Life cycle assessment of a DC-LINK capacitor used for automotive applications

In the automotive sector, which is increasingly focused on reducing its environmental impact, limited attention has been given to power systems and components involved in vehicle electrification. This study aims to propose a cradle-to-gate Life Cycle Assessment (LCA) applied to a DC-LINK capacitor (dimensions 130 mm∗48 mm∗247 mm and expected reference service life - RSL of 8000 h of driving), manufactured by a leading company in the sector. The aim of the research is filling existing gaps concerning the material composition of DC-LINKs and relative environmental impacts. The analysis examines the contributions of the various materials within the product and develops sensitivity scenarios to evaluate the influence of electricity used during manufacturing and the benefits associated with using secondary materials instead of virgin ones. The Climate Change impacts estimated for the Baseline scenario resulted in 9.50 kg CO2 eq per DC-LINK produced, with material components contributing 88.2 %. The complete hotspot analysis highlighted a general significant influence of the material components, which accounted for at least 57.8 % across all 18 environmental categories examined. The minimal contribution of electricity is justified by the company's decision to use a fully renewable energy mix. The use of secondary copper and aluminium proved advantageous, as it can reduce the climate change impacts of the finished product by 10–14 % with respect to the Baseline. In conclusion, the findings underscore the importance of considering the entire life cycle when assessing the sustainability of components used in the automotive sector and identifying the best strategies for reducing their impacts.