Shell-free press-fitting-free aluminum electrolytic capacitor module

Abstract

According to the design scheme of the non-shell press-fitting-free concentrated insulation type aluminum electrolytic capacitor module, an aluminum shell of an aluminum electrolytic capacitor single body is omitted, the core bag is directly assembled with a nest hole cavity of the metal heat conduction base body component, an efficient heat conduction path is established between the hot spot center of the core bag and the metal heat conduction base body component, and the heat conduction efficiency is improved. Most of thermal resistance conducted to the metal heat conduction base body component by the heat of the core cladding is eliminated; and particularly, a press-fitting process is saved, so that the capacitor module is easy to manufacture, the performance and the reliability are improved, and the cost is also greatly reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of aluminum electrolytic capacitor module structure design, in particular to provide an aluminum electrolytic capacitor module assembly structure design scheme without aluminum shell and without press-fitting process. BACKGROUND

[0002] Aluminum electrolytic capacitors are important basic electronic components, which are widely used in many fields such as consumer electronics, industrial electrical appliances, automobiles, aviation and military industry.

[0003] Generally, aluminum electrolytic capacitors exist as single bodies. In order to cope with high power, the volume needs to be increased to improve the ripple current capacity. For example, snap-in and screw aluminum electrolytic capacitors. After the volume of the capacitor is increased, various aspects such as high-frequency characteristics and unit capacity ripple current capacity will be reduced. If a small volume aluminum electrolytic capacitor is used to form a module and a heat sink is added to form an aluminum electrolytic capacitor module, it will have higher efficiency compared to using a large single aluminum electrolytic capacitor.

[0004] Generally, the capacitor module can be disassembled and replaced for individual capacitor single body maintenance. When the product is improved for reliability, such as adding glue filling, press machine press fitting and other processes, the single body cannot be disassembled and replaced for maintenance. At this time, the module is more appropriate. Among various constitutions of small aluminum electrolytic capacitor modules, the concentrated insulation type aluminum electrolytic capacitor module of patent 202110059122.8 has the advantages of simplified process, high reliability and low cost.

[0005] The concentrated insulation type aluminum electrolytic capacitor module is tightly assembled without insulation by aluminum electrolytic capacitor single body and heat conduction uniform temperature metal member, and then an insulating heat conduction sheet is used to insulate and install a heat sink device for cooling and heat dissipation. The ideal design is that the heat generated inside the aluminum electrolytic capacitor is quickly conducted to the heat conduction uniform temperature metal member through the aluminum shell. However, in fact, there are two big thermal resistance links in heat conduction. First, there is no efficient heat transfer path between the core package and the aluminum shell. Second, the contact thermal resistance cannot be avoided between the aluminum shell of the aluminum electrolytic capacitor single body and the uniform temperature metal member.

[0006] The aluminum electrolytic capacitor module needs to be pressed into the corresponding nest hole of the uniform temperature aluminum member by a press machine. The press-fitting reliability is the key to determine the performance of the aluminum electrolytic capacitor module. Due to the light and thin quality of the aluminum shell of the small aluminum electrolytic capacitor, there is a deviation in the consistency of the cylindrical size during the single body manufacturing process. The hole diameter of the corresponding nest hole cannot be matched with high precision. The interference fitting process is adopted by taking advantage of the good ductility of the aluminum shell material. However, if the press-fitting is too tight, it is easy to cause the aluminum shell to break, which has irreversible consequences. Therefore, controlling the press-fitting force is the difficulty and key of the manufacturing of the aluminum electrolytic capacitor module. SUMMARY

[0007] The application provides a shell-free and pressure-free assembled concentrated insulation type aluminum electrolytic capacitor module design, which comprises an aluminum electrolytic capacitor core package and a sealing rubber plug or cover plate, a metal heat-conducting base member, an insulating shell and an insulating heat-conducting sheet; the nest hole cavity of the metal heat-conducting base member is provided with an auxiliary structure for fixing, supporting and pushing the core package and a cavity internal pressure release valve mechanism; the insulating heat-conducting sheet of the aluminum electrolytic capacitor module is used for concentrated insulation installation of an external heat dissipation device; and the insulating shell is used for covering and insulating the aluminum electrolytic capacitor module.

