A method and equipment for rolling a high voltage capacitor core

Abstract

The present application provides a rolling method and rolling equipment for a high-voltage capacitor core, including: using a rolling equipment to prepare a test paper sample, the rolling equipment includes at least two material shafts, wherein the material shafts are used to place a metallized film; among the N layers of metallized films stacked and disassembled from the test paper sample, at least one metallized film is selected as a reference film, and metallized films other than the reference film are selected as alignment films, the metallized film includes a base film and a metal vapor-deposited layer arranged on one side of the base film in a first direction and arranged at intervals; according to the overlapping size of the projection of the metal vapor-deposited layer of the reference film in the stacking direction and the projection of the metal vapor-deposited layer of the alignment film in the stacking direction, the position of the material shaft used to place the alignment film in the rolling equipment is adjusted; and the capacitor core is prepared using the adjusted rolling equipment. The high-voltage capacitor core obtained from batches based on the rolling method has higher product quality, and the error value of the capacitance value of the high-voltage capacitor core from batch to batch is small.

Description

Technical Field

[0001] The present application relates to capacitor rolling technology, and in particular to a rolling method and rolling equipment for a high-voltage capacitor core. Background Art

[0002] The usual method of preparing a film capacitor core is to directly overlap a metal foil as an electrode with a plastic film and then wind it together. The metallized film capacitor core is obtained by vapor-depositing a layer of metal film on a plastic film to obtain a metallized film, and then rolling the metallized film on a winding machine. By using the metal vapor-deposited layer as an electrode, the thickness of the metal foil can be omitted, and the volume of the capacitor core can be reduced. Related technologies can use metallized films to roll high-voltage capacitor cores on a winding machine, but the precision of the rolled high-voltage capacitor core products is generally low. Summary of the invention

[0003] The embodiments of the present application provide a method and equipment for rolling a high-voltage capacitor core. The high-voltage capacitor cores between batches obtained based on the rolling method have higher product quality, and the error value of the capacitance value of the high-voltage capacitor cores between batches is small.

[0004] The technical solution of the embodiment of the present application is implemented as follows:

[0005] The present application provides a method for rolling a high-voltage capacitor core:

[0006] A test paper sample is prepared by using a rolling device, wherein the rolling device comprises at least two material shafts, wherein the material shafts are used to place the metallized film;

[0007] Among the N layers of stacked metallized films disassembled from the test paper sample, at least one layer of the metallized film is selected as a reference film, and metallized films other than the reference film are selected as alignment films, wherein the metallized film includes a base film and a metal vapor-deposited layer arranged on a surface of one side of the base film in a first direction and arranged at intervals, wherein N is an integer greater than or equal to 2, and the first direction is perpendicular to the stacking direction of the metallized film;

[0008] adjusting the position of a material axis for arranging the alignment film in a rolling device according to an overlapping size of a projection of the metal vapor-deposited layer of the reference film in the stacking direction and a projection of the metal vapor-deposited layer of the alignment film in the stacking direction;

[0009] The capacitor core is prepared using the adjusted rolling equipment.

[0010] The high-voltage capacitor cores obtained from batches based on the rolling method have higher product quality, and the error value of the capacitance value of the high-voltage capacitor cores from batch to batch is small.

[0011] In one embodiment, the first film layer group is transferred to a core rod, and the first film layer group is wound on the core rod; in response to the first film layer group being wound a first preset number of times, the second film layer group is transferred to the core rod, so that the first film layer group and the second film layer group are wound on the core rod in a stacked manner. In the embodiment of the present application, the first film layer group can be pre-wound on the core rod for a first preset number of times, so as to achieve the effect of fixing the first film layer group. When the second film layer group is transferred to the core rod, the second film layer group is inserted between adjacent first film layer groups, so that the first film layer group and the second film layer group are wound in a stacked manner. Therefore, the first film layer group can exert a force on the second film layer group to prevent the relative movement of the first film layer group and the second film layer group, thereby reducing the capacitance value error of the prepared capacitor core.

[0012] In one embodiment, the first film layer and the second film layer are transferred to the core rod and the first film layer and the second film layer are wound on the core rod; in response to the first film layer and the second film layer being wound on the surface of the core rod for a first preset number of times, the third film layer and the fourth film layer are transferred to the core rod, so that the first film layer, the second film layer, the third film layer, and the fourth film layer are wound on the core rod in a stacked manner. The embodiment of the present application can pre-wind the first film layer and the second film layer on the core rod for a first preset number of turns, which can achieve the effect of fixing the first film layer and the second film layer, and transmit different film layer groups to the core rod in sequence, which can ensure the stability of the winding process, and when the third film layer and the fourth film layer are transmitted to the core rod, the third film layer and the fourth film layer are inserted between adjacent first film layer groups, so that the first film layer, the second film layer, the third film layer and the fourth film layer are wound in a stacked manner. Therefore, the first film layer group composed of the first film layer and the second film layer can exert a force on the second film layer group composed of the third film layer and the fourth film layer to prevent the relative movement of the first film layer group composed of the first film layer and the second film layer and the second film layer group composed of the third film layer and the fourth film layer, thereby reducing the capacitance value error of the prepared capacitor core.

[0013] In one embodiment, the first film layer, the second film layer, and the third film layer are transferred to the mandrel, and the first film layer, the second film layer, and the third film layer are wound on the mandrel; in response to the first film layer, the second film layer, and the third film layer being wound on the surface of the mandrel for a first preset number of turns, the fourth film layer, the fifth film layer, and the sixth film layer are transferred to the mandrel, so that the first film layer, the second film layer, the third film layer, the fourth film layer, the fifth film layer, and the sixth film layer are wound on the mandrel in a stacked manner. In the embodiment of the present application, the first film layer, the second film layer, and the third film layer can be pre-wound on the mandrel for a first preset number of turns, so as to achieve the effect of fixing the first film layer, the second film layer, and the third film layer. Transferring different film layer groups to the core rod in sequence can ensure the stability of the winding process, and when the fourth film layer, the fifth film layer and the sixth film layer are transferred to the core rod, the fourth film layer, the fifth film layer and the sixth film layer are inserted between adjacent first film layer groups, so that the first film layer, the second film layer, the third film layer, the fourth film layer, the fifth film layer and the sixth film layer are wound in a stacked manner. Therefore, the first film layer group can exert a force on the fourth film layer, the fifth film layer and the sixth film layer to prevent the relative movement of the first film layer group composed of the first film layer, the second film layer and the third film layer and the second film layer group composed of the fourth film layer, the fifth film layer and the sixth film layer, thereby reducing the capacitance value error of the prepared capacitor core.

[0014] In one embodiment, in response to the first film layer group and the second film layer group starting to be wound synchronously, the number of rotations of the mandrel is counted; in response to the difference between the counted number of rotations and the set number of rotations reaching the set value, the envelope is transferred to the mandrel and wound synchronously with the metallized film; in response to the counted number of rotations reaching the set number of rotations, the metallized film is cut off, and the envelope continues to be wound driven by the mandrel. In the embodiment of the present application, the envelope can be inserted into the metallized film before the metallized film is finished rolling, and the extrusion effect of the metallized film on the envelope can be used to fix the envelope, so that the prepared capacitor core has better structural stability.

[0015] In one embodiment, the size of the test paper sample in the direction of its winding axis is tested; if the size of the test paper sample in the direction of its winding axis exceeds a preset height range, the test paper sample is disassembled to obtain a metallized film with N layers stacked. In the embodiment of the present application, the size of the test paper sample in the direction of its winding axis can be tested. If the size in the direction of the winding axis does not meet the requirements, the film alignment step is performed again to ensure that the capacitor core prepared subsequently has good quality.

