CN114360908A - Large-current axial high-frequency resonant capacitor and manufacturing method thereof - Google Patents
Large-current axial high-frequency resonant capacitor and manufacturing method thereof Download PDFInfo
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Abstract
The invention relates to a high-current axial high-frequency resonance capacitor and a manufacturing method thereof, wherein the high-current axial high-frequency resonance capacitor comprises a capacitor core and a shell, the capacitor core is formed by winding a double-sided metal film, a single-sided metal film and an intermediate film arranged between the double-sided metal film and the single-sided metal film, a heat conduction hole is formed in the capacitor core, and a gold spraying layer is sprayed on the surface of the capacitor core; the shell is arranged on the outer side of the capacitor core, and sealing pouring materials are arranged between the shell and the capacitor core. The structure can improve the withstand voltage field intensity and the self-healing performance of the capacitor, the volume is smaller, the number of welding spots connected with the capacitor core in parallel is reduced, the fault rate of capacitor cold solder is reduced, the use safety of the capacitor is effectively improved, and the flashover caused by creepage is avoided.
Description
Technical Field
The invention relates to the field of capacitors, in particular to a high-current axial high-frequency resonant capacitor and a manufacturing method thereof.
Background
Chinese patent document No. CN2899063Y discloses a high-frequency resonant heating capacitor in 5/9/2007, which includes a case, electrodes, and a capacitor core group formed by connecting a plurality of capacitor unit cores, wherein an insulating filler is disposed around the capacitor core group and placed in the case, the capacitor is of a dry structure, a cooler is embedded inside the capacitor, two leading-out ends of the cooler are connected to an external cooling pipe, and heat generated by the capacitor during operation can be dissipated through the cooler. Therefore, further improvements are necessary.
Disclosure of Invention
The invention aims to provide a high-current axial high-frequency resonant capacitor and a manufacturing method thereof, so as to overcome the defects in the prior art.
The high-current axial high-frequency resonance capacitor designed according to the purpose comprises a capacitor core and a shell, and is characterized in that: the capacitor core is formed by winding a double-sided metal film, a single-sided metal film and an intermediate film arranged between the double-sided metal film and the single-sided metal film, a heat conduction hole is formed in the capacitor core, and a gold spraying layer is sprayed on the surface of the capacitor core; the shell is arranged on the outer side of the capacitor core, and sealing pouring materials are arranged between the shell and the capacitor core.
The double-sided metal film comprises a first film medium and double-sided conductive metal layers distributed on the two sides of the first film medium; and double-sided middle reserved edges are arranged between the double-sided conductive metal layers.
The single-sided metal film comprises a second film medium and a single-sided conductive metal layer distributed on one side of the second film medium; the single-sided conductive metal layers are provided with single-sided middle margins, and/or single-sided outer margins are arranged on the outer sides of the single-sided conductive metal layers.
The intermediate film is an optical film or, or the intermediate film and the single-sided metal film have the same structure, and the single-sided conductive metal layer of the intermediate film and the single-sided metal film are inverted from top to bottom.
A plurality of the double-sided middle reserved edges are arranged; the double-sided conductive metal layers are distributed on the two sides of the first film medium in an equal-size mode at equal intervals through a plurality of double-sided middle reserved edges.
Or one of the two sides is reserved; the double-sided conductive metal layers are distributed on the two sides of the first film medium through the reserved edges in the two sides.
The single-side conductive metal layer is provided with a single-side middle margin and a single-side outer margin; a plurality of single-side middle reserved edges are arranged; the single-side outer margin is arranged at the two outer sides of the single-side conductive metal layer; the single-sided conductive metal layer is distributed on the single side of the second film medium in an equidistance and equal size mode through matching of a plurality of single-sided middle edges and two outer single-sided conductive metal layers.
Or the single-side outer margin is arranged on the two outer sides of the single-side conductive metal layer, and the single-side outer margin is arranged in the middle of the single side of the second film medium through the two outer sides.
The size of the first thin film medium is larger than or smaller than that of the second thin film medium and the intermediate film.
The size of the second thin film medium is the same as that of the intermediate film.
The size of the single-sided conductive metal layer is larger than or equal to that of the double-sided conductive metal layer.
The size of the margin in the double-sided is the same as that of the margin in the single-sided.
The size of the single-sided middle margin is larger than or smaller than that of the single-sided outer margin.
The first film medium and the second film medium are both polypropylene films or polyester films; the double-sided conductive metal layer and the single-sided conductive metal layer are both aluminum-plated layers.
The shell is an insulating explosion-proof shell, and the upper end surface and the lower end surface of the shell are open; the capacitor core is placed in the shell; and the upper end and the lower end of the heat conduction hole are respectively provided with a leading-out nut.
The outer side of the lead-out nut extends axially and linearly and is arranged in the heat conducting hole, and the end face of the lead-out nut is higher than the end face of the capacitor core;
or the inner side of the lead-out nut is axially and linearly arranged in the heat conducting hole in an extending mode, and the outer side of the lead-out nut extends to form a nut annular side edge and is covered on the end face of the capacitor core through the nut annular side edge;
or the inner side of the lead-out nut is axially and linearly arranged in the heat conducting hole in an extending mode, the outer side of the lead-out nut extends to form a nut annular side edge, a metal piece is connected to the nut annular side edge, and the nut annular side edge and the metal piece are matched and covered on the capacitor core;
the sealing pouring material is poured among the shell, the capacitor core, the lead-out nut or the metal piece.
The two shells are respectively annularly arranged outside the capacitor core, and the end surfaces of the two shells are flush with each other; and the upper end and the lower end of the heat conduction hole are respectively provided with a lead-out copper block.
The inner side of the lead-out copper block extends axially and linearly and is arranged in the heat conducting hole, an annular groove is formed in the outer side of the lead-out copper block, and the lead-out copper block is covered on the capacitor core and the end face of the shell through the annular groove.