[0008] The aluminum electrolytic capacitor module, wherein the number of the nest hole cavity of the metal heat-conducting base member and the corresponding aluminum electrolytic capacitor units can be one, two, three, four, five, six or the like.

[0009] Specifically, the aluminum electrolytic capacitor unit comprises a core package with a negative electrode extension structure, a sealing rubber plug or cover plate, a nest hole cavity and a cavity internal pressure release valve mechanism arranged therein.

[0010] Specifically, the nest hole cavity of the metal heat-conducting base member is provided with a convex ridge at the bottom, which contacts and pushes the negative electrode extension part of the core package to increase the effective contact area and reduce the contact thermal resistance.

[0011] Further, the inner wall of the nest hole cavity of the metal heat-conducting base member is provided with a core package axial extension reinforcing rib, which is used for clamping and fixing the core package and is beneficial to axial heat conduction and heat dissipation.

[0012] Specifically, the fixed column is arranged at the bottom of the nest hole cavity of the metal heat-conducting base member and penetrates into the center winding hole of the core package, so as to fix the position of the core package and improve the heat conduction of the center of the core package.

[0013] Further, the fixed column can be extended to the position of the capacitor sealing rubber plug or cover plate, so as to have a support column effect on the sealing rubber plug or cover plate and limit the axial installation position of the capacitor sealing rubber plug or cover plate.

[0014] Specifically, the shape of the metal heat-conducting base member can be any regular or irregular shape according to the needs of installation and use.

[0015] Further, the nest hole cavity of the metal heat-conducting base member can be a traditional cylindrical shape, an oval shape or a square shape and the like.

[0016] Further, the nest hole cavity of the metal heat-conducting base member can accommodate and assemble multiple core packages.

[0017] The pressure release valve mechanism attached to the nest hole cavity of the metal heat-conducting base member comprises a valve body and an air passage.

[0018] Specifically, the valve body can be classified as integrated and separate, depending on whether the valve body and the metal heat-conducting base member exist independently.

[0019] Further, referring to the general aluminum shell manufacturing process, the traditional aluminum shell thin-walled negative "X" and "Y" grooves are used as the valve body, and the integrated valve body and air passage can be synchronously formed and manufactured with the nest hole of the metal heat-conducting base member. Figure 2 )

[0020] Specifically, the air passage is the passage of the gas inside the nest hole cavity of the metal heat-conducting base member to the outside, and the air passage inlet can be arranged on the bottom or sidewall of the nest hole cavity. One or more air passages can be provided, and the passage inlet and outlet can be circular or square.

[0021] Further, the air passage can be omitted in certain cases.

[0022] Specifically, the valve body is a component through which the pressure gas inside the nest hole cavity of the metal heat-conducting base member can be released under a limited air pressure condition. The separate valve body can be made of rubber, plastic, metal, or other materials.

[0023] Further, the separate valve body can be made of a single material or multiple materials, and can be a single part or a combination of parts.

[0024] Specifically, the valve body can be arranged on the inlet side or outlet side of the air passage.

[0025] Further, according to actual needs, the nest hole cavity of the metal heat-conducting base member can be provided with one air passage cooperating with one valve body, or multiple air passages cooperating with one valve body.

[0026] Specifically, the separate valve body can be assembled with the metal heat-conducting base member by sealing methods such as bonding, welding, clamping, and riveting.

[0027] Further, the pressure release valve body plane can be inside the metal heat-conducting member plane, forming an internal cavity with the insulating shell to ensure that the electrolyte does not splash outward under the condition that the pressure release valve is open.

[0028] Further, the insulating shell covers the part outside the mounting surface of the insulating heat-conducting sheet of the metal heat-conducting base member, and provides an internal pressure gas passage at the position corresponding to the pressure release valve cavity to ensure that the gas is released outside the aluminum electrolytic capacitor module.

[0029] Further, after the core package and the sealing plug or cover plate are sequentially assembled into the nest hole cavity of the metal heat-conducting base member, the electrode lead terminal end surface is lower than the plane of the metal heat-conducting base member to form a pit, and electronic potting glue is poured into the pit to enhance the sealing performance of the electrolytic capacitor unit.