[0016] In one embodiment, the adjusted rolling equipment is used to prepare the test capacitor core; the electrical parameters of the test capacitor core are tested; if the electrical parameters obtained by the test are within the preset electrical parameter range, the test capacitor core is subjected to a quality test to obtain a quality test result; if the quality test result meets the set conditions, the finished capacitor core is rolled based on the adjusted rolling equipment. In the embodiment of the present application, the adjusted rolling equipment can be used to prepare the test capacitor core before the finished capacitor core is prepared, and the electrical parameters and quality test of the test capacitor core are tested. If the test capacitor core passes the electrical parameter test and the quality test, the next batch rolling (finished capacitor core) can be carried out to ensure that the capacitor core prepared subsequently has good quality.

[0017] In one embodiment, the adjusted rolling device is used to prepare the test capacitor core; the electrical parameters of the test capacitor core are tested; if the electrical parameters obtained from M consecutive tests are within the preset electrical parameter range, a partial discharge test is performed on the test capacitor core to obtain a partial discharge test result; if the partial discharge test result meets the set conditions, the finished capacitor core is rolled based on the adjusted rolling device. The embodiment of the present application can perform M measurements and compare the results as evaluation data. The M measurements can improve the reliability and credibility of the data and provide stronger support for the judgment criteria.

[0018] In one embodiment, the electrical parameter includes at least one of a capacitance value and a dielectric loss value. In the embodiment of the present application, the capacitance value and the dielectric loss value can be used to prove that the capacitor core is preliminarily qualified.

[0019] In one embodiment, the metallized film reaches the core rod through at least one of a balance wheel, a passing wheel and a pressure wheel. In the embodiment of the present application, the metallized film passing through can be rolled into a capacitor core smoothly, at a uniform speed and stably through the balance wheel, the passing wheel and the pressure wheel.

[0020] The present application provides a high-voltage capacitor core rolling device:

[0021] In one embodiment, the rolling equipment includes: at least two material shafts, the material shafts are used to place metallized films; a film adjustment rotary rod is arranged on one side of each of the material shafts, and the film adjustment rotary rod is used to adjust the position of the material shaft; a controller, the controller is used to: select at least one layer of metallized film as a reference film from the N layers of stacked metallized films disassembled from the test paper sample, and select metallized films other than the reference film as alignment films, the metallized film including a base film and a metal vapor-deposited layer arranged on the surface of one side of the base film and arranged at intervals in a first direction, wherein N is an integer greater than or equal to 2, and the first direction is perpendicular to the stacking direction of the metallized film; according to the overlapping size of the projection of the metal vapor-deposited layer of the reference film in the stacking direction and the projection of the metal vapor-deposited layer of the alignment film in the stacking direction, control the movement of the target film adjustment rotary rod to adjust the position of the material shaft where the alignment film is placed, and the target film adjustment rotary rod is the film adjustment rotary rod arranged on one side of the material shaft where the alignment film is placed. The rolling equipment of the embodiment of the present application can control the movement of the target film adjustment rotary rod to adjust the position of the material axis for placing the alignment film according to the overlapping size of the projection of the metal vapor-deposited layer of the reference film in the stacking direction and the projection of the metal vapor-deposited layer of the alignment film in the stacking direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is a flow chart of a rolling method provided by an embodiment of the present application;

[0023] Figure 2 is a schematic diagram of the structure of the metallized film used in the embodiment of the present application;

[0024] Figure 3 A schematic diagram of the structure of a two-layer stacked metallized film provided in an embodiment of the present application;

[0025] Figure 4 A schematic diagram of the structure of a metallized film with four stacked layers provided in an embodiment of the present application;

[0026] Figure 5 It is a schematic diagram of the structure of the disassembled test paper sample in the case of four volumes in one provided in an embodiment of the present application;

[0027] Figure 6 Schematic diagram of the structure of the unfolded metallized film with four stacked layers provided in an embodiment of the present application;

[0028] Figure 7 It is a schematic diagram of a rolling device in a two-roll-one process provided in an embodiment of the present application;

[0029] Figure 8 is a schematic diagram of a rolling device in a four-roll-in-one process provided in an embodiment of the present application;

[0030] Fig. 9 It is a schematic diagram of a rolling device in a six-roll-one process provided in an embodiment of the present application;

[0031] Fig.10 It is a schematic diagram of the mandrel and the metallized film in the two-roll-one process;

[0032] Fig.11 It is a schematic diagram of the mandrel and the metallized film in the four-roll-one process;

[0033] Fig.12 It is a schematic diagram of the mandrel and the metallized film in the six-roll-one process;

[0034] Fig.13 It is a flow chart of a rolling method provided in another embodiment of the present application.

[0035] Reference numerals:

[0036] 1. First material axis; 2. Second material axis; 3. Third material axis; 4. Fourth material axis; 5. First coating axis; 6. Second coating axis; 6a. Coating; 7. Fifth material axis; 8. Sixth material axis; 9. Film adjustment rod; 10. Core rod; 10a. First metallized film; 10b. Second metallized film; 10c. Third metallized film; 10d. Fourth metallized film; 10e. Fifth metallized film; 10f. Sixth metallized film; 11. Left pressure wheel; 12. Right pressure wheel; 13a. First passing wheel; 13b. Second passing wheel; 14a. First tension balance wheel; 14b. Second tension balance wheel; 100. Base film; 200. Metal vapor deposition layer. DETAILED DESCRIPTION

[0037] In order to make the purpose, technical solutions and advantages of the present application clearer, the present application will be further described in detail below in conjunction with the accompanying drawings. The described embodiments should not be regarded as limiting the present application. All other embodiments obtained by ordinary technicians in the field without making creative work are within the scope of protection of this application.

[0038] In the following description, reference is made to “some embodiments”, which describe a subset of all possible embodiments, but it will be understood that “some embodiments” may be the same subset or different subsets of all possible embodiments and may be combined with each other without conflict.

[0039] In the following description, the terms "first\second\third" involved are merely used to distinguish similar objects and do not represent a specific ordering of the objects. It can be understood that "first\second\third" can be interchanged with a specific order or sequence where permitted, so that the embodiments of the present application described herein can be implemented in an order other than that illustrated or described herein.

[0040] Unless otherwise defined, all technical and scientific terms used in the embodiments of the present application have the same meanings as those commonly understood by those skilled in the art. The terms used in the embodiments of the present application are only for the purpose of describing the embodiments of the present application and are not intended to limit the present application.

[0041] Before further describing the embodiments of the present application in detail, the nouns and terms involved in the embodiments of the present application are explained. The nouns and terms involved in the embodiments of the present application are subject to the following interpretations.

[0042] 1) Two rolls to one refers to the method of using two rolls of metallized film to roll a high-voltage capacitor core.

[0043] 2) Four-roll-one refers to the method of using four rolls of metallized film to roll a high-voltage capacitor core.

[0044] 3) Six-roll-one refers to the method of using six rolls of metallized film to roll a high-voltage capacitor core.

[0045] The capacitance value of the high-voltage capacitor core is positively correlated with the area of ​​the overlapping region between the two electrode sheets (metal vapor-deposited layers). When other conditions are the same, the capacitance value of the high-voltage capacitor core will increase accordingly as the overlapping region of the two electrode sheets increases. Therefore, before rolling the high-voltage capacitor core, the staff can control the size of the overlapping region of the metallized film through design, and thus control the capacitance value of the rolled high-voltage capacitor core. However, in the preparation process of the high-voltage capacitor core, there are many factors that affect the size of the overlapping region of the metallized film, resulting in large differences in the overlapping region of the metallized film between batches. The differences between batches may cause fluctuations in the quality of the high-voltage capacitor core, affecting the consistency and reliability of the high-voltage capacitor core products.

[0046] In order to solve the above technical problems, an embodiment of the present application discloses a rolling method and a rolling device for a high-voltage capacitor core. The high-voltage capacitor cores between batches obtained based on the rolling method and the rolling device have higher product quality, and the error value of the capacitance value of the high-voltage capacitor core between batches is small.

[0047] The following is a further description of the high-voltage capacitor core rolling equipment provided in the embodiment of the present application.

