Combined capacitor structure convenient for test welding and manufacturing method thereof

Abstract

The invention relates to the technical field of capacitors, in particular to a combined capacitor structure convenient to test welding and a manufacturing method, the combined capacitor structure comprises an outer packaging layer, a capacitor core body is arranged on the inner side of the outer packaging layer, and the capacitor core body comprises an outer ring core body arranged on the inner side of the outer packaging layer and an inner ring core body arranged on the inner side of the outer ring core body; the outer ring core body and the inner ring core body are coaxially arranged, the axis of the outer ring core body and the axis of the inner ring core body coincide, a capacitor core shaft is arranged at the axis of the inner ring core body, the inner ring core body comprises an inner ring metal layer and a dielectric film which are wound in a stepped mode, the invalid winding thickness of the dielectric film is increased by removing part of the inner ring metal layer, and the diameter of the capacitor core shaft is equivalently increased. The electrode contact area can be increased, welding points are more conspicuous, contact is facilitated, the electrode contact area is increased by more than 50%, the welding reliability of the two ends of the inner ring core body is greatly improved, meanwhile, the precision and consistency of the welding testing process are improved, and the testing and welding convenience is further improved.

Description

Technical Field

[0001] The present invention relates to the technical field of capacitors, and in particular to a combined capacitor structure and a manufacturing method thereof that is convenient for testing welding. Background Art

[0002] A combined capacitor is a capacitor composed of multiple capacitor elements, usually by combining capacitors of different specifications or types in series or parallel to meet specific electrical performance requirements. Traditional combined capacitors use a metallized polypropylene film winding structure, usually with a small-capacity core (inner layer) and a large-capacity core (outer layer) coaxially wound on a plastic core shaft with a diameter of 9 mm, separated by an isolation film (204). However, due to the low capacity requirement and the small number of metallized film layers, the diameter of the inner layer small-capacity core is significantly smaller than that of the outer layer core. When welding the inner layer core with a smaller diameter, the electrode contact area is insufficient, which easily leads to welding failure or detachment, making welding more difficult. At the same time, the test probe is prone to slipping when contacting the core, which is unstable and affects the accuracy of electrical parameter measurement. Summary of the Invention

[0003] In order to overcome the deficiencies of the prior art, the present invention provides a combined capacitor structure and a manufacturing method that are convenient for testing welding, thereby solving the problems of the prior art.

[0004] In order to solve the above technical problems, the present invention provides the following technical solutions: A combined capacitor structure that is convenient for testing welding includes an outer packaging layer, a capacitor core is arranged on the inner side of the outer packaging layer, the capacitor core includes an outer ring core arranged on the inner side of the outer packaging layer, and an inner ring core arranged on the inner side of the outer ring core, and the axes of the outer ring core and the inner ring core coincide, a capacitor core shaft is arranged at the axis center of the inner ring core, an isolation film is arranged on the outer side of the inner ring core, the inner ring core includes a stepped inner ring metal layer and a dielectric film, and the ineffective winding thickness of the dielectric film is increased by removing part of the inner ring metal layer, thereby equivalently increasing the diameter of the capacitor core shaft.

[0005] As a further optimized solution of the present invention, the dielectric film is made of polypropylene material.

[0006] As a further optimization solution of the present invention, both ends of the inner ring metal layer are respectively provided with welding ends, and the area of ​​the welding ends is a reserved uncleaned metallized area.

[0007] As a further optimization solution of the present invention, the isolation membrane is insulated and connected to the inner ring of the outer ring core, and the outer ring core includes an outer ring metal layer wound on the isolation membrane.

[0008] As a further optimization solution of the present invention, the diameter of the capacitor core shaft is in the range of 12 to 15 mm, so that the welding ends at both ends of the capacitor core shaft are more easily contacted.

[0009] A method for manufacturing a combined capacitor structure that is convenient for testing welding comprises the following steps: S1. Metal layer cleaning: Before winding the inner core, the inner metal layer on one side of the dielectric film is periodically removed through electrochemical or laser cleaning process to form alternating conductive and non-conductive areas; S2, step winding: The treated dielectric film is wound alternately in "conductive area-non-conductive area". The non-conductive area occupies extra space because there is no inner metal layer, which effectively increases the core diameter. S3. Outer layer winding: Wind untreated large-capacity film directly on the inner core body, and achieve interlayer insulation through the isolation film.

