Drying and impregnation integrated equipment and process for capacitor element

Abstract

The invention relates to a drying and impregnation integrated device and process for a capacitor element. The drying and impregnation integrated device comprises a closed case formed by a top plate, side plates and a bottom plate in a surrounding mode. The device is characterized in that a process chamber is formed in the case; the at least one drying device is arranged in the process chamber and is used for drying the capacitor elements; the at least one impregnation device is arranged in the process chamber and is used for impregnating the capacitor elements dried by the drying device; the dehumidification mechanism is used for adjusting and maintaining the air humidity in the process chamber within a preset drying range; the material transfer mechanism is arranged in the process chamber and is used for transferring the dried capacitor elements from the drying device to the impregnation device; and the drying and impregnation processes of the capacitor element are both carried out in the process chamber in a preset low-dew-point drying atmosphere. The capacitor is used for solving the problem of secondary moisture absorption caused by exposure of an element in the atmosphere after drying and before impregnation, and the quality of the capacitor is effectively improved.

Description

Technical Field

[0001] This invention relates to the field of capacitor manufacturing technology, and in particular to an integrated drying and impregnation equipment and process for capacitor elements. Background Technology

[0002] The impregnation process is an intermediate step in the manufacturing of liquid aluminum electrolytic capacitors. The purpose of this process is to fully immerse the electrolyte into the porous microstructure of the aluminum foil of the capacitor core, enabling the capacitor to achieve the desired electrical performance. In the manufacturing process of aluminum electrolytic capacitors, the drying and impregnation of the core are two crucial steps. The core must first be thoroughly dried at high temperature to remove moisture, and then quickly transferred to an impregnation tank, where it is impregnated with electrolyte or impregnating material under vacuum conditions.

[0003] Currently, the industry commonly uses separate equipment for production. First, the raw materials are dried in a drying oven, then removed by operators or robotic arms, exposed to the workshop environment, and then transferred and placed into a vacuum impregnation tank for impregnation (e.g., a fully automatic hydraulic impregnation machine, patent application number CN120164735A). This traditional production method has significant drawbacks: the raw materials removed from the drying oven are at high temperatures and extremely dry, rapidly absorbing moisture from the air during transfer. Even when operating in a drying chamber, it is difficult to completely avoid secondary moisture absorption. Trace amounts of residual moisture in the raw materials can cause side reactions with the electrolyte, leading to increased loss tangent, higher leakage current, shorter lifespan, and difficulty in ensuring product performance consistency. Furthermore, to reduce the impact of environmental humidity, high-standard ultra-clean drying chambers are typically required, with extremely high construction and maintenance costs. The microstructural optimization and performance breakthroughs that traditional step-by-step processes cannot achieve remain long-standing production challenges. Summary of the Invention

[0004] To overcome the technical defects of the existing technology, the present invention provides an integrated drying and impregnation equipment and process for capacitor elements, achieving microstructure optimization and performance breakthrough. This solves the problem that secondary moisture absorption caused by exposure of elements to the atmosphere after drying and before impregnation leads to the subsequent side reaction of trace moisture with the electrolyte, which damages the electrode structure and causes the capacitor to fail due to increased loss tangent, increased leakage current, and shortened lifespan.

[0005] The technical problem solved by this invention is achieved through the following technical solution: An integrated drying and impregnation equipment and process for capacitor elements includes a closed chassis formed by a top plate, side plates, and a bottom plate; characterized in that a process chamber is formed inside the chassis; the process chamber is provided with a frame for housing the impregnation equipment; the impregnation equipment includes at least a drying device, an impregnation device, a dehumidification mechanism, and a material transfer mechanism; at least one of the drying devices is disposed in the process chamber for drying the capacitor elements; at least one of the impregnation devices is disposed in the process chamber for impregnating the capacitor elements dried by the drying device; the dehumidification mechanism is used to adjust and maintain the air humidity in the process chamber within a predetermined drying range; the material transfer mechanism is disposed in the process chamber for transferring the dried capacitor elements from the drying device to the impregnation device; the drying and impregnation processes of the capacitor elements are both carried out in the process chamber with a preset drying atmosphere.