[0048] In some embodiments, the rolling equipment includes: at least two material shafts, which are used to place metallized films; a film adjustment rotary rod is arranged on one side of each material shaft, and the film adjustment rotary rod is used to adjust the position of the material shaft; a controller, which is used to: select at least one layer of metallized film as a reference film from the N layers of stacked metallized films disassembled from the test paper sample, and select metallized films other than the reference film as alignment films, the metallized film including a base film and a metal vapor-deposited layer arranged on the surface of one side of the base film in a first direction and arranged at intervals, wherein N is an integer greater than or equal to 2, and the first direction is perpendicular to the stacking direction of the metallized film; according to the overlapping size of the projection of the metal vapor-deposited layer of the reference film in the stacking direction and the projection of the metal vapor-deposited layer of the alignment film in the stacking direction, control the movement of the target film adjustment rotary rod to adjust the position of the material shaft for placing the alignment film, and the target film adjustment rotary rod is a film adjustment rotary rod arranged on one side of the material shaft for placing the alignment film.

[0049] As an example, the position of the material axis can be adjusted by controlling the movement of the film adjustment rotary rod, thereby adjusting the position of the metallized film. Specifically, after selecting the reference film and the alignment film from the N-layer stacked metallized film disassembled from the test paper sample, the target film adjustment rotary rod can be controlled to move according to the overlapping size of the projection of the metal vapor-deposited layer of the reference film in the stacking direction and the projection of the metal vapor-deposited layer of the alignment film in the stacking direction, so as to adjust the position of the material axis where the alignment film is placed, thereby adjusting the position of the alignment film, and then adjusting the overlapping size of the projection of the metal vapor-deposited layer of the reference film in the stacking direction and the projection of the metal vapor-deposited layer of the alignment film in the stacking direction.

[0050] The following is a further description of the high-voltage capacitor core rolling method and rolling equipment provided by the embodiment of the present application in conjunction with the specific drawings. Figure 1 As shown, Figure 1 1 is a flow chart of a rolling method provided by an embodiment of the present application. The rolling method may include steps 101 to 104:

[0051] Step 101: Prepare a test paper sample using a rolling device.

[0052] The rolling device includes at least two material shafts, wherein the material shafts are used to place the metallized film.

[0053] The test paper sample in the embodiment of the present application refers to a high-voltage capacitor core used to test whether the overlapping size of the projection of the metal vapor deposition layer in the stacking direction meets the preset conditions. In the subsequent embodiments, for the convenience of description, the high-voltage capacitor core is referred to as the capacitor core.

[0054] The present application embodiment does not specifically limit the preparation process of the test paper sample, and the preparation method of the rolled capacitor core known in the art can be adopted.

[0055] Step 102: Select at least one layer of the N-layer stacked metallized films disassembled from the test paper sample as a reference film, and select metallized films other than the reference film as alignment films.

[0056] The metallized film includes a base film and metal vapor-deposited layers arranged on one surface of the base film and spaced apart in a first direction, wherein N is an integer greater than or equal to 2, and the first direction is perpendicular to the stacking direction of the metallized film.

[0057] In some embodiments, since the metallized film is wound on a core rod, the alignment of the reference film and the alignment film cannot be determined by observation during the winding process. Therefore, it is necessary to disassemble the test paper sample and flatten the N layers of metallized film of the test paper sample to obtain an N-layer stacked metallized film.

[0058] In the embodiment of the present application, the alignment film is a metallized film other than the reference film, and the metallized film includes a base film and a metal vapor-deposited layer arranged on a surface of one side of the base film in a first direction and arranged at intervals. It should be noted that N is an integer greater than or equal to 2, and the first direction is perpendicular to the stacking direction of the metallized film. For details, see Figure 2 , as shown Figure 2 is a schematic diagram of the structure of the metallized film used in the embodiment of the present application. Figure 2 In the embodiment, the metallized film includes a base film 100 and metal vapor deposition layers 200 arranged at intervals in a first direction of the base film 100.

[0059] In the present application, the reference film and the alignment film are different metallized films. The present application embodiment does not specifically limit the implementation method of selecting the reference film and the alignment film, and only requires that the reference film and the alignment film are different metallized films.

[0060] For example, see Figure 3 , Figure 3 A schematic diagram of the structure of a two-layer stacked metallized film provided in an embodiment of the present application, wherein the first metallized film 10a can be selected as a reference film, and the second metallized film 10b can be selected as an alignment film, and the metal vapor-deposited layers of the first metallized film 10a and the second metallized film 10b overlap in the stacking direction. For example, see Figure 4 , Figure 4The schematic diagram of the structure of the metallized film with four stacked layers provided in the embodiment of the present application, the first metallized film 10a and the third metallized film 10c can be selected as the reference film, when the number of metallized films of the reference film is greater than 1, the metal vapor-deposited layers of these metallized films do not overlap in the stacking direction, that is, the metal vapor-deposited layers of the first metallized film 10a and the third metallized film 10c do not overlap in the stacking direction. When the first metallized film 10a and the third metallized film 10c are selected as the reference film, the second metallized film 10b and the fourth metallized film 10d can be selected as the alignment film. When the second metallized film 10b and the fourth metallized film 10d are selected as the reference film (that is, the metal vapor-deposited layers of the second metallized film 10b and the fourth metallized film 10d do not overlap in the stacking direction), the first metallized film 10a and the third metallized film 10c can be selected as the alignment film.

[0061] The embodiments of the present application are merely exemplary introductions of two situations of selecting a reference film and an alignment film, and the above examples do not constitute specific limitations.

[0062] Step 103: adjusting the position of the material axis for placing the alignment film in the rolling device according to the overlapping size of the projection of the metal vapor-deposited layer of the reference film in the stacking direction and the projection of the metal vapor-deposited layer of the alignment film in the stacking direction.

[0063] The following diagram illustrates the film alignment steps for the four-roll-to-one case.

[0064] Figure 5 It is a schematic diagram of the structure of the disassembled test paper sample in the case of four rolls in one provided in an embodiment of the present application; the test paper sample may include a core rod 10, a first metallized film 10a, a second metallized film 10b, a third metallized film 10c, a fourth metallized film 10d and a coating 6a arranged in a stacked manner. Among them, the first metallized film 10a, the second metallized film 10b, the third metallized film 10c, and the fourth metallized film 10d all have a vapor-deposited portion (that is, the portion on the base film 100 covered by the metal vapor-deposited layer 200) and a non-vapor-deposited portion (that is, the portion on the base film 100 not covered by the metal vapor-deposited layer 200).

[0065] The embodiment of the present application does not specifically limit the size of the vapor-deposition part and the size of the non-vapor-deposition part, and the sizes known in the art can be adopted.

[0066] In some embodiments, the above rolling method can be implemented based on the above rolling equipment. For example, a rolling device with a width of X can be used. 1 1 roll of metallized film each, installed on the third material axis and the first material axis of the rolling machine respectively, with a width of X 2 The metallized films of each roll are respectively installed on the fourth material axis and the second material axis of the rolling machine, that is, the width of the first metallized film 10a and the second metallized film 10b is X 2The width of the third metallized film 10c and the fourth metallized film 10d is X 1 The width of the vapor deposition part on each metallized film is X 3 The width of the non-evaporation part between the two evaporation parts is X 4 Unless otherwise specified, the width involved in the embodiments of the present application refers to the dimension in the first direction.

[0067] In the present application, the first metallized film 10a, the second metallized film 10b, the third metallized film 10c and the fourth metallized film 10d can be the same metallized film or metallized films with different markings. It should be noted that, in the embodiments of the present application, unless otherwise specified, the width of the first metallized film 10a and the second metallized film 10b is X. 2 The width of the third metallized film 10c and the fourth metallized film 10d is X 1 The dimensions are described using an example.

[0068] In practical applications, the capacitance of the rolled capacitor core is directly related to the number of windings and the area of ​​the metal vapor-deposited layer (the overlapping size of the projection in the stacking direction). Therefore, the overlapping size of the projection of the metal vapor-deposited layer of the reference film in the stacking direction and the projection of the metal vapor-deposited layer of the alignment film in the stacking direction can be used as a guiding parameter to guide the corresponding size of the material axis corresponding to the alignment film, so that the capacitor rolled using the moved material axis has better quality.