[0010] By means of the above technical solution, the present invention provides a combined capacitor structure and manufacturing method that is convenient for testing welding. Compared with the prior art, the present invention has at least the following beneficial effects: 1. The present invention comprises an outer core and an inner core to form a capacitor core. The inner core comprises a stepped inner metal layer and a dielectric film. By removing part of the inner metal layer, the ineffective winding thickness of the dielectric film is increased, which effectively increases the diameter of the capacitor core shaft and the electrode contact area. This helps make the welding point more visible and easier to contact. The electrode contact area is increased by more than 50%, greatly improving the welding reliability at both ends of the inner core and enhancing the accuracy and consistency of the welding process.

[0011] 2. The present invention increases the diameter of the capacitor core shaft, which helps to stabilize the contact between the probe and the core body, and the parameter measurement error is less than 1%. It not only improves the convenience of testing and welding, but also significantly improves the test efficiency, ensures the reliability of the capacitor under various test conditions, and greatly improves the test accuracy.

[0012] 3. The present invention provides a capacitor core shaft with a larger diameter at the axis center of the inner core body, eliminating the need to change the core shaft or outer shell size. This makes it suitable for standardized production lines, improves the compatibility of the capacitor structure, and helps improve the structural stability of the capacitor. Increasing its diameter can enhance the overall mechanical strength of the capacitor, reduce the risk of deformation or breakage under external force, and improve the durability of the capacitor. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The drawings described herein are used to provide a further understanding of the present application and constitute a part of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application and do not constitute an improper limitation on the present application. In the drawings: Figure 1It is a schematic diagram of the overall structure of the present invention; Figure 2 It is a front cross-sectional view of the present invention; Figure 3 It is a schematic diagram of the physical structure of the present invention.

[0014] In the figure: 100, outer packaging layer; 200, capacitor core; 201, outer core; 202, inner core; 203, capacitor core shaft; 212, inner metal layer; 222, dielectric film; 204, isolation membrane; 205, outer metal layer. DETAILED DESCRIPTION

[0015] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0016] Example 1 Combined capacitors are capacitors composed of multiple capacitor elements and are widely used in situations where multiple capacitance characteristics or larger capacitance are required. Due to the small inner core diameter of traditional combined capacitors, the electrode contact area is insufficient during welding, making welding more difficult. In order to increase the electrode contact area during welding and make it more convenient to weld, refer to Figure 1 - Figure 3 The present embodiment provides a combined capacitor structure that is convenient for test welding, including an outer packaging layer 100, which is usually made of an insulating resin material. A capacitor core 200 is arranged on the inner side of the outer packaging layer 100, and the capacitor core 200 includes an outer ring core 201 arranged on the inner side of the outer packaging layer 100, and an inner ring core 202 arranged on the inner side of the outer ring core 201, and the axes of the outer ring core 201 and the inner ring core 202 coincide. The outer ring core 201 and the inner ring core 202 of the capacitor not only achieve electrical isolation, but also provide a stable connection point and protective layer during test welding. A capacitor core shaft 203 is arranged at the axis center of the inner ring core 202. The capacitor core shaft 203 is an axis for supporting and fixing the dielectric. The diameter of the capacitor core shaft 203 ranges from 12 to 15 mm, so that the welding ends of the capacitor core shaft 203 at both ends are easier to contact.

[0017] The inner ring core 202 includes an inner ring metal layer 212 and a dielectric film 222 that are wound in a step-by-step manner. The inner ring metal layer 212 is made of a conductive metal material, and the dielectric film 222 is made of a polypropylene material. Welding ends are respectively provided at both ends of the inner ring metal layer 212, and the area of ​​the welding end is a reserved uncleaned metallized area. By removing part of the inner ring metal layer 212, the ineffective winding thickness of the dielectric film 222 is increased, which is equivalent to increasing the diameter of the capacitor core shaft 203.