[0030] The aluminum electrolytic capacitor module adopts an insulating heat-conducting sheet to externally insulate and install a heat dissipation device for heat dissipation.

[0031] Specifically, the insulating heat-conducting sheet can be an insulating heat-conducting silica gel cloth or an insulating heat-conducting ceramic or the like material with voltage resistance and high thermal conductivity.

[0032] The aluminum electrolytic capacitor module can be independently installed with a heat sink, or can be installed with a heat dissipation device shared with other capacitor modules or power semiconductor MOSFET / IGBT devices for heat dissipation.

[0033] Further, the heat dissipation device can be a fin heat sink, a water-cooled heat sink or other housings with heat dissipation functions, etc.

[0034] The electrode lead terminals of the aluminum electrolytic capacitor module can be directly electrically connected with the PCBA module, or can use a PCB circuit board or a specially-made busbar connection terminal plate for electrical connection conversion busbar rows, and the conversion lead terminals can be transformed in position, length and form according to actual installation needs.

[0035] Specifically, the aluminum electrolytic capacitor module can be provided with fixed mounting foot positions on the insulating shell, or can be assembled and fixed by using an insulating installation heat dissipation device.

[0036] The shell-free pressure-free assembly centralized insulation type aluminum electrolytic capacitor module design scheme provided by the application cancels the aluminum shell of the aluminum electrolytic capacitor monomer, so that the core package is directly assembled with the nest cavity of the metal heat-conducting base member, the core package hot spot center establishes a high-efficiency heat conduction path with the metal heat-conducting base member, and most of the thermal resistance of the core package heat conduction to the metal heat-conducting base member is eliminated; in particular, the pressure assembly process is saved, so that the product manufacturing of the capacitor module becomes easy, thereby improving the product performance and manufacturing reliability, and also greatly reducing the cost. BRIEF DESCRIPTION OF DRAWINGS

[0037] Figure 1 is an aluminum electrolytic capacitor core package and sealing plug assembly appearance

[0038] Figure 2 is a metal heat-conducting base member of an integrated valve body

[0039] Figure 3 is a metal heat-conducting base member of a discrete valve body

[0040] Figure 4 is a discrete valve body aluminum electrolytic capacitor module valve body assembly drawing

[0041] Figure 5 is a discrete valve body aluminum electrolytic capacitor module core package plug assembly drawing

[0042] Figure 6This is an assembly diagram for the insulation, installation, and heat dissipation of an aluminum electrolytic capacitor module.

[0043] The numbers in the image are:

[0044] 1. Aluminum electrolytic capacitor core package

[0045] 11. Core-packed negative electrode extension section

[0046] 12. Core hole

[0047] 2. Sealing plug

[0048] 3. Metal thermally conductive substrate components

[0049] 31. Fixed column

[0050] 32. Pushing protrusion

[0051] 4. Pressure relief valve mechanism

[0052] 41. Air passage + valve body

[0053] 42. Separate valve body

[0054] 43. Air passage

[0055] 5. Thermally conductive insulating sheet

[0056] 6. Insulating outer casing

[0057] 7. Finned radiator Detailed implementation method:

[0058] The present invention will be further described in detail below with reference to specific embodiments and accompanying drawings. Features in the embodiments can be combined with each other. In the following embodiments, those skilled in the art will readily recognize that some features can be replaced or omitted by other materials or methods in different situations. In some cases, certain operations are not shown or described in the specification to avoid obscuring the core parts of the present invention with excessive description. Those skilled in the art can fully understand the relevant operations based on the description in the specification and general technical knowledge in the field.

[0059] The following are preferred embodiments:

[0060] like Figure 1 As shown, the core package electrode lead is inserted into the sealing plug electrode lead-out hole, the bottom of the core package has a negative electrode extension 11, and the core package center has a core winding hole 12.

[0061] like Figure 2As shown, the metal heat-conducting substrate component of the integrated valve body has multiple engraved "Y" grooves on the outside of the cavity of the metal heat-conducting substrate component. The pressure relief valve body 4 corresponds to the position of the air passage inside the cavity, and the valve body 4 separates the inside and outside of the cavity.