[0069] Test the overlap size of the evaporated parts between the metallized films. If the overlap size of the projection of the metal evaporated layer of the reference film in the stacking direction and the projection of the metal evaporated layer of the alignment film in the stacking direction exceeds the preset overlap range, adjust the position of the material axis for placing the alignment film in the rolling device. In this application, the material axis for placing the alignment film can be referred to as the material axis corresponding to the alignment film.

[0070] The embodiment of the present application does not specifically limit the preset overlapping range, and the preset range can be set according to the size of the vapor deposition part.

[0071] For details, please refer to Figure 6 , as shown Figure 6 Schematic diagram of the structure of the metallized film with four stacked layers provided in the embodiment of the present application. Figure 6 In the embodiment, the overlap size of each vapor deposition part between the second metallized film 10b and the third metallized film 10c is L 1 ±0.1 mm, the overlap size of each vapor deposition part between the first metallized film 10a and the fourth metallized film 10d is L 1 ±0.1 mm, the overlap size of each vapor deposition part between the first metallized film 10a and the second metallized film 10b is L 2±0.05mm, the overlap size of each vapor-deposited portion between the third metallized film 10c and the fourth metallized film 10d is L 2 ±0.05mm. At this time, there is no need to adjust the position of the material axis corresponding to the alignment film.

[0072] If the overlap size between the vapor-deposited portion of the second metallized film 10b and the vapor-deposited portion of the third metallized film 10c is not within L 1 ±0.1 mm, the position of the material axis corresponding to the second metallized film 10b is adjusted so that in the subsequently rolled capacitor core, the overlap size of the vapor-deposited portion between the second metallized film 10b and the third metallized film 10c is within L 1 Within ±0.1mm.

[0073] The embodiment of the present application does not specifically limit the implementation method of adjusting the position of the material axis. As an implementation method, the position of the material axis can be adjusted by adjusting the film adjustment rotary rod next to the material axis so that the overlapping size of the vapor-deposited parts between the metallized films is within a preset overlapping range.

[0074] In some embodiments, a specific membrane adjustment process can be as follows:

[0075] The controller of the rolling device is used to select the first metallized film 10a and the third metallized film 10c as reference films, and the remaining second metallized film 10b and the fourth metallized film 10d are selected as alignment films. The metal vapor-deposited layers of the first metallized film 10a and the third metallized film 10c do not overlap in the stacking direction. When the first metallized film 10a remains fixed, the second metallized film 10b and the fourth metallized film 10d are adjusted so that the overlapping size of the vapor-deposited parts between the metallized films is within a preset overlapping range. The axial distances that the second metallized film 10b and the fourth metallized film 10d need to be adjusted on the material axis are recorded respectively. By adjusting the film adjustment rotary rod next to the material axis, the second metallized film 10b and the fourth metallized film 10d are adjusted according to the obtained axial distance, and finally the overlapping size of the vapor-deposited parts between the metallized films in the capacitor element subsequently rolled is within the preset overlapping range.

[0076] In other embodiments, a specific membrane adjustment process may also be as follows:

[0077] The controller of the above-mentioned rolling device is used to rotate the film adjustment rotary rods corresponding to the first material axis, the second material axis, the third material axis, and the fourth material axis respectively, so that the first metallized film 10a, the second metallized film 10b, the third metallized film 10c, and the fourth metallized film 10d are moved inward and outward on the winding shaft mandrel 10 (referring to the axial movement of the metallized film along the mandrel); the film adjustment rotary rod corresponding to the second film coating axis 6 is rotated to align the outer edge of the coating 6a with the outer edge of the winding shaft mandrel 10 inward L 3(See here Figure 5 ); (a transmission mechanism (gear mechanism) is set between one end of the film adjustment rotary rod and one end of the corresponding material shaft. By rotating the film adjustment rotary rod, the corresponding material shaft can be driven to move along its axial direction, thereby driving the adjustment of the axial position of the metallized film) When the rotary rod is adjusted clockwise, the metallized film moves outward; conversely, the metallized film moves inward. By adjusting the film adjustment rotary rod, finally, the overlapping size of the vapor-deposited part between the metallized films in the subsequently rolled capacitor core is made within the preset overlapping range.

[0078] Step 104: Use the adjusted rolling equipment to prepare the capacitor core.

[0079] The preparation method provided in the embodiment of the present application adjusts the position of the material axis for accommodating the alignment film in the rolling equipment by testing the overlapping size of the projection of the metal vapor-deposited layer of the reference film in the stacking direction and the projection of the metal vapor-deposited layer of the alignment film in the stacking direction in the test paper sample, thereby ensuring that in the capacitor core prepared based on the adjusted rolling equipment, the overlapping size of the projection of the metal vapor-deposited layer of the reference film in the stacking direction and the projection of the metal vapor-deposited layer of the alignment film in the stacking direction are both within a preset overlapping range, the capacitance value error of the prepared capacitor core is small, and the capacitor core prepared between batches has better product consistency and reliability.

[0080] The rolling process is further described below.

[0081] Typically, the rolling equipment is provided with a first pressing wheel and a second pressing wheel, wherein the first pressing wheel and the second pressing wheel are arranged on the left and right sides of the core rod 10. Therefore, in this application, the first pressing wheel can be referred to as the left pressing wheel, and the second pressing wheel can be referred to as the right pressing wheel.

[0082] In the embodiment of the present application, the N-layer metallized film can be divided into a first film layer group and a second film layer group, and the metallized film passing through the first pressure wheel is referred to as the first film layer group, and the metallized film passing through the second pressure wheel is referred to as the second film layer group. In some embodiments, the metallized film includes a first film layer group and a second film layer group, and the step of winding the metallized film mounted on the material shaft on the mandrel includes: transferring the first film layer group to the mandrel, and the first film layer group is wound on the mandrel; in response to the first film layer group being wound for a first preset number of turns, the second film layer group is transferred to the mandrel, so that the first film layer group and the second film layer group are wound on the mandrel in a stacked manner. In this embodiment, the first film layer group is pre-wound on the mandrel for a first preset number of turns, so as to achieve the effect of fixing the first film layer group. Different film layer groups are transferred to the core rod from different sides, which can ensure the stability of the winding process. When the second film layer group is transferred to the core rod, the second film layer group can be inserted between adjacent first film layer groups, so that the first film layer group and the second film layer group are wound in a stacked manner. Therefore, the first film layer group can exert a force on the second film layer group to prevent the relative movement of the first film layer group and the second film layer group, thereby reducing the capacitance value error of the prepared capacitor core.

[0083] The embodiment of the present application does not specifically limit the value of the first preset number of turns, and the value of the first preset number of turns can be set according to demand. For example, the value of the first preset number of turns can be 5 turns to 10 turns.

[0084] The following is combined with specific Figure 7 And the rolling process of the capacitor core is explained.

[0085] See also Figure 7 , as shown Figure 7 It is a schematic diagram of the rolling equipment in the two-roll-one process provided by the embodiment of the present application. The rolling equipment may include: a first material shaft 1, a second material shaft 2, a third material shaft 3, a fourth material shaft 4, a first film-wrapping shaft 5, a second film-wrapping shaft 6, a fifth material shaft 7, and a sixth material shaft 8. In this embodiment, the second material shaft 2 is used to place the first metallized film 10a, and the fourth material shaft 4 is used to place the second metallized film 10b; the first film-wrapping shaft 5 and the second film-wrapping shaft 6 are respectively used to place the material shafts of the film 6a; there is a film-adjusting rotary rod 9 near each material shaft and each film-wrapping shaft, which can be used to adjust the position of the metallized film during the film-adjusting step; when the first metallized film 10a is wound on the mandrel 10 according to a preset path, it will pass through the first passing wheel 13a, the first tension balance wheel 14a, and the left pressure wheel 11. When the second metallized film 10b is wound on the mandrel 10 according to a preset path, it will pass through the second passing wheel 13b, the second tension balance wheel 14b, and the right pressure wheel 12.