The sealing pouring material is poured among the shell, the capacitor core and the lead-out copper block.
A method for manufacturing a high-current axial high-frequency resonant capacitor is characterized by comprising the following steps: the high-current axial high-frequency resonant capacitor is included; wherein the manufacturing method comprises the following steps:
step 1: the double-sided metal film, the intermediate film and the single-sided metal film are sequentially stacked from top to bottom and then wound by a winding machine to form the cylindrical capacitor core;
step 2: spraying the gold spraying layer on the capacitor core, wherein the gold spraying layer is sprayed for a plurality of times, zinc spraying is carried out for the first time, and zinc tin alloy spraying is carried out for the last two times;
and step 3: placing the capacitor core sprayed with the gold spraying layer in the shell;
and 4, step 4: the lead-out nuts are respectively placed at the upper and lower positions in the heat conduction holes, wherein the end surfaces of the upper and lower lead-out nuts are respectively 3-8mm higher than the end surface of the capacitor core;
and 5: welding holes are formed in the lead-out nut, low-temperature tin paste is smeared on the bottom of the lead-out nut and the position, opposite to the gold spraying layer of the capacitor core, of the lead-out nut, and then the welding holes are welded through high-temperature tin adding, so that the bottom of the lead-out nut and the gold spraying layer of the capacitor core are welded and fixed;
step 6: and the upper and lower extraction nuts are respectively provided with a hole part, one hole part is a through hole, the other hole part is a non-through hole, an extraction electrode is arranged on the through hole of the extraction nut, and then the end surface positions among the shell, the capacitor core, the extraction nut or metal piece and the extraction electrode are sealed and packaged by using the sealing pouring material so as to finally finish the manufacture of the high-current axial high-frequency resonance capacitor.
A method for manufacturing a high-current axial high-frequency resonant capacitor is characterized by comprising the following steps: the high-current axial high-frequency resonant capacitor is included; wherein the manufacturing method comprises the following steps:
step 1: the double-sided metal film, the intermediate film and the single-sided metal film are sequentially stacked from top to bottom and then wound by a winding machine to form the cylindrical capacitor core;
step 2: spraying the gold spraying layer on the capacitor core, wherein the gold spraying layer is sprayed for a plurality of times, zinc spraying is carried out for the first time, and zinc tin alloy spraying is carried out for the last two times;
and step 3: sleeving the two shells on the upper and lower positions of the outer side of the capacitor core sprayed with the gold spraying layer respectively;
and 4, step 4: the number of the lead-out copper blocks is two, the annular grooves of the two lead-out copper blocks are 1-5mm, solder paste is respectively smeared in the annular grooves, and the lead-out copper blocks are placed on a heating platform or are completely dissolved in the annular grooves by means of induction heating;
and 5: respectively pressing the upper position and the lower position of the capacitor core into the two annular grooves for 1-7s to weld and fix the two lead-out copper blocks and the end face of the capacitor core, and then placing the two lead-out copper blocks and the end face of the capacitor core into an industrial alcohol box for cooling;
step 6: and hole parts are respectively arranged on the two lead-out copper blocks, one hole part is a through hole, the other hole part is a non-through hole, lead-out electrodes are arranged on the through holes of the lead-out copper blocks, and then the sealing and pouring material is utilized to carry out sealing and packaging on the side positions among the shell, the capacitor core and the lead-out copper blocks so as to finally finish the manufacture of the high-current axial high-frequency resonance capacitor.
Through the improvement of the structure, compared with the prior art, the invention has the following advantages:
1. the two sides of the double-sided metal film are separated by an edge gap, so that the current-carrying sectional area of the capacitor can be increased, and the current-resisting capacity of the capacitor is increased; the double-sided metal film, the intermediate film and the single-sided metal film are polypropylene films or polyester film media, and the metal layer is aluminized, so that the self-healing property of the double-sided metal film, the intermediate film and the single-sided metal film is improved; the aluminum layer of the double-sided metal film is used as an electrode, so that the withstand voltage field strength and the self-healing performance of the capacitor are improved, the size is smaller, the number of welding spots in parallel connection of the capacitor core is reduced, and the fault rate of capacitor insufficient solder is reduced.
2. The arrangement of the double-sided middle margin, the single-sided middle margin and the single-sided outer margin aims to ensure that certain insulating strength exists among the double-sided metal film, the middle film and the single-sided metal film when the capacitor is wound, and meanwhile, the arrangement size among the margins has a certain range, so that the high-voltage-resistant safety distance of the capacitor is effectively increased on the basis of controlling the production cost of the capacitor, and flashover caused by creepage is avoided.
3. The double-sided metal film forms the polar plate of the capacitor and has good self-healing performance, which is a most critical area for forming capacitance and maintaining the electrical characteristics of the capacitor, can ensure proper metal component proportion, prevent electrochemical corrosion under alternating current conditions, simultaneously can improve the relative withstand voltage of the capacitor, simultaneously, the double-sided aluminum coating layer can also change the electrical characteristics of the capacitor such as withstand voltage, pulse, dv/dt and the like, and can be used as high-frequency large-current resonance in induction heating equipment.
Drawings
FIG. 1 is an exploded view of a first embodiment of a capacitor core according to the present invention.
FIG. 2 is an exploded view of a capacitor core according to a second embodiment of the present invention.
FIG. 3 is an exploded view of a capacitor core according to a third embodiment of the present invention.
FIG. 4 is an exploded view of a capacitor core according to a fourth embodiment of the present invention.
Fig. 5 is a schematic view of a capacitor mounting structure according to a first embodiment of the present invention.
Fig. 6 is a sectional structural view of the capacitor assembly according to the first embodiment of the present invention.
Fig. 7 is a schematic view of a capacitor mounting structure according to a second embodiment of the present invention.
Fig. 8 is a sectional structural view of the capacitor assembly according to the second embodiment of the present invention.
