CN107293406B - Capacitor for electric drive and method for manufacturing the same - Google Patents

Capacitor for electric drive and method for manufacturing the same Download PDF

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Publication number
CN107293406B
CN107293406B CN201610200616.2A CN201610200616A CN107293406B CN 107293406 B CN107293406 B CN 107293406B CN 201610200616 A CN201610200616 A CN 201610200616A CN 107293406 B CN107293406 B CN 107293406B
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China
Prior art keywords
capacitor
mounting plate
capacitor bank
bank
shell
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CN107293406A (en
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汤泽波
庞猛
张献伟
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Shanghai Saitekang Trade Co ltd
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Stgcon New Energy Technology Co ltd
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01GCAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
    • H01G4/00Fixed capacitors; Processes of their manufacture
    • H01G4/002Details
    • H01G4/224Housing; Encapsulation
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01GCAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
    • H01G4/00Fixed capacitors; Processes of their manufacture
    • H01G4/002Details
    • H01G4/228Terminals
    • H01G4/236Terminals leading through the housing, i.e. lead-through

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Fixed Capacitors And Capacitor Manufacturing Machines (AREA)

Abstract

The invention provides an electrically-driven capacitor and a manufacturing method thereof, wherein the method comprises the following steps: the shell is of a structure with one open end; a capacitor bank disposed within the housing; the bus bar assembly is arranged on the capacitor bank, and a capacitor insulating layer is arranged between the bus bar assembly and the capacitor bank; potting resin filled between the inner wall of the housing and the capacitor bank; a top-sealing resin covering the capacitor bank at the housing opening. Compared with the prior art, the invention has the following beneficial effects: the specially designed bus bar is used as a leading-out terminal, so that ESL and ESR of the capacitor can be effectively reduced; the capacitor bank is formed by connecting a plurality of flat capacitor cores without hard core rods in parallel, and the space utilization rate and the energy density of the capacitor are effectively improved by designing the capacitor shell.