[0086] In the present application, the pass wheel is also called the flattening axis, which is used to flatten the metallized film and remove wrinkles. The tension balance wheel is used to apply tension in the opposite direction to the metallized film to ensure that the rolling process is carried out at a uniform speed and improve the stability of the rolling process. The pressure wheel can work together with the tension balance wheel to maintain the metallized film tension of the metallized film. At the same time, by applying a certain pressure, the friction between the metallized film and the core rod is increased to ensure that the metallized film will not be unable to be rolled due to the reverse tension applied by the tension balance wheel, while further improving the stability of the rolling process.

[0087] Please continue to see Figure 7 When two rolls of metallized film are used to roll the capacitor core, the first metallized film 10a placed on the second material shaft 2 passes through the first passing wheel 13a and the first tension balance wheel 14a during the rolling process, passes through the left pressure wheel 11 and starts to be wound clockwise from one side of the mandrel 10 for 5 to 10 turns, so that the first metallized film 10a can be fixed on the mandrel 10 to avoid falling off due to the reverse tension applied by the first tension balance wheel 14a. After that, the second metallized film 10b placed on the fourth material shaft 4 passes through the second passing wheel 13b and the second tension balance wheel 14b, passes through the right pressure wheel 12 and starts to be wound clockwise from the other side of the mandrel 10 for 5 to 10 turns, so that the metallized film can be fixed on the mandrel 10 to avoid falling off due to the reverse tension applied by the second tension balance wheel 14b, and then the first metallized film 10a and the second metallized film 10b are wound synchronously.

[0088] After the first metallized film 10a and the second metallized film 10b are correctly wound on the mandrel 10, the mandrel 10 is kept in a slow-winding state, and the left and right pressure wheels 11 and 12 are controlled to move toward the mandrel 10 and squeeze the mandrel 10 to apply pressure to the first and second metallized films 10a and 10b. Then, the rolling is performed according to the rolling parameters.

[0089] In some embodiments, the rolling parameters include: the pre-set material tension of each metallized film, the pressure of the left pressure wheel and the right pressure wheel, the core rod diameter, the width and thickness of the film, etc. According to the selected material axis and coating axis used for rolling, the tension balance wheels of each material axis and coating axis apply tension in the opposite direction to provide the set tension for the metallized film and the coating.

[0090] In actual applications, when N (N is an integer greater than or equal to 2) metallized films are wound on the core rod 10, the metallized films are not wound on the core rod 10 one by one in the above manner, but the metallized films passing through the pressure wheel on the same side are wound on the core rod 10 together, and then the metallized film passing through the pressure wheel on the other side is inserted into the metallized film already wound on the core rod 10 by using the film insertion technology, so that all the metallized films are wound on the core rod 10.

[0091] In some embodiments, the first film layer group includes a first film layer and a second film layer, the second film layer group includes a third film layer and a fourth film layer, and the step of winding the metallized film mounted on the material shaft onto the mandrel includes: transferring the first film layer and the second film layer to the mandrel, and winding the first film layer and the second film layer onto the mandrel; in response to the first film layer and the second film layer being wound on the surface of the mandrel for a first preset number of turns, transferring the third film layer and the fourth film layer to the mandrel, so that the first film layer, the second film layer, the third film layer, and the fourth film layer are wound onto the mandrel in a stacked manner. In this embodiment, the first film layer and the second film layer are wound on the mandrel for a first preset number of turns in advance, so as to achieve the effect of fixing the first film layer and the second film layer. Different film layer groups are transmitted to the core rod in sequence, which can ensure the stability of the winding process, and when the third film layer and the fourth film layer are transmitted to the core rod, the third film layer and the fourth film layer are inserted between adjacent first film layer groups, so that the first film layer, the second film layer, the third film layer and the fourth film layer are wound in a stacked manner. Therefore, the first film layer group composed of the first film layer and the second film layer can exert a force on the second film layer group composed of the third film layer and the fourth film layer to prevent the relative movement of the first film layer group composed of the first film layer and the second film layer and the second film layer group composed of the third film layer and the fourth film layer, thereby reducing the capacitance value error of the prepared capacitor core.

[0092] The following is combined with specific Figure 8 The winding process of the capacitor core is explained.

[0093] Figure 8 It is a schematic diagram of the rolling equipment in the four-roll-in-one process provided in an embodiment of the present application.

[0094] See also Figure 8 In the four-roll-one process, the first material shaft 1 is used to place the third metallized film 10c, the second material shaft 2 is used to place the first metallized film 10a, the third material shaft 3 is used to place the fourth metallized film 10d, and the fourth material shaft 4 is used to place the second metallized film 10b; the second film coating shaft 6 is a material shaft for placing the coating 6a. In some embodiments, the first film coating shaft 5 can be used to place the coating 6a.

[0095] For the third metallized film 10c placed on the first material shaft 1 and the first metallized film 10a placed on the second material shaft 2, the metal vapor-deposited layers of the first metallized film 10a and the third metallized film 10c do not overlap in the stacking direction. During the rolling process, the third metallized film 10c and the first metallized film 10a pass through the first passing wheel 13a and the first tension balance wheel 14a, then pass through the left pressure wheel 11 and start from the upper part of the core rod 10 to be wound clockwise for 5 to 10 turns, so that the first metallized film 10a and the third metallized film 10c can be fixed on the core rod 10 to avoid falling off due to the reverse tension applied by the first tension balance wheel 14a. Afterwards, the second metallized film 10b placed on the fourth material shaft 4 and the fourth metallized film 10d placed on the third material shaft 3 pass through the second passing wheel 13b and the second tension balance wheel 14b, pass through the right pressure wheel 12 and start from the lower part of the core rod 10 to be wound clockwise for 5 to 10 turns, so that the second metallized film 10b and the fourth metallized film 10d can be fixed on the core rod 10 to avoid falling off due to the reverse tension applied by the second tension balance wheel 14b, and then the first metallized film 10a, the third metallized film 10c, the second metallized film 10b, and the fourth metallized film 10d are synchronously wound.

[0096] In some embodiments, the first film layer group includes a first film layer, a second film layer, and a third film layer, and the second film layer group includes a fourth film layer, a fifth film layer, and a sixth film layer. The step of winding the metallized film mounted on the material shaft on the mandrel includes: transferring the first film layer, the second film layer, and the third film layer to the mandrel, and winding the first film layer, the second film layer, and the third film layer on the mandrel; in response to the first film layer, the second film layer, and the third film layer being wound on the surface of the mandrel for a first preset number of turns, transferring the fourth film layer, the fifth film layer, and the sixth film layer to the mandrel, so that the first film layer, the second film layer, the third film layer, the fourth film layer, the fifth film layer, and the sixth film layer are wound on the mandrel in a stacked manner. In this embodiment, the first film layer, the second film layer, and the third film layer are pre-wound on the mandrel for a first preset number of turns, so as to achieve the effect of fixing the first film layer, the second film layer, and the third film layer. Different film layer groups are transmitted to the core rod in sequence, which can ensure the stability of the winding process, and when the fourth film layer, the fifth film layer and the sixth film layer are transmitted to the core rod, the fourth film layer, the fifth film layer and the sixth film layer are inserted between adjacent first film layer groups, so that the first film layer, the second film layer, the third film layer, the fourth film layer, the fifth film layer and the sixth film layer are wound in a stacked manner. Therefore, the first film layer group can exert a force on the fourth film layer, the fifth film layer and the sixth film layer to prevent the relative movement of the first film layer group composed of the first film layer, the second film layer and the third film layer and the second film layer group composed of the fourth film layer, the fifth film layer and the sixth film layer, thereby reducing the capacitance value error of the prepared capacitor core.

[0097] The following is combined with specific Fig. 9 The winding process of the capacitor core is explained.

[0098] Fig. 9 It is a schematic diagram of the rolling equipment in the six-roll-in-one process provided in an embodiment of the present application.