Fig. 9 and 10 are schematic structural views of a lead-out nut according to a second embodiment of the present invention.
Fig. 11 is a schematic view of a capacitor mounting structure according to a third embodiment of the present invention.
Fig. 12 is a sectional structural view showing the capacitor mounting according to the third embodiment of the present invention.
Fig. 13 and 14 are schematic structural views of a lead-out nut according to a third embodiment of the present invention.
Fig. 15 is a schematic view of a capacitor mounting structure according to a fourth embodiment of the present invention.
Fig. 16 is a sectional view schematically showing the structure of the capacitor mounting according to the fourth embodiment of the present invention.
Fig. 17 is a schematic view of a capacitor mounting structure according to a fifth embodiment of the present invention.
Fig. 18 is a sectional structural view showing the assembly of a capacitor according to a fifth embodiment of the present invention.
Fig. 19 is a schematic structural view of a lead-out nut according to a fifth embodiment of the present invention.
Detailed Description
The invention is further described with reference to the following figures and examples.
First embodiment
Referring to fig. 1-6, the high-current axial high-frequency resonant capacitor comprises a capacitor core 1 and a shell 3, wherein the capacitor core 1 is formed by winding a double-sided metal film, a single-sided metal film and an intermediate film 10 arranged between the double-sided metal film and the single-sided metal film, a heat conduction hole 23 is formed in the capacitor core, and a metal spraying layer 2 is sprayed on the surface of the capacitor core; the shell 3 is arranged on the outer side of the capacitor core 1, and a sealing pouring material 4 is arranged between the shell and the capacitor core.
The double-sided metal film comprises a first thin film medium 11 and double-sided conductive metal layers 12 distributed on two sides of the first thin film medium 11; the double-sided conductive metal layers 12 are provided with double-sided intermediate margins 13 therebetween.
The single-sided metal film comprises a second film medium 14 and a single-sided conductive metal layer 15 distributed on one side of the second film medium 14; a single-side middle margin 16 is arranged between the single-side conductive metal layers 15, and/or a single-side outer margin 17 is arranged outside the single-side conductive metal layers 15.
The intermediate film 10 is an optical film or, alternatively, the intermediate film 10 is a metal film having the same structure as the single-sided metal film, and the single-sided conductive metal layer 15 of the intermediate film 10 and the single-sided metal film are inverted from top to bottom.
A plurality of the double-sided middle reserved edges 13 are arranged; the double-sided conductive metal layer 12 is distributed on both sides of the first thin film medium 11 in equal size and at equal distance through a plurality of double-sided middle margins 13.
Or, one of the two sides 13 is arranged; the double-sided conductive metal layer 12 is distributed on both sides of the first thin film medium 11 through one of the double-sided middle margins 13.
A single-side middle margin 16 and a single-side outer margin 17 are arranged on the single-side conductive metal layer 15; a plurality of single-side middle reserved edges 16 are arranged; the single-side outer margin 17 is arranged at two outer sides of the single-side conductive metal layer 15; the single-sided conductive metal layer 15 is distributed on the single side of the second film medium 14 in an equal size and at equal intervals through matching of a plurality of single-sided middle margins 16 and two outer single-sided conductive metal layers 15.
Or the single-sided outer margins 17 are arranged on two outer sides of the single-sided conductive metal layer 15, and the single-sided outer margins 17 are arranged in the middle of the single side of the second thin film medium 14.
The first thin film medium 11 and the second thin film medium 14 are both polypropylene films or polyester films; the double-sided conductive metal layer 12 and the single-sided conductive metal layer 15 are both aluminum-plated layers.
Specifically, as shown in fig. 1, the two-sided middle margin 13 is provided with a plurality of sides; the double-sided conductive metal layer 12 is distributed on both sides of the first thin film medium 11 in equal size and at equal distance through a plurality of double-sided middle margins 13. A single-side middle margin 16 and a single-side outer margin 17 are arranged on the single-side conductive metal layer 15; a plurality of single-side middle reserved edges 16 are arranged; the single-side outer margin 17 is arranged at two outer sides of the single-side conductive metal layer 15; the single-sided conductive metal layer 15 is distributed on the single side of the second film medium 14 in an equal size and at equal intervals through matching of a plurality of single-sided middle margins 16 and two outer single-sided conductive metal layers 15. The intermediate film 10 and the single-sided metal film have the same structure, and the single-sided conductive metal layer 15 of the intermediate film and the single-sided metal film are inverted from top to bottom. Namely, the single-sided conductive metal layer 15 of the intermediate film 10 faces downward, and the single-sided conductive metal layer 15 of the single-sided metal film faces upward.
The first film medium 11 is a polypropylene PET film, and the second film medium 14 and the intermediate film 10 are polyester PP films; six strings of films can be formed among the double-sided metal film, the intermediate film and the single-sided metal film. The overlapping winding between the intermediate film and the single-sided metal film can increase the plated aluminum electrodes between the capacitor cores 1, effectively increase the overcurrent capacity of the capacitor, and has the advantages of low product loss, low ESR (equivalent series resistance) and low heat productivity of the product.
As shown in fig. 2, a plurality of the double-sided middle margins 13 are arranged; the double-sided conductive metal layer 12 is distributed on both sides of the first thin film medium 11 in equal size and at equal distance through a plurality of double-sided middle margins 13. A single-side middle margin 16 and a single-side outer margin 17 are arranged on the single-side conductive metal layer 15; a plurality of single-side middle reserved edges 16 are arranged; the single-side outer margin 17 is arranged at two outer sides of the single-side conductive metal layer 15; the single-sided conductive metal layer 15 is distributed on the single side of the second film medium 14 in an equal size and at equal intervals through matching of a plurality of single-sided middle margins 16 and two outer single-sided conductive metal layers 15. The intermediate film 10 is an optical film, which means a strip of film medium without a vapor deposited metal coating.