[0006] Preferably, the drying device includes a cavity, a sealing cover, a heat source assembly, and a negative pressure assembly. The heat source assembly is disposed on the inner wall of the cavity to form a surrounding heat source for providing baking heat to the cavity. The negative pressure assembly is connected to the cavity and is used to adjust the air pressure in the cavity within a predetermined negative pressure range.

[0007] Preferably, the cavity is provided with a first carrier and a second carrier for loading capacitor elements, and a power component for driving the first carrier to move is provided on the outside of the cavity. The power component passes through the cavity and is connected to the first carrier, and the first carrier and the second carrier can overlap and separate.

[0008] Preferably, the impregnation device includes a cylinder, a negative pressure port, a liquid injection port, and a coil, wherein the negative pressure port is connected to the cylinder and is used to adjust the gas pressure intensity inside the cylinder, the liquid injection port is connected to the cylinder and is used to inject the impregnation liquid, and the coil is located on the inner wall of the cylinder and is used to adjust the cylinder temperature.

[0009] Preferably, the dehumidification mechanism includes a drying component, an air inlet pipe, an air outlet, and an exhaust pipe, wherein the air inlet pipe and the exhaust pipe are connected to the outside of the chassis, the air outlet is connected to the process chamber, and one end of the air inlet pipe, the air outlet, and the exhaust pipe are all connected to the drying component to form a circulating dehumidification air duct.

[0010] Preferably, the material transfer mechanism includes a clamp and a sliding track. The clamp is slidably mounted on the sliding track, which extends along the X and Y axes on a horizontal plane. The clamp moves on the sliding track to transfer capacitor elements. The working range of the material transfer mechanism can cover the drying device and the impregnation device.

[0011] Preferably, the frame includes a support column and a support plate. The support column is used to fix the support plate, and the upper end of the support plate is provided with a plurality of mounting seats arranged at intervals. The mounting seats in different columns are respectively used to install the drying device and the impregnation tank.

[0012] Preferably, the process chamber and the dehumidification mechanism are combined to form a circulating dehumidification air duct, which is used to maintain a slightly positive pressure dry environment inside the process chamber.

[0013] Preferably, the predetermined drying range is a dew point of -30°C to -70°C, corresponding to an air humidity range of [missing information].

[0014] Preferably, the drying and impregnation process includes the following steps: Step S1: Preparation and Placement; Place the capacitor elements into the drying device within the process chamber of the enclosed machine; Step S2: Drying and dehumidification; start the dehumidification mechanism to maintain a low dew point dry environment in the process chamber; at the same time, start the drying device to dry the raw materials; Step S3: Sealed transfer; Under the premise of maintaining a low dew point dry environment in the process chamber, the dried capacitor elements are transferred to the impregnation device through the material transfer mechanism; Step S4: Vacuum impregnation; The capacitor elements are subjected to vacuum impregnation in an impregnation device.

[0015] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention integrates the drying and impregnation processes within a humidity-controlled, sealed space, achieving a seamless transition from drying to impregnation of the raw materials. It effectively avoids atmospheric exposure during intermediate steps, completely eliminates secondary moisture absorption, and ensures that the raw materials are always in the optimal dry state before impregnation. The residual moisture content can be reduced to below 20 ppm, achieving deep dehydration and meeting the advanced process requirements of electronic components.

[0016] 2. After dehumidification by this equipment, the extremely high dryness of the raw materials allows for more thorough and rapid penetration of the electrolyte during impregnation. This powerfully drives the electrolyte deep into the microscopic pores of the aluminum foil and expels internal gases. The electrolyte fully fills oxide film defects, forming a more uniform conductive layer; the expelled gases prevent the breakage of conductive polymer chains at high temperatures, resulting in a denser and more stable oxide film. The breakdown voltage can be significantly increased from approximately 100V in conventional processes to over 600V; the equivalent series resistance (ESR) is significantly reduced; and the leakage current is decreased. Specifically, the leakage current is reduced by 15%, and the ESR value is reduced by 20%. This significantly optimizes key performance parameters such as loss tangent and leakage current in the final product, greatly improving product consistency and reliability.