[0099] See also Fig. 9 In the six-roll-one process, the first material shaft 1 is used to place the third metallized film 10c, the second material shaft 2 is used to place the first metallized film 10a, the third material shaft 3 is used to place the fourth metallized film 10d, the fourth material shaft 4 is used to place the second metallized film 10b, the fifth material shaft 7 is used to place the fifth metallized film 10e, and the sixth material shaft 8 is used to place the sixth metallized film 10f; the second film coating shaft 6 is a material shaft for placing the coating 6a. In some embodiments, the first film coating shaft 5 can be used to place the coating 6a.

[0100] In some embodiments, when six rolls of metallized film are used to roll a capacitor core, the metal vapor-deposited layers of the first metallized film 10a, the third metallized film 10c, and the fifth metallized film 10e do not overlap in the stacking direction, and the third metallized film 10c placed on the first material shaft 1, the first metallized film 10a placed on the second material shaft 2, and the fifth metallized film 10e placed on the fifth material shaft 7 are transferred to the mandrel 10, and are wound clockwise from one side of the mandrel 10 for 5 to 10 turns (the number of winding turns is only for illustration and is not used as the embodiment of the present application). The first metallized film 10a, the third metallized film 10c, and the fifth metallized film 10e are fixed on the mandrel 10 to avoid falling off due to the reverse tension applied by the first tension balance wheel 14a. The transmission methods of the first metallized film 10a, the third metallized film 10c, and the fifth metallized film 10e are similar. The transmission method of the first metallized film 10a is taken as an example for explanation. After the first metallized film 10a passes through the first passing wheel 13a and the first tension balance wheel 14a, it passes through the left pressure wheel 11 and is finally transmitted to the mandrel 10. It should be noted that in the actual rolling process, the fifth metallized film 10e will be transmitted to the mandrel 10, but in Fig. 9 In the image shown, the fifth metallized film 10e is partially blocked near the core rod 10, so Fig. 9The transmission section of the fifth metallized film 10e is not fully illustrated. Afterwards, the second metallized film 10b placed on the fourth material shaft 4, the fourth metallized film 10d placed on the third material shaft 3, and the sixth metallized film 10f placed on the sixth material shaft 8 are transferred to the mandrel 10, and are wound clockwise for 5 to 10 turns from the other side of the mandrel 10 (the number of winding turns is only for illustration and is not a limitation of the embodiment of the present application), so that the second metallized film 10b, the fourth metallized film 10d, and the sixth metallized film 10f can be fixed on the mandrel 10 to avoid falling off due to the reverse tension applied by the second tension balance wheel 14b, wherein the transmission method of the second metallized film 10b, the fourth metallized film 10d, and the sixth metallized film 10f are similar, and the transmission method of the second metallized film 10b is taken as an example for explanation below, and the second metallized film 10b passes through the second passing wheel 13b and the second tension balance wheel 14b, passes through the right pressure wheel 12, and is finally transmitted to the mandrel 10. It should be noted that, in the actual rolling process, the sixth metallized film 10f will be transferred to the mandrel 10, but Fig. 9 In the image shown, the sixth metallized film 10f is partially blocked near the core rod 10, so Fig. 9 The transmission section of the sixth metallized film 10f is not fully illustrated. Then, the first metallized film 10a, the second metallized film 10b, the third metallized film 10c, the fourth metallized film 10d, the fifth metallized film 10e, and the sixth metallized film 10f are wound synchronously.

[0101] In some embodiments, in response to the first film layer group and the second film layer group starting to be wound synchronously, the number of rotations of the mandrel is counted; in response to the difference between the counted number of rotations and the set number of rotations reaching a set value, the envelope is transferred to the mandrel and wound synchronously with the N layers of metallized film to be wound; in response to the number of rotations reaching the set number of rotations, the metallized film is cut off, and the envelope continues to be wound driven by the mandrel.

[0102] The embodiment of the present application does not specifically limit the value of the set number of turns, and the set number of turns can be configured according to the required capacitance value of the capacitor core. For example, the set number of turns is 200 turns.

[0103] The embodiment of the present application does not specifically limit the value of the set value, and the set value can be configured according to requirements. For example, the set value can be 5 turns.

[0104] As an example, assuming that the set number of turns is 200 turns and the set value is 5 turns, when the first film layer group and the second film layer group start to be wound synchronously, the number of rotations of the mandrel 10 starts to be counted. When the difference between the counted number of rotations and the set number of rotations reaches the set value of 5 turns (equivalent to when the first film layer group and the second film layer group start to be wound synchronously, the mandrel 10 has rotated 195 times), the coating is transferred to the mandrel 10 and wound synchronously with the N layers of metallized film to be wound. When the number of rotations of the mandrel 10 reaches the set number of 200 turns, the metallized film is cut off, and the coating continues to be wound driven by the mandrel 10. The mandrel 10 also needs to rotate to complete the set number of coating turns. The number of coating turns can be set according to actual conditions. The number of coating turns can be 10 turns. After cutting off the metallized film, the mandrel 10 needs to be wound at least 10 times.

[0105] See also Fig.10 , Fig.10 Schematic diagram of the core rod and the metallized film in the two-on-one process. The film 6a is inserted between the adjacent first metallized film 10a and the second metallized film 10b wound on the core rod 10 by using the film insertion technology, so as to realize the winding of the film 6a on the core rod 10. Fig.11 , Fig.11 Schematic diagram of the core rod and the metallized film in the four-in-one process. The film insertion technology is used to insert the envelope 6a into the adjacent first metallized film 10a, second metallized film 10b, third metallized film 10c and fourth metallized film 10d that have been wound on the core rod 10, so as to realize the wrapping film 6a being wound on the core rod 10. Fig.12 , Fig.12 It is a schematic diagram of the core rod and the metallized film in the six-winding process, and the film insertion technology is used to insert the coating 6a into the adjacent first metallized film 10a, second metallized film 10b, third metallized film 10c, fourth metallized film 10d, fifth metallized film 10e and sixth metallized film 10f that have been wound on the core rod 10, so as to realize the winding of the coating 6a on the core rod 10.

[0106] In this embodiment, before the metallized film is rolled, the envelope is inserted into the metallized film, and the envelope is fixed by the squeezing effect of the metallized film on the envelope, so that the prepared capacitor core has better structural stability.

[0107] In some embodiments, after the step of preparing the test paper sample, the rolling method also includes: testing the size of the test paper sample in the direction of its winding axis; if the size of the test paper sample in the direction of its winding axis exceeds a preset height range, disassembling the test paper sample to obtain a metallized film with N layers stacked.

[0108] As an example, the size of the test paper sample in the winding axis direction can be measured using a digital display vernier caliper, with the width of the first metallized film 10a and the second metallized film 10b as X. 2 The width of the third metallized film 10c and the fourth metallized film 10d is X 1 For example, the preset height range corresponding to the test paper sample is L 4 If the size of the test paper sample in the winding axis direction exceeds L 4 Within the scope of the invention, the test paper sample is disassembled to obtain a metallized film with an N-layer stacking arrangement.

[0109] In this embodiment, the dimensions of the test paper sample in the direction of the winding axis are tested. If the dimensions in the direction of the winding axis do not meet the requirements, the filming step is performed again to ensure that the capacitor core prepared subsequently has good quality.

[0110] In some embodiments, before the step of filming, the test paper samples need to be tested for electrical parameters. The electrical parameters are measured by a capacitor tester to measure the capacitance and dielectric loss of each capacitor core. If the capacitance and dielectric loss of each test paper sample are qualified, subsequent quality tests are performed. In this application, the quality test includes: partial discharge test, power frequency withstand voltage test and lightning impulse test.

[0111] If at least one of the capacitance and dielectric loss values ​​of each test paper sample is not within the preset electrical parameter range, the cause shall be found out and batch production shall be allowed only after the test is passed.