The first film medium 11 is a polypropylene PET film, and the second film medium 14 and the intermediate film 10 are polyester PP films; six strings of films can be formed among the double-sided metal film, the intermediate film and the single-sided metal film. The overlapping winding between the intermediate film and the single-sided metal film can increase the plated aluminum electrodes between the capacitor cores 1, effectively increase the overcurrent capacity of the capacitor, and has the advantages of low product loss, low ESR (equivalent series resistance) and low heat productivity of the product.
As shown in fig. 3, one of the two sides 13 is provided; the double-sided conductive metal layer 12 is distributed on both sides of the first thin film medium 11 through one of the double-sided middle margins 13. The single-side outer margin 17 is arranged on two outer sides of the single-side conductive metal layer 15, and the single-side outer margin 17 is arranged in the middle of the single side of the second film medium 14. The intermediate film 10 and the single-sided metal film have the same structure, and the single-sided conductive metal layer 15 of the intermediate film and the single-sided metal film are inverted from top to bottom. Namely, the single-sided conductive metal layer 15 of the intermediate film 10 faces downward, and the single-sided conductive metal layer 15 of the single-sided metal film faces upward.
The first film medium 11 is a polypropylene PET film, and the second film medium 14 and the intermediate film 10 are polyester PP films; two strings of films may be formed between the double-sided metal film, the intermediate film, and the single-sided metal film. The overlapping winding between the intermediate film and the single-sided metal film can increase the plated aluminum electrodes between the capacitor cores 1, effectively increase the overcurrent capacity of the capacitor, and has the advantages of low product loss, low ESR (equivalent series resistance) and low heat productivity of the product.
As shown in fig. 4, one of the two sides 13 is left; the double-sided conductive metal layer 12 is distributed on both sides of the first thin film medium 11 through one of the double-sided middle margins 13. The single-side outer margin 17 is arranged on two outer sides of the single-side conductive metal layer 15, and the single-side outer margin 17 is arranged in the middle of the single side of the second film medium 14. The intermediate film 10 is an optical film, which means a strip of film medium without a vapor deposited metal coating.
The first film medium 11 is a polypropylene PET film, and the second film medium 14 and the intermediate film 10 are polyester PP films; two strings of films may be formed between the double-sided metal film, the intermediate film, and the single-sided metal film. The overlapping winding between the intermediate film and the single-sided metal film can increase the plated aluminum electrodes between the capacitor cores 1, effectively increase the overcurrent capacity of the capacitor, and has the advantages of low product loss, low ESR (equivalent series resistance) and low heat productivity of the product.
The sheet resistance value of one surface of the double-sided metal film in the figures 1-4 is required to be less than or equal to 1.2 omega/□, the sheet resistance value of the other surface of the double-sided metal film is required to be less than or equal to 1.0 omega/□, and the sheet resistance value required by the single-sided metal film is required to be 1-3 omega/□.
The size of the first thin film medium 11 is larger or smaller than the size of the second thin film medium 14 and the intermediate film 10.
The second thin-film medium 14 has the same dimensions as the intermediate film 10.
The size of the single-sided conductive metal layer 15 is larger than or equal to that of the double-sided conductive metal layer 12.
The dimensions of the double-sided intermediate margin 13 are the same as the dimensions of the single-sided intermediate margin 16.
The size of the single-sided middle margin 16 is larger or smaller than the size of the single-sided outer margin 17.
As shown in fig. 1 and 2, the dimension W1 of the first thin film medium 11 is larger than the dimension W2 of the second thin film medium 14 and the intermediate film 10. The sizes of the double-sided conductive metal layer 12 and the single-sided conductive metal layer 15 are both L1. The size of the double-sided middle margin 13 and the single-sided middle margin 16 is B1. The size B1 of the double-sided middle margin 13 and the single-sided middle margin 16 is larger than the size B2 of the single-sided outer margin 17.
As shown in fig. 3 and 4, the dimension W1 of the first thin film medium 11 is larger than the dimension W2 of the second thin film medium 14 and the intermediate film 10. The dimension L1 of the double-sided conductive metal layer 12 is smaller than the dimension L2 of the single-sided conductive metal layer 15. The size B1 of the double-sided middle margin 13 is larger than the size B2 of the single-sided outer margin 17.
The shell 3 is an insulating explosion-proof shell, and the upper end surface and the lower end surface of the shell are open; the capacitor core 1 is placed in the shell 3; the upper end and the lower end of the heat conduction hole 23 are respectively provided with a lead-out nut 5.
The outer side of the lead-out nut 5 extends axially and linearly and is arranged in the heat conduction hole 23, and the end face of the lead-out nut 5 is higher than the end face of the capacitor core 1.
The sealing pouring material 4 is poured among the shell 3, the capacitor core 1 and the lead-out nut 5.
The method for manufacturing the high-current axial high-frequency resonant capacitor comprises the following steps:
step 1: the double-sided metal film, the intermediate film 10 and the single-sided metal film are sequentially stacked from top to bottom, and then wound by a winding machine to form the cylindrical capacitor core 1;
step 2: spraying the gold spraying layer 2 on the capacitor core 1, wherein the gold spraying layer 2 is sprayed for a plurality of times, zinc spraying is carried out for two times, and zinc tin alloy spraying is carried out for two times finally, so as to increase the weldability;
and step 3: placing the capacitor core 1 sprayed with the gold spraying layer 2 in the shell 3;
and 4, step 4: the lead-out nuts 5 are respectively arranged at the upper and lower positions in the heat conduction holes 23, wherein the end surfaces of the upper and lower lead-out nuts 5 are respectively 3-8mm, preferably 5-6mm,
and 5: a welding hole is formed in the lead-out nut 5, low-temperature tin paste is smeared on the bottom of the lead-out nut 5 and the position, opposite to the gold spraying layer 2 of the capacitor core 1, of the lead-out nut, and then the welding hole is welded by adopting high-temperature tin adding, so that the bottom of the lead-out nut 5 and the gold spraying layer 2 of the capacitor core 1 are welded and fixed;
step 6: and hole parts are respectively arranged on the upper and lower extraction nuts 5, wherein one hole part is a through hole, the other hole part is a non-through hole, an extraction electrode is arranged on the through hole of the extraction nut 5, and then the end surface positions among the shell 3, the capacitor core 1, the extraction nut 5 and the extraction electrode are sealed and packaged by using the sealing pouring material 4, so that the manufacture of the high-current axial high-frequency resonance capacitor is finally completed.