[0062] like Figure 3 As shown, the metal heat-conducting substrate component 3 of the discrete valve body has a core-pack fixing column 31, a core-pack pushing protrusion 32, and an air passage 43 for the pressure relief valve mechanism inside the cavity. The air passage connects the inside of the cavity with the outside of the metal heat-conducting substrate component.

[0063] like Figure 4 As shown, the air passage 43 of the pressure relief mechanism of the metal heat-conducting substrate component 3 of the discrete valve body is covered by the discrete valve body 42. After the valve body is installed in the slot, it can be sealed by potting compound along the surrounding engraved groove, or by laser welding.

[0064] like Figure 5 As shown, the core package 1 and the sealing plug 2 are sequentially inserted into the cavity of the metal heat-conducting substrate component. The bottom fixing post 31 is inserted into the core hole 12 of the core package 1. After the sealing plug 2 is inserted, its end face is lower than the plane of the metal heat-conducting substrate component 3 to form a pit. The sealing glue is poured into the pit to enhance the sealing performance.

[0065] like Figure 6 As shown, the assembled aluminum electrolytic capacitor unit's metal thermally conductive substrate component 3 is installed into the outer casing 6, which is then insulated from the outside. The heat dissipation mounting surface of the metal thermally conductive substrate component is fitted with a finned heat sink 7 through an insulating thermally conductive sheet 5 for centralized insulated heat dissipation.

Claims

1. A caseless, pressure-free, centrally insulated aluminum electrolytic capacitor module, comprising: Aluminum electrolytic capacitor core and sealing plug or cover, metal thermally conductive substrate components, insulating shell and insulating thermally conductive sheet; The porous cavity of the metal thermally conductive substrate component is equipped with auxiliary structures for fixing, supporting, and pushing the core package, as well as a pressure relief valve mechanism inside the cavity; the aluminum electrolytic capacitor module is centrally insulated and installed with insulating thermally conductive sheets for heat dissipation.

2. The aluminum electrolytic capacitor module as described in claim 1, wherein the pressure relief valve mechanism is characterized in that: the integrated valve body and air passage are manufactured simultaneously with the porous cavity of the metal heat-conducting substrate component in one step.

3. The aluminum electrolytic capacitor module as described in claim 1, wherein the pressure relief valve mechanism is characterized in that: the discrete valve body can be made of materials such as rubber, plastic and metal, can be composed of a single material or multiple materials, and can be a single part or a combination of components.

4. The aluminum electrolytic capacitor module as described in claim 1, wherein the sealing plug or cover plate is characterized in that: after the core package and the sealing plug or cover plate are sequentially installed into the cavity, the end face of its electrode lead-out terminal is lower than the plane of the metal heat-conducting substrate component to form a pit, and potting compound is poured into the pit to enhance the sealing performance.

5. The aluminum electrolytic capacitor module as described in claim 1, wherein the insulating thermally conductive sheet is characterized by being made of materials with high voltage resistance and high thermal conductivity, such as insulating thermally conductive silicone cloth or insulating thermally conductive ceramic.

6. The aluminum electrolytic capacitor module as described in claim 1 is characterized in that: it can be installed with a heat sink independently, or it can share a heat sink with other capacitor modules or power semiconductor MOSFET / IGBT devices for heat dissipation. The heat sink can be a finned heat sink, a water-cooled heat sink, or other housings with heat dissipation function.

7. The aluminum electrolytic capacitor module as described in claim 1 is characterized in that: the electrode lead-out terminals can be directly electrically connected to the PCBA module, or they can be used as electrical connection conversion busbars by using PCB circuit boards or making special busbar connection terminal boards. The position, length and form of the lead-out terminals can be changed according to actual installation needs.

8. The aluminum electrolytic capacitor module as described in claim 1, wherein the insulating shell is characterized by: covering the portion of the metal thermally conductive substrate component other than the mounting surface of the insulating thermally conductive sheet, and providing a gas venting passage at the position corresponding to the pressure relief valve.

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