[0112] The following is a further description of the electrical parameter test process:

[0113] In some embodiments, the capacitor core includes a test capacitor core and a finished capacitor core; the steps of preparing the capacitor core using the adjusted rolling equipment include: preparing the test capacitor core using the adjusted rolling equipment; testing the electrical parameters of the test capacitor core; if the electrical parameters obtained by the test are within the preset electrical parameter range, performing a quality test on the test capacitor core to obtain a quality test result; if the quality test result meets the set conditions, the finished capacitor core is rolled based on the adjusted rolling equipment. Before preparing the finished capacitor core, the preparation method uses the adjusted rolling equipment to prepare the test capacitor core, and performs electrical parameter tests and quality tests on the test capacitor core. If the test capacitor core passes the electrical parameter tests and quality tests, the next batch rolling (finished capacitor core) can be carried out to ensure that the finished capacitor core prepared subsequently has good quality.

[0114] In some embodiments, the capacitor core includes a test capacitor core and a finished capacitor core; the step of preparing the test capacitor core using the adjusted rolling equipment includes: preparing the test capacitor core using the adjusted rolling equipment; testing the electrical parameters of the test capacitor core; if the electrical parameters obtained from M consecutive tests are within the preset electrical parameter range, a partial discharge test is performed on the test capacitor core to obtain a partial discharge test result; if the partial discharge test result meets the set conditions, the finished capacitor core is rolled based on the adjusted rolling equipment. This embodiment performs M measurements and compares the results as evaluation data. The M measurements can improve the reliability and credibility of the data and provide stronger support for the judgment criteria.

[0115] In some embodiments, the electrical parameter includes at least one of a capacitance value and a dielectric loss value. In this embodiment, the capacitance value and the dielectric loss value can be used to prove that the capacitor core is preliminarily qualified.

[0116] In some embodiments, the preset electrical parameters include: at least one of a preset capacitance range and a preset dielectric loss value range.

[0117] The embodiment of the present application does not specifically limit the preset capacitance range, and the preset capacitance range can be set according to actual needs. For example, the preset capacitance range corresponding to the finished capacitor core with an ideal capacitance value of 2nF is 1.98~2.02nF.

[0118] The embodiment of the present application does not specifically limit the preset dielectric loss value range, and the preset dielectric loss value range can be set according to actual needs. For example, the preset dielectric loss value range corresponding to the finished capacitor core with an ideal capacitance value of 2nF is below 0.00060.

[0119] Still taking the metallized film used when rolling the above-mentioned four-roll capacitor core and the overlapping size of the vapor-deposited part as an example, in the actual application process, when the corresponding capacitance value is 2nF, the number of windings required for the core rod is 200, the test winding number can be set to 6, and the number of windings can be set to 200. After receiving the start command, the winding machine rolls out six capacitor cores obtained by winding 200 turns of four metallized films. At this time, the capacitance values ​​of the six capacitor cores tested by the capacitor tester are between 1.98 and 2.02nF, and the dielectric loss value is less than or equal to 0.00060, indicating that the six capacitor cores are initially qualified. At this time, each capacitor core is sprayed with gold, heat-set and peeled, and then a partial discharge test, a power frequency withstand voltage test and a lightning impulse test are carried out to determine whether the obtained test data are qualified. If all six capacitor cores are qualified, the next batch rolling can be carried out.

[0120] It is worth noting that the embodiment of the present application is only an exemplary introduction to an example of testing the capacitance value and dielectric loss value of the test capacitor core at the same time. In some embodiments, the capacitance value of the test capacitor core can be tested separately. If the capacitance value obtained by the test is within the preset capacitance range, the partial discharge test is directly performed on the test capacitor core. In some embodiments, the dielectric loss value of the test capacitor core can be tested separately. If the dielectric loss value obtained by the test is within the preset dielectric loss value range, the partial discharge test is directly performed on the test capacitor core.

[0121] In some embodiments, the metallized film reaches the mandrel through at least one of a balance wheel, a passing wheel, and a pressure wheel. The passing wheel is also called a flattening shaft, which is used to flatten and wrinkle the metallized film. The tension balance wheel is used to apply tension in the opposite direction to the metallized film to ensure that the rolling process is carried out at a uniform speed and improve the stability of the rolling process. The left pressure wheel and the right pressure wheel can work together with the tension balance wheel to maintain the material tension of the metallized film. At the same time, by applying a certain pressure, the friction between the metallized film and the mandrel is increased to ensure that the metallized film will not be unable to be rolled due to the reverse tension applied by the tension balance wheel, while further improving the stability of the rolling process. In this embodiment, the passing metallized film is rolled into a capacitor core smoothly, at a uniform speed, and stably through the balance wheel, the passing wheel, and the pressure wheel.

[0122] In practical applications, before N sheets of metallized film are wound from the material shaft according to the preset path and fixed on the mandrel, the following requirements are imposed on the staff:

[0123] Determine the rolling room environment, wear protective equipment, take out materials in advance, and store them in the prescribed form.

[0124] Here, in order to ensure the normal progress of the rolling process and the quality of the rolled capacitor core, the temperature in the rolling room is generally required to be maintained in the range of 23℃±2℃, and the relative humidity is required to be no more than 35%. In addition, after each rolling work is completed, when the rolling room is idle, the air shower and purification device are turned on to remove impurities in the rolling room; before entering the rolling room, the staff needs to correctly wear protective equipment such as masks, fine yarn gloves, anti-static clothing, head covers, and foot covers; when receiving a rolling task, the staff needs to unpack the materials and place them on the shelves in the rolling room 12 hours or more in advance to ensure that the material temperature is consistent with the temperature in the rolling room when the rolling task is in progress.

[0125] The following is a further description of the solution of this application in conjunction with specific examples. Fig.13 , Fig.13 This is a flow chart of a rolling method provided by another embodiment of the present application, which can be implemented by the following steps:

[0126] In step 201, the metallized film is replaced.

[0127] As an example, a capacitor core with a capacitance value of 2 nF can be rolled. To roll the capacitor core, a width of X 1 One roll of metallized film with red and green markings is installed on the third material axis 3 and the first material axis 1 of the winding machine respectively, with a width of X 2 One roll of metallized film with red and green markings is installed on the fourth material shaft 4 and the second material shaft 2 of the winding machine respectively, and the coated material roll is installed on the second coating shaft 6.

[0128] In step 202, a test paper sample is prepared.

[0129] As an example, according to the material threading path diagram, the metallized film can be correctly passed through the tension balance wheel, the pass wheel (flattening axis), and the left pressure wheel, and then wound on the mandrel clockwise from the top for 5 to 10 turns; the metallized film can be correctly passed through the tension balance wheel, the pass wheel (flattening axis), and the right pressure wheel, and then wound on the mandrel clockwise from the bottom for 5 to 10 turns. At this time, after pressing the slow roll button, press the left and right pressure wheel buttons at the same time, keep in the slow roll state so that the left and right pressure wheels slowly fall and completely press on the winding axis mandrel. After that, you can set the rolling parameters: set the material tension to the first preset tension (250~1250g); set the left and right pressure wheel pressure to the second preset pressure (500~10500g); input parameters such as mandrel diameter, film width and film thickness, and then set the tension balance wheels of the first material axis 1, the second material axis 2, the third material axis 3, the fourth material axis 4, and the second film coating axis 6 to apply tension in the opposite direction.

[0130] In step 203, it is determined whether the height of the test paper sample exceeds a preset height range.

[0131] As an example, by width X 1 The metallized film and the width are X 2 The capacitor core made of metallized film can be set to a height of L 4 The film height of the test paper sample can be measured by a digital display vernier caliper. If the height of the test paper sample exceeds the preset height range, the process goes to step 202 to prepare the test paper sample again. If the height of the test paper sample does not exceed the preset height range, the process goes to step 204.

[0132] In step 204, the test paper sample is disassembled to obtain an N-layer stacked metallized film.

[0133] In step 205, the obtained N-layer stacked metallized films are aligned.

[0134] The distance of the material axis of the alignment film that needs to be adjusted is determined according to the overlapping size of the metallized film in the stacking direction.