The mandrel of the capacitor core 1 is wound by a large mandrel, so that the heat in the capacitor core 1 can be dissipated through the lead-out nut 5. The flame-retardant and explosion-proof shell 3 can increase the flame-retardant and explosion-proof performance of the capacitor core 1, and a circular insulating shell is made of FR4 or SMC, so that the capacitor core has the advantages of good heat dissipation and high reliability, and can not burn when being used as a rubber-coated paper product.
In this embodiment, preferably, the end surfaces of the upper and lower lead-out nuts 5 are respectively 5-6mm higher than the end surface of the capacitor core 1, so that the heat of the capacitor core 1 can be rapidly taken away through the lead-out nuts 5; the welding holes are arranged to ensure the weldability of the metal spraying layer 2 and the lead-out nut 5 of the capacitor core 1 during high-temperature welding, and the high-temperature tin-adding welding and the solder paste are matched to quickly and uniformly melt, so that the welding reliability of the metal spraying layer 2 of the lead-out nut 5 bottom and the capacitor core 1 is ensured, and the overcurrent capacity is improved. The interior of the lead-out nut 5 extends to the interior of the heat conduction hole 23, the specific extension size is determined according to the maximum safe creepage distance insulation, and the heat in the capacitor core 1 is rapidly taken out through the interior of the lead-out nut 5. Because of leading out the electrode customer and all contacting through water-cooling board and leading out the electrode when using, when heavy current the leading out nut 5 does not have at all to generate heat, and customer installation copper is close the packaging face of electric capacity core 1, can take away the heat of condenser product itself fast through these, increase the current capacity of product. The sealing pouring material 4 is pouring epoxy resin.
Specifically, the internal extension size of the extraction nut 5 is consistent with the size of the inner hole of the winding mandrel, the mandrel is selected according to the size requirement between 18 and 30, and the resonance current can reach 50 to 150A (no water cooling) and 200 to 300A (water cooling).
The large-current axial high-frequency resonance capacitor produced by the manufacturing method can be used for a resonance circuit of high-power induction heating equipment, a series and parallel resonance circuit of various intermediate frequency, super-audio frequency and other electronic equipment, a power output transformer, primary and secondary LC parallel resonance and the like, and has wide application range.
Second embodiment
Referring to fig. 7 to 10, the present large current axial high frequency resonant capacitor and the method of manufacturing the same are different from the first embodiment in that: the inner side of the lead-out nut 5 extends axially and linearly and is arranged in the heat conduction hole 23, and the outer side of the lead-out nut 5 extends to form a nut annular side 51 and covers the end face of the capacitor core 1 through the nut annular side 51.
Specifically, the extension size of the inside of the extraction nut 5 is consistent with the size of the inner hole of the winding mandrel, the extraction nut 5 is wound by a reel with the inner diameter of 30, the outer diameter of the extraction nut 5 is more than 50, the resonance current can reach 150 and 350A (when no water cooling) and 400 and 600A (when water cooling), and the mandrel can be selected according to the size requirement.
The lead-out nut 5 and the nut annular side 51 are directly formed by one-time processing of a copper block, or the lead-out nut 5 and the nut annular side 51 can be welded and fixed with each other after being formed by processing of the copper block. The periphery of the lead-out nut 5 is equal to the size of the core shaft and serves as a welding surface of the end face of the capacitor core 1, the bottom face of the lead-out nut 5 is machined and milled to be flat, and the appearance treatment is finished and then the tapping lines are machined.
The other parts not described are the same as those of the first embodiment.
Third embodiment
Referring to fig. 11 to 14, the present large current axial high frequency resonant capacitor and the method of manufacturing the same are different from the first embodiment in that: the inner side of the lead-out nut 5 extends axially and linearly and is arranged in the heat conduction hole 23, the outer side of the lead-out nut 5 extends to form a nut annular side 51, a metal piece 8 is connected to the outer side of the lead-out nut 5 through the nut annular side 51, and the lead-out nut and the metal piece 8 are matched and covered on the capacitor core 1.
Specifically, the outer peripheries of the shell 3 and the metal piece 8 are circular; the periphery of the annular side edge 5 of the nut is provided with a threaded part, the metal piece 8 is an aluminum block or a copper block, the inner ring of the metal piece is also provided with a threaded part, the threaded part is just matched with the threaded part of the annular side edge 5 of the nut, the leading-out nut 5 and the metal piece 8 are used for wrapping at least parts of the end surface and the outer side of the capacitor core 1, the middle position of the outer side of the capacitor core 1 is wrapped by the shell 3, two packaging explosion-proof holes are formed in the upper portion of the metal piece 8 and used for injecting the sealing injection material 4, and therefore the sealing performance of a product is effectively guaranteed.
Silver paste or low-temperature tin paste or other welding metals are smeared at the contact position between the leading-out nut 5 and the metal piece 8, the leading-out nut 5 and the metal piece 8 are heated to be melted, the heat dissipation performance of the product and the consistency of the whole effect are guaranteed, the whole heat dissipation performance of the product is further enhanced, the metal piece 8 can be adjusted in position according to the leading-out nut 5, the overcurrent capacity of the product is increased, the heat dissipation capacity is enhanced, and the practicability is high.