Description

Capacitor for electric drive and method for manufacturing the same
Technical Field
The invention relates to the field of capacitors, in particular to an electrically-driven capacitor and a manufacturing method thereof.
Background
With the development of pure electric vehicles and hybrid electric vehicles, capacitors for electric driving have also been developed greatly. Besides the super capacitor for storing electric energy, the electric automobile also has an electric drive capacitor, and the main purpose of the electric drive capacitor is to smooth and filter various irregular harmonic waves in an electric automobile power system and improve the operating environment of the electric power system.
Because the automobile inner space is small, the space provided for the capacitor for electric drive is limited, the absorption capacitor is generally removed from the circuit system, the conventional capacitor also has the defects of high self-inductance ESL and equivalent series resistance ESR, the circular capacitor core causes low space utilization rate, and the energy density needs to be improved.
Disclosure of Invention
In view of the defects in the prior art, the invention aims to provide an electric driving capacitor with high energy density and a manufacturing method thereof.
In order to solve the above technical problems, the present invention provides a humidity sensor, comprising: the shell is of a structure with one open end; a capacitor bank disposed within the housing; the bus bar assembly is arranged on the capacitor bank, and a capacitor insulating layer is arranged between the bus bar assembly and the capacitor bank; potting resin filled between the inner wall of the housing and the capacitor bank; a top-sealing resin covering the capacitor bank at the housing opening.
Preferably, the busbar assembly includes: the capacitor comprises a first copper bar and a second copper bar, wherein the first copper bar comprises a first connecting plate and a first mounting plate which are connected, an included angle between the first connecting plate and the first mounting plate is 90 degrees, the first mounting plate is arranged on the capacitor, and a first leading-out end is arranged on the first connecting plate; the second copper bar comprises a second connecting plate and a second mounting plate which are connected, the included angle between the second connecting plate and the second mounting plate is 90 degrees, the second mounting plate is arranged on the capacitor, and a second leading-out end is arranged on the second connecting plate; wherein the first mounting plate is disposed on the second mounting plate.
Preferably, a busbar insulating layer is arranged between the first mounting plate and the second mounting plate.
Preferably, the capacitor bank comprises four capacitor cores connected in parallel; or the capacitor bank comprises: the first capacitor and the second capacitor are connected in series; the four capacitor cores are connected in parallel; the first capacitor and the second capacitor which are connected in series are connected with four capacitor cores in parallel, and the connection point of the first capacitor and the second capacitor is grounded.
Preferably, the capacitor core is wound from two layers of metallized film, the metallized film comprising: a base film; the metal layer is wrapped on the outer side of the base film; the metal layer comprises a plurality of independent metal units, and the metal units are connected through metal explosion-proof wires.
Preferably, the thickness of the metal layer is designed to be gradually changed along the axial direction of the metallized film.
Preferably, the housing comprises: the device comprises a shell, wherein fixing lugs are arranged on two sides of the shell; and the embedding hole is arranged on the fixing lug, and the outer wall of the embedding hole is of a sawtooth structure.
A method for manufacturing an electrically-driven capacitor comprises the following steps:
step 1, winding two layers of metallized films with explosion-proof wires into a capacitor core, and flattening the wound capacitor core into a flat shape;
step 2, applying pressure of 2.5 MPa-3.5 MPa to the capacitor core, and putting the capacitor core into a drying oven at 110 ℃ for 3-6 hours for heat setting;
step 3, spraying zinc-tin alloy on two ends of the capacitor core to form a capacitor bank;
step 4, putting the capacitor bank and the busbar assembly into a shell and welding the capacitor bank and the busbar assembly;
step 5, pouring potting resin and top sealing resin;
and 6, testing.
Preferably, the step 5 comprises:
step 5.1, respectively putting polyurethane and a curing agent into respective charging barrels to be stirred and heated under the condition of-30 kPa to-40 kPa; wherein the heating temperature of the polyurethane is 65-70 ℃, the heating temperature of the curing agent is 30-35 ℃, and the mixing ratio of the polyurethane to the curing agent is 100:20, mixing to obtain the potting resin;
step 5.2, injecting the prepared potting resin under the vacuum condition to enable the potting resin to submerge the capacitor bank and the busbar assembly, and curing for 3 hours in an oven at the temperature of 60 +/-3 ℃;
and 5.3, injecting top sealing resin until the position is 1mm lower than the shell opening, and curing for 8-24 hours in a drying room at the temperature of 35-40 ℃.
Preferably, in the step 3, the thickness of the zinc-tin alloy is 0.5mm to 1.0mm.
Compared with the prior art, the invention has the following beneficial effects: the specially designed bus bar is used as a leading-out terminal, so that ESL and ESR of the capacitor can be effectively reduced; the capacitor bank is formed by connecting a plurality of capacitor cores of flat hard core rods without the same specification in parallel, and the space utilization rate and the energy density of the capacitor are effectively improved by designing the capacitor shell.
Drawings
Other characteristic objects and advantages of the invention will become more apparent upon reading the detailed description of non-limiting embodiments given with reference to the following drawings.
FIG. 1 is a schematic structural diagram of a capacitor for electric driving according to a first embodiment of the present invention;
FIG. 2 is a cross-sectional view of a first embodiment of an electrically driven capacitor according to the present invention;
FIG. 3 is a first schematic structural diagram of a second embodiment of an electrically driven capacitor according to the present invention;
FIG. 4 is a second schematic structural view of a second embodiment of an electrically driven capacitor according to the present invention;
FIG. 5 is a sectional view of a second embodiment of the capacitor for electric driving according to the present invention;
fig. 6 is a circuit diagram of a capacitor bank of a second embodiment of the electric driving capacitor of the present invention;
fig. 7 is a schematic structural view of a capacitor metallized film for electric driving according to the present invention.
In the figure:
1-housing 2-capacitor bank 3-first connection board
4-first mounting plate 5-second connecting plate 6-second mounting plate
7-embedding hole 8-potting resin 9-top-sealing resin
10-first capacitor 11-second capacitor 12-base film
13-metal unit 14-explosion-proof wire 15-fixing lug