[0017] 3. The equipment is integrated to achieve intelligence and automation. The entire drying, transfer and impregnation process can be completed automatically in a closed system, reducing human intervention and improving production efficiency.

[0018] 4. By isolating the core processes from the external environment, the requirements for temperature, humidity and cleanliness of the entire production workshop are reduced, resulting in a 35% reduction in energy consumption. Furthermore, there is no need to build expensive, large-scale, high-grade drying rooms, thus saving a significant amount of construction investment and long-term operation and maintenance energy consumption. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0020] Figure 1 This is a three-dimensional structural diagram of the chassis of the present invention.

[0021] Figure 2 This is a perspective three-dimensional structural diagram of the chassis of the present invention.

[0022] Figure 3 This is a schematic diagram of the internal three-dimensional structure of the chassis of the present invention.

[0023] Figure 4 This is a partial structural diagram of the cross-section of the device of the present invention.

[0024] Figure 5 This is a three-dimensional structural diagram of the drying device of the present invention.

[0025] Figure 6 This is a perspective structural diagram of the drying device of the present invention.

[0026] Figure 7 This is a three-dimensional structural diagram of the combination of the first carrier and the second carrier of the present invention.

[0027] Figure 8 This is a schematic diagram of the impregnation device of this invention.

[0028] Figure 9 This is a schematic diagram of the dehumidification mechanism of the present invention.

[0029] Figure 10 This is a schematic diagram of the side plate and fixing plate structure of the present invention.

[0030] Figure 11 This is the present invention. Figure 10 A schematic diagram of the first connecting component of component A.

[0031] Figure 12 This is the present invention. Figure 10 A schematic diagram of the second connecting component in section B.

[0032] Figure 13 This is a schematic diagram of the combined structure of the first connector and the second connector of the present invention.

[0033] Reference numerals in the attached diagrams are as follows: 1. Chassis; 101. Top plate; 102. Side plate; 103. Bottom plate; 104. Process chamber; 105. Fixing plate; 106. Sealed transfer window; 1021. Observation window; 1022. Door; 1023. First connector; 10231. Insertion groove; 10232. First sealing groove; 10233. Connecting groove; 10234. Through hole; 1051. Second connector; 10511. First insertion surface; 10512. Second insertion surface; 10513. Second sealing groove; 1052. Sealing element; 10521. Cavity; 2. Frame; 201. Support column; 202. Support plate; 2021. Mounting base; 3. Drying device; 301. Chamber; 302. Sealing cover; 303, First carrier frame; 3031, First carrier base; 3032, First through slot; 304. Second carrier frame; 3041. Second carrier base; 3042. Second through slot; 305. Power assembly; 3051. Connecting rod; 3052. Power arm; 306, Heat source assembly; 3061, Heating element; 3062, Baffle; 307. Negative pressure assembly; 4. Impregnation device; 401. Cylinder body; 402. Vacuuming port; 403. Liquid injection port; 404. Coil; 5. Dehumidification mechanism; 501. Drying assembly; 502. Air inlet duct; 503. Air outlet; 504. Exhaust duct; 6. Material transfer mechanism; 601. Fixture; 602. Sliding track; 7. Control Panel; 8. Liquid storage tank; Detailed Implementation

[0034] The embodiments of the present invention will be further described in detail below with reference to the accompanying drawings: The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] In the description of this invention, it should be understood that the terms "both sides," "both ends," "upper," "lower," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. In the description of this invention, unless otherwise stated, "a plurality of" means two or more. In addition, the term "comprising" and any variations thereof mean "at least comprising."

[0036] In the description of this invention, it should be understood that the terms "first," "second," etc., are used to distinguish and do not indicate the order of precedence.