The lead-out nut 5 and the nut annular side 51 are directly formed by one-time processing of a copper block, or the lead-out nut 5 and the nut annular side 51 can be welded and fixed with each other after being formed by processing of the copper block. The periphery of the lead-out nut 5 is equal to the size of the core shaft and serves as a welding surface of the end face of the capacitor core 1, the bottom face of the lead-out nut 5 is machined and milled to be flat, and the appearance treatment is finished and then the tapping lines are machined. The periphery of the annular side 51 of the nut is directly machined with a threaded portion.
The other parts not described are the same as those of the first embodiment.
The other parts not described are the same as those of the first embodiment.
Fourth embodiment
Referring to fig. 15 and 16, the present large current axial high frequency resonant capacitor and the method for manufacturing the same are different from the third embodiment in that: the peripheries of the shell 3 and the metal piece 8 are square. Four mounting holes are additionally formed in the periphery of the metal piece 8, so that the assembly of a product can be facilitated, and meanwhile, the heat dissipation contact capacity of the product can be further improved.
The other parts not described are the same as those of the third embodiment.
Fifth embodiment
Referring to fig. 17 to 19, the present large current axial high frequency resonance capacitor and the method of manufacturing the same are different from the first embodiment in that: the two shells 3 are metal explosion-proof shells, and are annularly arranged on the outer side of the capacitor core 1 respectively, and the end surfaces of the two shells 3 are flush with each other; the upper end and the lower end of the heat conduction hole 23 are respectively provided with a lead-out copper block 6.
The inner side of the lead-out copper block 6 extends axially and linearly and is arranged in the heat conduction hole 23, the outer side of the lead-out copper block 6 is provided with an annular groove 7, and the annular groove 7 covers the end faces of the capacitor core 1 and the shell 3.
The sealing pouring material 4 is poured among the shell 3, the capacitor core 1 and the lead-out copper block 6.
The method for manufacturing the high-current axial high-frequency resonant capacitor comprises the following steps:
step 1: the double-sided metal film, the intermediate film 10 and the single-sided metal film are sequentially stacked from top to bottom, and then wound by a winding machine to form the cylindrical capacitor core 1;
step 2: spraying the gold spraying layer 2 on the capacitor core 1, wherein the gold spraying layer 2 is sprayed for a plurality of times, zinc spraying is carried out for two times, and zinc tin alloy spraying is carried out for the last two times;
and step 3: sleeving the two shells 3 at the upper and lower positions of the outer side of the capacitor core 1 sprayed with the gold spraying layer 2 respectively;
and 4, step 4: the number of the lead-out copper blocks 6 is two, the annular grooves 7 of the two lead-out copper blocks 6 are 1-5mm, solder paste is respectively smeared in the annular grooves, and the lead-out copper blocks 6 are placed on a heating platform or the solder paste is completely dissolved in the annular grooves 7 by means of induction heating;
and 5: respectively pressing the upper position and the lower position of the capacitor core 1 into the two annular grooves 7 for 1-7s to weld and fix the two lead-out copper blocks 6 and the end surface of the capacitor core 1, and then placing the lead-out copper blocks and the end surface of the capacitor core 1 into an industrial alcohol box for cooling;
step 6: hole parts are respectively arranged on the two lead-out copper blocks 6, one hole part is a through hole, the other hole part is a non-through hole, lead-out electrodes are arranged on the through holes of the lead-out copper blocks 6, and then the sealing and pouring material 4 is utilized to seal and package the side positions among the shell 3, the capacitor core 1 and the lead-out copper blocks 6 so as to finally finish the manufacture of the high-current axial high-frequency resonance capacitor.
In the embodiment, the shell 3 is an aluminum ring or copper ring shell, which can increase the flame-retardant and anti-explosion performance of the capacitor core 1, the aluminum ring and the copper ring are directly abutted against the capacitor core 1 and the leading-out electrode, so that the capacitor core is good in heat dissipation and high in reliability, compared with a rubber-coated paper product, the capacitor core is non-combustible, when the leading-out electrode is assembled and dissipated through a user water-cooled copper plate, the peripheral temperature of the capacitor core is synchronously and rapidly dissipated by the same metal ring, and the metal ring is directly contacted with the surface of the capacitor core 1 without insulation.
When alcohol is required to be cooled, the depth of the cooling alcohol is less than or equal to the thickness of the lead-out electrode, and the welding mode effectively increases the overcurrent capacity of the capacitor core 1 and the welding of the whole end face of the capacitor core into the lead-out copper block 6 electrode.
The interior of the lead-out copper block 6 extends to the interior of the heat conduction hole 23, the specific extension size is determined according to the maximum safe creepage distance insulation, and the heat in the capacitor core 1 is rapidly taken out through the interior of the lead-out copper block 6. Because of leading out the contact of electrode customer's time all through water-cooling board and leading out electrode when using, when heavy current draw out copper billet 6 and do not have at all to generate heat, and customer installation copper and whole draw out the contact of copper billet 6, the water-cooling heat dissipation can take away the heat of condenser product itself fast through these, increases the ability of overflowing of product.
The sealing filling material 4 is filling epoxy resin, and is directly filled in the gap between the shell 3 and the side surface of the capacitor core 1, so that the sealing performance and the oxidation resistance of the product are effectively ensured.
Specifically, the extension size of the inside of the lead-out copper block 6 is consistent with the size of the inner hole of the winding mandrel, a reel with the inner diameter of 30 is adopted for winding, the outer diameter of the lead-out copper block 6 is more than 50, the resonant current can reach 300-600A (when no water cooling) and 800-1200A (when water cooling), and the mandrel can be selected according to the size requirement.