[0135] In step 206, the position of the material shaft for placing the alignment film in the winding equipment is adjusted.

[0136] After pressing the slow-winding button, turn the film adjustment lever to move the metallized film inwards and outwards on the winding shaft mandrel according to the required adjustment distance (the metallized film moves axially along the mandrel); turn the film adjustment lever to align the outer side of the film with the outer side of the winding shaft mandrel inwards. 3 (A transmission mechanism (gear mechanism) is set between one end of the adjusting rotary rod and one end of the corresponding material shaft. By screwing the adjusting rotary rod, the corresponding material shaft can be driven to move along its axial direction, thereby driving the axial position adjustment of the metallized film - axial position adjustment of the metallized film on the winding mandrel) When the rotary rod is adjusted clockwise, the metallized film moves outward; otherwise, the metallized film moves inward.

[0137] In step 207, a test capacitor core is prepared and a capacitance value of the test capacitor core is measured.

[0138] In step 208, it is determined whether the capacitance value of the test capacitor core is within the preset capacitance range. If the capacitance value of the test capacitor core is not within the preset capacitance range, the cause is found out. If the capacitance value of the test capacitor core is within the preset capacitance range, the process proceeds to step 209.

[0139] In step 209, it is determined whether the dielectric loss value of the test capacitor core is within the preset dielectric loss range. If the dielectric loss value of the test capacitor core is not within the preset dielectric loss range, the cause is found out. If the dielectric loss value of the test capacitor core is within the preset dielectric loss range, the process proceeds to step 2010.

[0140] In step 2010, it is determined whether the partial discharge test result of the capacitor core is qualified. If the partial discharge test result of the capacitor core is unqualified, the cause is found out. If the partial discharge test result of the capacitor core is qualified, the process proceeds to step 2011.

[0141] In step 2011, finished capacitor elements are mass-produced.

[0142] It should be noted that, in some embodiments, the capacitor core can be prepared by using the adjusted rolling equipment through steps 207-2011.

[0143] The above is only an embodiment of the present application and is not intended to limit the protection scope of the present application. Any modifications, equivalent substitutions and improvements made within the spirit and scope of the present application are included in the protection scope of the present application.

Claims

1. A method for rolling a high-voltage capacitor core, characterized in that: include: A test paper sample is prepared by using a rolling device, wherein the rolling device comprises at least two material shafts, wherein the material shafts are used to place the metallized film; Among the N layers of stacked metallized films disassembled from the test paper sample, at least one layer of the metallized film is selected as a reference film, and metallized films other than the reference film are selected as alignment films, wherein the metallized film includes a base film and a metal vapor-deposited layer arranged on a surface of one side of the base film in a first direction and arranged at intervals, wherein N is an integer greater than or equal to 2, and the first direction is perpendicular to the stacking direction of the metallized film; adjusting the position of a material axis for arranging the alignment film in a rolling device according to an overlapping size of a projection of the metal vapor-deposited layer of the reference film in the stacking direction and a projection of the metal vapor-deposited layer of the alignment film in the stacking direction; The capacitor core is prepared using the adjusted rolling equipment.

2. The rolling method according to claim 1, characterized in that: The metallized film includes a first film layer group and a second film layer group, and the step of preparing the capacitor core includes: transferring the first film layer group to a core rod, wherein the first film layer group is wound on the core rod; In response to the first film layer group being wound for a first preset number of turns, the second film layer group is transferred to the mandrel, so that the first film layer group and the second film layer group are wound on the mandrel in a stacked manner.

3. The rolling method according to claim 2, characterized in that: The first film layer group includes a first film layer and a second film layer, the second film layer group includes a third film layer and a fourth film layer, and the step of preparing the capacitor core includes: The first film layer and the second film layer are transferred to the core rod, and the first film layer and the second film layer are wound on the core rod; In response to the first film layer and the second film layer being wound a first preset number of times on the surface of the core rod, the third film layer and the fourth film layer are transmitted to the core rod so that the first film layer, the second film layer, the third film layer, and the fourth film layer are wound on the core rod in a stacked manner.

4. The rolling method according to claim 2, characterized in that: The first film layer group includes a first film layer, a second film layer and a third film layer, the second film layer group includes a fourth film layer, a fifth film layer and a sixth film layer, and the step of preparing the capacitor core includes: The first film layer, the second film layer and the third film layer are transferred to the core rod, and the first film layer, the second film layer and the third film layer are wound on the core rod; In response to the first film layer, the second film layer and the third film layer being wound a first preset number of times on the surface of the mandrel, the fourth film layer, the fifth film layer and the sixth film layer are transmitted to the mandrel so that the first film layer, the second film layer, the third film layer, the fourth film layer, the fifth film layer and the sixth film layer are wound on the mandrel in a stacked manner.

5. The rolling method according to any one of claims 2 to 4, characterized in that: The step of preparing the capacitor core also includes: In response to the first film layer group and the second film layer group starting to be synchronously wound, counting the number of rotations of the mandrel; In response to the difference between the counted number of rotations and the set number of rotations reaching a set value, the envelope film is transferred to the mandrel and is synchronously wound with the metallized film; In response to the counted number of rotations reaching the set number of rotations, the metallized film is cut off, and the envelope continues to be wound under the drive of the mandrel.

6. The rolling method according to claim 1, characterized in that: Between the steps of preparing the test paper sample and determining the reference film and the alignment film, the method further comprises: Testing the size of the test paper sample in the direction of its winding axis; If the size of the test paper sample in the winding axis direction exceeds the preset height range, the test paper sample is disassembled to obtain a metallized film with N layers stacked.

7. The rolling method according to claim 1, characterized in that: The capacitor core includes a test capacitor core and a finished capacitor core; Using the adjusted rolling equipment, the steps of preparing the capacitor core include: Using the adjusted rolling equipment to prepare the test capacitor core; Testing electrical parameters of the test capacitor core; If the electrical parameter obtained by the test is within the preset electrical parameter range, a quality test is performed on the test capacitor core to obtain a quality test result; If the quality test results meet the set conditions, the finished capacitor core is rolled based on the adjusted rolling equipment.

8. The rolling method according to claim 1, characterized in that: The capacitor core includes a test capacitor core and a finished capacitor core; Using the adjusted rolling equipment, the steps of preparing the capacitor core include: Using the adjusted rolling equipment to prepare the test capacitor core; Testing electrical parameters of the test capacitor core; If the electrical parameters obtained from the M consecutive tests are all within the preset electrical parameter range, a partial discharge test is performed on the test capacitor core to obtain a partial discharge test result; If the partial discharge test result meets the set conditions, the finished capacitor core is rolled based on the adjusted rolling equipment.

9. The rolling method according to claim 7 or 8, characterized in that: The electrical parameter includes at least one of a capacitance value and a dielectric loss value.

10. The rolling method according to any one of claims 2 to 4, characterized in that: The metallized film reaches the core rod via at least one of a balance wheel, a passing wheel and a pressure wheel.

11. A rolling device, characterized in that: The rolling equipment comprises: At least two material shafts, the material shafts are used to place the metallized film; A film adjusting rotary rod is provided on one side of each material shaft, and the film adjusting rotary rod is used to adjust the position of the material shaft; A controller, the controller being used to: Among the N layers of stacked metallized films disassembled from the test paper sample, at least one layer of the metallized film is selected as a reference film, and metallized films other than the reference film are selected as alignment films, wherein the metallized film includes a base film and a metal vapor-deposited layer arranged on a surface of one side of the base film in a first direction and arranged at intervals, wherein N is an integer greater than or equal to 2, and the first direction is perpendicular to the stacking direction of the metallized film; According to the overlapping size of the projection of the metal vapor-deposited layer of the reference film in the stacking direction and the projection of the metal vapor-deposited layer of the alignment film in the stacking direction, the movement of the target film adjustment rod is controlled to adjust the position of the material axis on which the alignment film is placed. The target film adjustment rod is the film adjustment rod arranged on one side of the material axis on which the alignment film is placed.

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