[0037] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integrally formed connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. Example 1

[0038] like Figures 1-4As shown, an integrated drying and impregnation device for capacitor elements includes a closed enclosure 1 formed by a top plate 101, side plates 102, and a bottom plate 103; a process chamber 105 is formed inside the enclosure 1; a frame 2 for housing the impregnation equipment is provided inside the process chamber 105; the impregnation equipment includes at least a drying device 3, an impregnation device 4, a dehumidification mechanism 5, and a material transfer mechanism 6; at least one drying device 3 is disposed in the process chamber 105 for drying capacitor elements; at least one impregnation device 4 is disposed in the process chamber 105 for impregnating the capacitor elements dried by the drying device; the dehumidification mechanism 5 is used to adjust and maintain the air humidity in the process chamber 105 within a predetermined low dew point drying range; the material transfer mechanism 6 is disposed in the process chamber 105 for transferring the dried capacitor elements from the drying device 3 to the impregnation device 4; the drying and impregnation processes of the capacitor elements are both carried out in the process chamber 105 with a preset drying atmosphere.

[0039] like Figures 1-2 As shown, a rectangular enclosed chassis 1 houses a process chamber 105, within which several vacuum ovens 3 are placed near the center. Several vacuum impregnation cylinders 4 are placed on one side of the drying chambers 3. An air inlet duct 502 and an exhaust duct 504 for a dehumidification mechanism 5 are installed on one side of the chassis 1. A six-axis articulated robot arm 6 serves as a material transfer mechanism, its base fixed to the bottom of the chassis 1. The working range of the material transfer mechanism 6 covers both the drying chambers 3 and the impregnation cylinders 4. Simultaneously, the material transfer mechanism 6 transfers elements pushed from upstream and downstream workstations. A sealed transfer window is provided on the side of the chassis 1 for connecting with upstream and downstream workstations to transfer processed elements. A buffer rack can also be installed inside the chassis 1 for temporary storage of elements.

[0040] A sealed transfer window 106 is provided on the outside of the chassis 1. The sealed transfer window 106 is used to replenish the raw materials to be processed into the chassis 1 from the outside without stopping the machine, or to take out the raw materials that have been impregnated. The sealed transfer window 106 is connected to other upstream and downstream equipment to ensure the continuity of the production process.

[0041] The enclosed enclosure 1 is made of metal plate, preferably stainless steel plate in this embodiment, which has good airtightness and structural strength. The size of the enclosure 1 is not limited. The outer periphery of the enclosure 1 is provided with an observation window 1021 and a maintenance door 1022, as well as facilities for controlling parameters and reading impregnation and drying information.

[0042] The top plate 101, side plate 102, and bottom plate 103 of the chassis 1 form the main frame. The side plate 102 is connected to a fixing plate 105 via a first connector 1023. Further, the first connector 1023 includes a insertion groove 10231, a first sealing groove 10232, a connecting groove 10233, and a through hole 10234. The fixing plate 105 is provided with a second connector 1051 and a sealing element 1052. Further, the second connector 1051 includes a first insertion surface 10511, a second insertion surface 10512, and a second sealing slot 10513. The sealing element 1052 has an internal cavity 10521.

[0043] The fixing plate 105 is used to connect the side plates 102 to each other to form the chassis 1. The first connector 1023 and the second connector 1051 are inserted into each other to fix the side plates 102 to the fixing plate 105 and form a seal. More specifically, such as Figures 11 to 13 As shown, when the first connector 1023 and the second connector 1051 are inserted, the first insertion surface 10511 is inserted into the insertion groove 10231, the second insertion surface 10512 is inserted into the connecting groove 10233, and the first sealing groove 10232 is mated with the second sealing slot 10513. A sealing element 1052 is provided between the first sealing groove 10232 and the second sealing slot 10513, wherein the cavity 10521 of the sealing element 1052 communicates with the through hole 10234 on the first connector 1023. The through hole 10234 communicates with the process chamber 105. When the air pressure in the process chamber 105 is increased, the airflow enters the cavity 10521 of the seal 1052 through the inlet hole 10234, causing the seal 1052 to expand and tightly fit the first sealing groove 10232 and the second sealing slot 10513, forming a seal and blocking the convection of gas inside and outside the process chamber 105. This improves the sealing performance of the process chamber 105 and provides a sealing condition for regulating and maintaining the air humidity inside the process chamber 105 within a predetermined low dew point drying range during dehumidification.