[0018] An isolation membrane 204 is provided on the outside of the inner ring core 202, and the isolation membrane 204 is insulated and connected to the inner ring of the outer ring core 201. The outer ring core 201 includes an outer ring metal layer 205 wound on the isolation membrane 204, and the outer ring metal layer 205 is made of conductive metal material.

[0019] Example 2 A method for manufacturing a combined capacitor structure that is convenient for testing welding comprises the following steps: S1. Metal layer cleaning: Before winding the inner core 202, the inner metal layer 212 on one side of the dielectric film 222 is periodically removed by electrochemical or laser cleaning process to form alternating conductive and non-conductive areas; S2, step winding: The treated dielectric film 222 is wound alternately in a "conductive area-non-conductive area" pattern. The non-conductive area occupies extra space due to the absence of the inner metal layer 212, which effectively increases the core diameter. S3. Outer layer winding: directly wind an untreated large-capacity film outside the inner ring core 202, and achieve interlayer insulation through the isolation film 204.

[0020] The present invention comprises an outer ring core 201 and an inner ring core 202 to form a capacitor core 200, and a capacitor core shaft 203 with a larger diameter is provided at the axis center of the inner ring core 202. At the same time, the inner ring core 202 is composed of a stepped inner ring metal layer 212 and a dielectric film 222. By removing part of the inner ring metal layer 212 to increase the ineffective winding thickness of the dielectric film 222, the diameter of the capacitor core shaft 203 is equivalently increased, and the electrode contact area is increased, so that the welding reliability at both ends of the inner ring core 202 is greatly improved, and at the same time, the contact between the probe and the core is stabilized, thereby improving the convenience of testing and welding.

[0021] It should be noted that, in this article, the terms "comprises", "includes" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or apparatus that includes a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or apparatus.

[0022] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A combined capacitor structure that is convenient for testing welding, comprising an outer packaging layer (100), characterized in that: A capacitor core (200) is provided on the inner side of the outer packaging layer (100), and the capacitor core (200) comprises an outer ring core (201) provided on the inner side of the outer packaging layer (100), and an inner ring core (202) provided on the inner side of the outer ring core (201), wherein the axes of the outer ring core (201) and the inner ring core (202) coincide with each other, and a capacitor core axis (203) is provided at the axis center of the inner ring core (202); An isolation film (204) is provided on the outer side of the inner ring core (202), and the inner ring core (202) comprises a stepped inner ring metal layer (212) and a dielectric film (222).

2. The combined capacitor structure convenient for test welding according to claim 1, characterized in that: The dielectric film (222) is made of polypropylene material.

3. The combined capacitor structure convenient for test welding according to claim 1, characterized in that: Both ends of the inner ring metal layer (212) are respectively provided with welding ends, and the areas of the welding ends are reserved and not cleaned metallized areas.

4. The combined capacitor structure convenient for test welding according to claim 1, characterized in that: The isolation film (204) is insulated and connected to the inner ring of the outer ring core (201), and the outer ring core (201) includes an outer ring metal layer (205) wound on the isolation film (204).

5. The combined capacitor structure convenient for test welding according to claim 1, characterized in that: The diameter of the capacitor core shaft (203) ranges from 12 to 15 mm, making it easier for the welding ends at both ends of the capacitor core shaft (203) to contact.

6. A method for manufacturing a combined capacitor structure that is convenient for test welding according to any one of claims 1 to 5, characterized in that: The steps include: S1. Metal layer cleaning: Before winding the inner ring core (202), the inner ring metal layer (212) on one side of the dielectric film (222) is periodically removed by an electrochemical or laser cleaning process to form alternating conductive areas and non-conductive areas; S2, step winding: the treated dielectric film (222) is wound alternately in a "conductive area-non-conductive area" pattern, and the non-conductive area occupies additional space due to the absence of an inner metal layer (212), which effectively increases the core diameter; S3, outer layer winding: directly winding an untreated large-capacity film outside the inner ring core (202), and achieving interlayer insulation through the isolation film (204).

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