibration while preserving low ESL and solderability. The modelling workflow powers the CLARA web tool’s Capacitor Banks module, enabling rapid design‑space exploration for 400/800‑V inverters without prototyping.