16-metal layer 17-first lead out 18-second lead out
Detailed Description
The present invention will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It should be noted that it would be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit of the invention. All falling within the scope of the present invention.
As shown in fig. 1 and 2, a capacitor in the first embodiment includes a capacitor group 2 formed by connecting 4 200 μ F flat capacitor cores without a hard core rod in parallel, a busbar assembly, a housing 1 and a potting resin 8, the busbar assembly includes two first copper bars and two second copper bars with main bodies bent at 90 °, the first mounting plate 4 of the first copper bar is laminated on the second mounting plate 6 of the second copper bar, most of the laminated part is superposed, a busbar insulation layer (not shown) is inserted between the first mounting plate 4 and the second mounting plate 6, the first connecting plate 3 and the second connecting plate 5 are parallel-symmetrical in the vertical part of the first copper bar and the second copper bar, and the first connecting plate 3 and the second connecting plate 5 have the same number of first leading-out terminals 17 and second leading-out terminals 18 with different polarities.
The capacitor shell 1 is made of polyphenylene sulfide or polycarbonate, the main body of the capacitor shell is a square shell 1 with a bottom, the capacitor shell is also provided with a fixing lug 15 for installation and positioning, a metal embedding hole 7 is arranged in an installation hole on the fixing lug 15, and the outer wall of the embedding hole 7 is of a sawtooth structure.
The main body part of the capacitor encapsulating resin 8 is polyurethane, the capacitor bank 2 and the busbar assembly main body are completely encapsulated by the polyurethane, and the layer close to the shell opening is top encapsulating resin 9 which adopts high temperature resistant epoxy resin.
The electrically driven capacitor in the second embodiment has a specification of 600V-390 μ F.
As shown in fig. 3 to 5, the capacitor comprises a capacitor group 2 formed by connecting 2 195 μ F flat capacitor cores without hard core rods in parallel, a busbar assembly, a housing 1 and a potting resin 8, wherein the busbar assembly comprises two first copper bars and two second copper bars, the main bodies of the first copper bars and the second copper bars are bent at 90 degrees, the first mounting plates 4 of the first copper bars are laminated on the second mounting plates 6 of the second copper bars, most of the laminated parts are superposed, a busbar insulation layer (not shown in the figure) is inserted between the first mounting plates 4 and the second mounting plates 6, the first connecting plates 3 and the second connecting plates 5 of the vertical parts of the first copper bars and the second copper bars are in parallel symmetry, and the first leading-out ends 17 and the second leading-out ends 18 with the same number and different polarities are arranged on the first connecting plates 3 and the second connecting plates 5.
The capacitor shell 1 is made of polyphenylene sulfide or polycarbonate, the main body is a square shell 1 with a bottom, and is also provided with a fixing lug 15 for mounting and positioning, a metal embedding hole 7 is arranged in a mounting hole on the fixing lug 15, and the outer wall of the embedding hole 7 is of a sawtooth structure.
The main body part of the capacitor encapsulating resin 8 is polyurethane, the capacitor bank 2 and the busbar assembly main body are completely encapsulated by the polyurethane, and the layer close to the shell opening is top encapsulating resin 9 which adopts high temperature resistant epoxy resin.
As shown in fig. 4 and 6, the capacitor may further include two Y capacitors, a first capacitor 10 and a second capacitor 11, the first capacitor 10 and the second capacitor 11 are connected in series and then connected in parallel with the capacitor bank 2, a ground terminal G is led out between neutral points of the first capacitor 10 and the second capacitor 11, and a capacitance of 0.1 μ F of the first capacitor 10 and a capacitance of the second capacitor 11 are far smaller than a capacitance of 690 μ F of the capacitor bank 2.
As shown in fig. 7, the capacitor core in the capacitor bank 2 is formed by winding two layers of metallized films with metal explosion-proof wires, the base film 12 of the metallized film is a polypropylene high-temperature film resistant to 105 ℃, the thickness of the metal layer 16 evaporated on the base film 12 is gradually reduced from one end to the other end, the metal layer 16 is divided into a plurality of relatively independent metal unit 13 areas by a metal-free area, and the metal unit 13 areas are connected through the thin metal explosion-proof wires 14.
The manufacturing method of the capacitor comprises the following steps:
(1) Winding: winding two layers of metallized films with metal explosion-proof wires 14 into a capacitor core, wherein the capacitor core does not use a hard core rod, but adopts an inner pad film or washes off tens of initial turns of metal layers of the metallized films to be used as a core shaft, and the wound capacitor core is flattened into a flat shape;
(2) Heat setting: placing the capacitor in a fixing clamp, applying a pressure of 2.5-3.5 MPa, fixing the clamp by using a bolt, and placing the capacitor in an oven for 3-6 hours at 110 ℃;
(3) Spraying gold: spraying zinc-tin alloy with the thickness of 0.5 mm-1.0 mm on two ends of the capacitor core;
(4) Welding: welding a specified number of capacitor cores and assembled busbar components together, and inserting a busbar capacitor insulating layer (not shown) between the capacitor group 2 and the busbar components, wherein the solder wires are helical active solder wires which are coiled in advance;
(5) Pouring: putting a polyurethane A, B material (A material is mainly polyurethane, B material is mainly curing agent) into a A, B charging basket, starting stirring and heating, setting the heating temperature of the A material to be 65-70 ℃, the heating temperature of the B material to be 30-35 ℃, and setting the mixing ratio to be 100:20, setting the vacuum degree to be-30 kPa to-40 kPa, placing a capacitor to be filled into a vacuum bin of a vacuum filling machine, closing a feeding door, vacuumizing, injecting mixed polyurethane, wherein the polyurethane completely submerges a capacitor group 2 and a busbar assembly main body, breaking vacuum, taking out the capacitor, curing the capacitor in a drying oven at 60 +/-3 ℃ for 3 hours, injecting proportioned high-temperature-resistant epoxy resin into the capacitor to a position which is about 1mm lower than the opening of a shell, and curing the capacitor in the drying oven at 35-40 ℃ for 8-24 hours;
(6) And (3) testing: the electrical properties of the capacitors were tested, wherein the self-inductance ESL of the capacitors was < 25nH and the equivalent series resistance ESR < 0.5m Ω.
The foregoing description of specific embodiments of the present invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes or modifications may be made by one skilled in the art within the scope of the appended claims without departing from the spirit of the invention. The embodiments and features of the embodiments of the present application may be combined with each other arbitrarily without conflict.