The lead-out copper block 6 is square, and copper nuts 9 are respectively arranged at the middle part and the periphery of the lead-out copper block; wherein, the copper nuts 9 around are separately arranged and then welded on the lead-out copper blocks 6, the copper nuts 9 in the middle and the lead-out copper blocks 6 are directly processed and formed by the copper blocks at one time, or the copper nuts 9 around and the lead-out copper blocks 6 are directly processed and formed by the copper blocks at one time, and the copper nuts 9 in the middle are separately arranged and then welded on the lead-out copper blocks 6. The periphery of the middle copper nut 9 is equal to the size of the mandrel and serves as a welding surface of the end face of the capacitor core 1, the bottom face of the middle copper nut 9 is machined and milled to be flat, and the appearance is machined and tapped after being treated.
The other parts not described are the same as those of the first embodiment.
The foregoing is a preferred embodiment of the present invention, and the basic principles, principal features and advantages of the invention are shown and described. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are merely illustrative of the principles of the present invention, but various changes and modifications may be made without departing from the spirit and scope of the invention as defined by the appended claims and their equivalents.
Claims (10)
1. The utility model provides a big axial high frequency resonance condenser of electric current, includes electric capacity core (1) and shell (3), its characterized in that: the capacitor core (1) is formed by winding a double-sided metal film, a single-sided metal film and an intermediate film (10) arranged between the double-sided metal film and the single-sided metal film, a heat conduction hole (23) is formed in the capacitor core, and a gold spraying layer (2) is sprayed on the surface of the capacitor core; the shell (3) is arranged on the outer side of the capacitor core (1), and a sealing pouring material (4) is arranged between the shell and the capacitor core.
2. The high-current axial high-frequency resonance capacitor according to claim 1, wherein: the double-sided metal film comprises a first thin film medium (11) and double-sided conductive metal layers (12) distributed on the two sides of the first thin film medium (11); double-sided middle margins (13) are arranged between the double-sided conductive metal layers (12);
the single-sided metal film comprises a second thin film medium (14) and a single-sided conductive metal layer (15) distributed on one side of the second thin film medium (14); a single-side middle margin (16) is arranged between the single-side conductive metal layers (15), or a single-side outer margin (17) is arranged on the outer side of the single-side conductive metal layers (15);
the intermediate film (10) is an optical film or the intermediate film (10) and the single-side metal film have the same structure, and the single-side conductive metal layer (15) of the intermediate film and the single-side metal film are inverted from top to bottom.
3. The high-current axial high-frequency resonance capacitor according to claim 2, wherein: a plurality of the double-sided middle reserved edges (13) are arranged; the double-sided conductive metal layers (12) are distributed on the two sides of the first film medium (11) in an equidistance and equal size mode through a plurality of double-sided middle reserved edges (13);
or one double-sided middle margin (13) is arranged; the double-sided conductive metal layers (12) are distributed on the two sides of the first film medium (11) through one double-sided middle margin (13).
4. The high-current axial high-frequency resonance capacitor according to claim 3, wherein: a single-side middle margin (16) and a single-side outer margin (17) are arranged on the single-side conductive metal layer (15); a plurality of single-side middle reserved edges (16) are arranged; the single-surface outer reserved edges (17) are arranged on two outer sides of the single-surface conductive metal layer (15); the single-sided conductive metal layer (15) is distributed on one side of the second thin film medium (14) in an equal size and at equal intervals through matching of a plurality of single-sided middle margins (16) and two outer single-sided conductive metal layers (15);
or the single-side outer margins (17) are arranged on two outer sides of the single-side conductive metal layer (15), and the single-side outer margins (17) are arranged in the middle of the single side of the second film medium (14).
5. The high-current axial high-frequency resonance capacitor according to claim 4, wherein: the size of the first thin film medium (11) is larger or smaller than that of the second thin film medium (14) and the intermediate film (10);
the size of the second thin film medium (14) is the same as the size of the intermediate film (10);
the size of the single-sided conductive metal layer (15) is larger than or equal to that of the double-sided conductive metal layer (12);
the size of the double-sided middle margin (13) is the same as that of the single-sided middle margin (16);
the size of the single-face middle margin (16) is larger than or smaller than that of the single-face outer margin (17).
6. The high-current axial high-frequency resonance capacitor according to claim 5, wherein: the first thin film medium (11) and the second thin film medium (14) are both polypropylene films or polyester films; the double-sided conductive metal layer (12) and the single-sided conductive metal layer (15) are both aluminum-plated layers.
7. The high-current axial high-frequency resonance capacitor according to claim 6, wherein: the shell (3) is an insulating explosion-proof shell, and the upper end surface and the lower end surface of the shell are open; the capacitor core (1) is placed in the shell (3); the upper end and the lower end of the heat conduction hole (23) are respectively provided with a lead-out nut (5);
the outer side of the lead-out nut (5) extends axially and linearly and is arranged in the heat conduction hole (23), the end surface of the lead-out nut (5) is higher than the end surface of the capacitor core (1),
or the inner side of the lead-out nut (5) extends axially and linearly and is arranged in the heat conduction hole (23), and a nut annular side edge (51) extends from the outer side of the lead-out nut (5) and is covered on the end surface of the capacitor core (1) through the nut annular side edge (51);
or the inner side of the lead-out nut (5) is axially and linearly arranged in an extending manner and is arranged in the heat conducting hole (23), the outer side of the lead-out nut (5) is extended with a nut annular side edge (51), is connected with a metal piece (8) through the nut annular side edge (51), and is matched with the metal piece (8) to be covered on the capacitor core (1);
the sealing pouring material (4) is poured among the shell (3), the capacitor core (1), the lead-out nut (5) or the metal piece (8).
8. The high-current axial high-frequency resonance capacitor according to claim 6, wherein: the two shells (3) are metal explosion-proof shells, and are arranged in an annular manner, and the two shells (3) are respectively arranged on the outer side of the capacitor core (1) in an annular manner, and the end faces of the shells are flush with each other; the upper end and the lower end of the heat conduction hole (23) are respectively provided with a lead-out copper block (6);
the inner side of the lead-out copper block (6) extends axially and linearly and is arranged in the heat conduction hole (23), an annular groove (7) is arranged on the outer side of the lead-out copper block (6), and the lead-out copper block is covered on the end faces of the capacitor core (1) and the shell (3) through the annular groove (7);
the sealing pouring material (4) is poured among the shell (3), the capacitor core (1) and the lead-out copper block (6).