Claims (7)

1. An electrically driven capacitor, comprising:
the shell is of a structure with one open end;
a capacitor bank disposed within the housing;
the bus bar assembly is arranged on the capacitor bank, and a capacitor insulating layer is arranged between the bus bar assembly and the capacitor bank;
a potting resin filled between the inner wall of the case and the capacitor bank;
a top sealing resin covering the capacitor bank at the housing opening;
the busbar assembly comprises:
the capacitor comprises a first copper bar and a second copper bar, wherein the first copper bar comprises a first connecting plate and a first mounting plate which are connected, an included angle between the first connecting plate and the first mounting plate is 90 degrees, the first mounting plate is arranged on the capacitor, and a first leading-out end is arranged on the first connecting plate;
the second copper bar comprises a second connecting plate and a second mounting plate which are connected, the included angle between the second connecting plate and the second mounting plate is 90 degrees, the second mounting plate is arranged on the capacitor, and a second leading-out end is arranged on the second connecting plate; wherein
The first mounting plate is arranged on the second mounting plate;
the capacitor bank comprises four capacitor cores connected in parallel; or
The capacitor bank includes:
the first capacitor and the second capacitor are connected in series;
the four capacitor cores are connected in parallel;
the first capacitor and the second capacitor which are connected in series are connected with four capacitor cores in parallel, and the connection point of the first capacitor and the second capacitor is grounded;
the capacitor core is formed by winding two layers of metallized films, and the metallized films comprise:
a base film;
the metal layer wraps the outer side of the base film; wherein
The metal layer comprises a plurality of independent metal units, and the metal units are connected through metal explosion-proof wires.
2. The electrically driven capacitor as claimed in claim 1, wherein a busbar insulation layer is provided between the first mounting plate and the second mounting plate.
3. The electrically driven capacitor as claimed in claim 1, wherein the thickness of the metal layer is designed to be gradually varied along the axial direction of the metallized film.
4. The electrically driven capacitor according to claim 1, wherein the housing comprises:
the device comprises a shell, wherein fixing lugs are arranged on two sides of the shell;
and the embedding hole is arranged on the fixing lug, and the outer wall of the embedding hole is of a sawtooth structure.
5. A method for manufacturing an electrically-driven capacitor is characterized by comprising the following steps:
step 1, winding two layers of metallized films with explosion-proof wires into a capacitor core, and flattening the wound capacitor core into a flat shape;
step 2, applying pressure of 2.5 MPa-3.5 MPa to the capacitor core, and putting the capacitor core into a drying oven at 110 ℃ for 3-6 hours for heat setting;
step 3, spraying zinc-tin alloy on two ends of the capacitor core to form a capacitor bank;
step 4, placing the capacitor bank and the busbar assembly into a shell and welding the capacitor bank and the busbar assembly;
step 5, pouring potting resin and top sealing resin;
and 6, testing.
6. The method of manufacturing an electric driving capacitor as set forth in claim 5, wherein said step 5 comprises:
step 5.1, respectively putting polyurethane and a curing agent into respective charging barrels to be stirred and heated under the condition of-30 kPa to-40 kPa; wherein the heating temperature of the polyurethane is 65-70 ℃, the heating temperature of the curing agent is 30-35 ℃, and the mixing ratio of the polyurethane to the curing agent is 100:20, mixing to obtain the potting resin;
step 5.2, injecting the prepared potting resin under the vacuum condition to enable the potting resin to submerge the capacitor bank and the busbar assembly, and curing for 3 hours in an oven at the temperature of 60 +/-3 ℃;
and 5.3, injecting top sealing resin until the position is 1mm lower than the shell opening, and curing for 8-24 hours in a drying room at the temperature of 35-40 ℃.
7. The method for manufacturing an electrically-driven capacitor according to claim 6, wherein in the step 3, the thickness of the zinc-tin alloy is 0.5mm to 1.0mm.
CN201610200616.2A 2016-03-31 2016-03-31 Capacitor for electric drive and method for manufacturing the same Active CN107293406B (en)

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CN107293406B true CN107293406B (en) 2023-02-17

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Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112289587B (en) * 2020-12-30 2021-05-18 宁波市江北九方和荣电气有限公司 Processing method of metallized film capacitor and metallized film capacitor
CN113410056B (en) * 2021-07-08 2022-09-09 无锡市电力滤波有限公司 Vacuum pouring process of direct-current support capacitor
CN115295312B (en) * 2022-08-10 2023-05-12 福建火炬电子科技股份有限公司 Preparation process of multi-core group capacitor
CN116798773B (en) * 2023-08-10 2024-03-29 上海工程技术大学 Annular distribution core low inductance capacitor

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CN203086036U (en) * 2013-03-19 2013-07-24 人民电器集团有限公司 Busbar system of withdrawable circuit breaker
CN203415415U (en) * 2013-07-05 2014-01-29 北京科佳信电容器研究所 Capacitor
CN103680943A (en) * 2013-11-19 2014-03-26 张家港市星河电子材料制造有限公司 Metallized safety film explosion-proof capacitor
CN104465092A (en) * 2014-12-11 2015-03-25 铜陵市启动电子制造有限责任公司 Manufacturing method for anti-electromagnetic interference thin-film capacitor
CN104934223A (en) * 2015-06-28 2015-09-23 无锡宸瑞新能源科技有限公司 Thin-film capacitor for automobile
CN104966616A (en) * 2015-05-27 2015-10-07 安徽赛福电子有限公司 Electric automobile smooth capacitor
CN205723162U (en) * 2016-03-31 2016-11-23 上海赛特康新能源科技股份有限公司 Electric drive electricity container

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN203086036U (en) * 2013-03-19 2013-07-24 人民电器集团有限公司 Busbar system of withdrawable circuit breaker
CN203415415U (en) * 2013-07-05 2014-01-29 北京科佳信电容器研究所 Capacitor
CN103680943A (en) * 2013-11-19 2014-03-26 张家港市星河电子材料制造有限公司 Metallized safety film explosion-proof capacitor
CN104465092A (en) * 2014-12-11 2015-03-25 铜陵市启动电子制造有限责任公司 Manufacturing method for anti-electromagnetic interference thin-film capacitor
CN104966616A (en) * 2015-05-27 2015-10-07 安徽赛福电子有限公司 Electric automobile smooth capacitor
CN104934223A (en) * 2015-06-28 2015-09-23 无锡宸瑞新能源科技有限公司 Thin-film capacitor for automobile
CN205723162U (en) * 2016-03-31 2016-11-23 上海赛特康新能源科技股份有限公司 Electric drive electricity container

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