9. A method for manufacturing a high-current axial high-frequency resonant capacitor is characterized by comprising the following steps: a high-current axial high-frequency resonance capacitor comprising the high-current axial high-frequency resonance capacitor as recited in claim 7; wherein the manufacturing method comprises the following steps:
step 1: the double-sided metal film, the intermediate film (10) and the single-sided metal film are sequentially stacked from top to bottom and then wound by a winding machine to form the cylindrical capacitor core (1);
step 2: spraying the gold spraying layer (2) on the capacitor core (1), wherein the gold spraying layer (2) is sprayed for a plurality of times, zinc spraying is carried out for two times, and zinc tin alloy spraying is carried out for the last two times;
and step 3: placing the capacitor core (1) sprayed with the gold spraying layer (2) in the shell (3);
and 4, step 4: the lead-out nuts (5) are respectively arranged at the upper and lower positions in the heat conduction holes (23), wherein the end surfaces of the upper and lower lead-out nuts (5) are respectively 3-8mm higher than the end surface of the capacitor core (1);
and 5: a welding hole is formed in the lead-out nut (5), low-temperature tin paste is smeared on the bottom of the lead-out nut (5) and the position of the gold spraying layer (2) opposite to the capacitor core (1), and then high-temperature tin is added to weld the welding hole, so that the bottom of the lead-out nut (5) and the gold spraying layer (2) of the capacitor core (1) are welded and fixed;
step 6: and hole parts are respectively arranged on the upper and lower extraction nuts (5), one hole part is a through hole, the other hole part is a non-through hole, extraction electrodes are arranged on the through hole of the extraction nut (5), and then the end face positions among the shell (3), the capacitor core (1), the extraction nut (5) or the metal piece (8) and the extraction electrodes are sealed and packaged by using the sealing pouring material (4) so as to finally finish the manufacture of the high-current axial high-frequency resonance capacitor.
10. A method for manufacturing a high-current axial high-frequency resonant capacitor is characterized by comprising the following steps: a high-current axial high-frequency resonance capacitor comprising the high-current axial high-frequency resonance capacitor as recited in claim 8; wherein the manufacturing method comprises the following steps:
step 1: the double-sided metal film, the intermediate film (10) and the single-sided metal film are sequentially stacked from top to bottom and then wound by a winding machine to form the cylindrical capacitor core (1);
step 2: spraying the gold spraying layer (2) on the capacitor core (1), wherein the gold spraying layer (2) is sprayed for a plurality of times, zinc spraying is carried out for two times, and zinc tin alloy spraying is carried out for the last two times;
and step 3: sleeving the two shells (3) at the upper and lower positions of the outer side of the capacitor core (1) sprayed with the gold spraying layer (2) respectively;
and 4, step 4: the number of the lead-out copper blocks (6) is two, the annular grooves (7) of the two lead-out copper blocks (6) are 1-5mm, solder paste is respectively smeared in the annular grooves, and the lead-out copper blocks (6) are placed on a heating platform or the solder paste is completely dissolved in the annular grooves (7) by means of induction heating;
and 5: respectively crimping the upper position and the lower position of the capacitor core (1) into the two annular grooves (7) for 1-7s, so that the two lead-out copper blocks (6) and the end face of the capacitor core (1) are welded and fixed, and then placing the lead-out copper blocks and the end face of the capacitor core into an industrial alcohol box for cooling;
step 6: hole parts are respectively arranged on the two lead-out copper blocks (6), one hole part is a through hole, the other hole part is a non-through hole, lead-out electrodes are arranged on the through holes of the lead-out copper blocks (6), and then the sealing pouring material (4) is utilized to seal and package the side positions among the shell (3), the capacitor core (1) and the lead-out copper blocks (6) so as to finally finish the manufacture of the high-current axial high-frequency resonance capacitor.
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| CN201302924Y (en) * | 2008-11-11 | 2009-09-02 | 佛山市顺德区创格电子实业有限公司 | Full-film water-cooled intermediate-frequency induction heating capacitor |
| CN202076133U (en) * | 2011-06-03 | 2011-12-14 | 安徽赛福电子有限公司 | Dry type capacitor with internal series structure |
| CN207282323U (en) * | 2017-12-15 | 2018-04-27 | 深圳市纬迪实业发展有限公司 | A kind of thin-film capacitor core and very high voltage film capacitor |
| CN209675127U (en) * | 2019-02-03 | 2019-11-22 | 佛山市欣源电子股份有限公司 | A kind of two-sided metallization string data high current thin film capacitor |
| JP2020004953A (en) * | 2018-06-20 | 2020-01-09 | Tdk株式会社 | Thin film capacitor, manufacturing method therefor, and multilayer circuit board embedded with thin film capacitor |
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2022
- 2022-01-15 CN CN202210045547.8A patent/CN114360908A/en active Pending
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN201302924Y (en) * | 2008-11-11 | 2009-09-02 | 佛山市顺德区创格电子实业有限公司 | Full-film water-cooled intermediate-frequency induction heating capacitor |
| CN202076133U (en) * | 2011-06-03 | 2011-12-14 | 安徽赛福电子有限公司 | Dry type capacitor with internal series structure |
| CN207282323U (en) * | 2017-12-15 | 2018-04-27 | 深圳市纬迪实业发展有限公司 | A kind of thin-film capacitor core and very high voltage film capacitor |
| JP2020004953A (en) * | 2018-06-20 | 2020-01-09 | Tdk株式会社 | Thin film capacitor, manufacturing method therefor, and multilayer circuit board embedded with thin film capacitor |
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