[0044] The frame 2 includes a support column 201 and a support plate 202. The support column 201 is located below the support plate 202 and is used to fix the support plate 202. The upper end of the support plate 202 is provided with a number of mounting seats 2021 arranged at intervals. The mounting seats 2021 in different rows are used to install the drying device 3 and the impregnation tank 4, respectively.

[0045] Specifically, the upper end of the support plate 202 is provided with several mounting seats 2021 arranged at intervals. The number and number of rows of mounting seats 2021 are not specifically limited, as they all achieve the same processing effect. The specific number is set according to the actual application. In this embodiment, the mounting seats 2021 are preferably arranged in two rows, with several mounting seats 2021 in each row. One row is used to install the drying device 3, and the other row is used to install the impregnation device 4. Furthermore, the number of drying devices 3 and impregnation devices 4 corresponds. This facilitates matching and docking with the drying and impregnation processes of the raw material.

[0046] The drying device 3 includes a cavity 301, a sealing cover plate 302, a heat source assembly 305, and a negative pressure assembly 307. The heat source assembly 305 is disposed on the inner wall of the cavity 301 to form a surrounding heat source for providing baking heat to the cavity 301. The negative pressure assembly 307 is connected to the cavity 301 and is used to adjust the air pressure in the cavity 301 within a predetermined negative pressure range.

[0047] The sealing cover 302 is used to seal the cavity 301, forming a closed space inside the cavity 301, which has atmospheric pressure resistance. The negative pressure assembly 307 is preferably a vacuum pump, which is connected to the cavity 301. Specifically, the negative pressure assembly 307 is installed on the outside of the cavity 301, and a vacuum pipe is connected to the vacuum pump. The vacuum pipe is controlled to open and close by a vacuum valve. One end of the vacuum pipe is connected to the vacuum pump, and the other end is connected to the inside of the cavity 301. The vacuum pump evacuates the cavity 301. Evacuation creates a negative pressure or vacuum state in the cavity 301, which lowers the boiling point of water, making it easier for water to vaporize and escape.

[0048] The heat source assembly 305 includes a heating tube 3051 and a baffle 3052. The heating tube 3051 is divided into an upper heating tube, a lower heating tube, and a side heating tube. The heating tubes 3051 are evenly arranged within the cavity 301 to provide uniform baking heat. The heating tubes 3051 can be one of a metal heating tube, a quartz heating tube, a halogen heating tube, or an infrared heating tube. The heating tubes 3051 all serve to dry the capacitor elements 8 at high temperatures. In this embodiment, an infrared heating tube is preferred. The baffle 3052 is disposed outside the heating tube 3051 to form a shield. A gap is formed between the baffle 3052 and the heating tube 3051. The baffle 3052 has a U-shaped or semi-circular cross-section. The baffle 3052 partially shields the heating tube 3051, so that the heat source of the capacitor elements directly radiated by the heating tube 3051 is blocked by the baffle 3052, resulting in a diffuse reflection effect. This improves the baking efficiency and allows the moisture in the elements to quickly vaporize and overflow from the micropores. The baffle 3052 can be made of bright stainless steel or aluminum plate, effectively reflecting the infrared thermal radiation of the heating tube to other corners of the cavity 301, preventing heat sources from concentrating around the heating tube. The baffle 3052 itself is heated, becoming a new, larger heat source, thus producing a softer, more diffuse thermal environment, helping to fill temperature dead zones and making the temperature gradient inside the entire cavity 301 smaller. The baffle 3052 and the inner wall of the cavity 301 form an air duct, guiding the flow of heat source. The heat source flows along a preset path, greatly improving heat exchange efficiency and temperature uniformity. This ensures that each capacitor element is heated evenly, avoiding performance damage due to overheating or incomplete drying in some areas. This embodiment preferably uses a high-infrared spectrum heating tube, where infrared light directly radiates to the surface and interior of the capacitor elements at the speed of light, providing instant heating without the need for a medium. The energy acts directly on the heated object, resulting in extremely high thermal efficiency conversion. Compared with existing technologies, it can save 20% and reduce energy consumption.

[0049] The substrate undergoes drying under a dual atmosphere of negative pressure and high temperature within drying device 3. The rated temperature of device 3 is 50-150℃, and the vacuum level can reach 1-20 Pa, effectively improving the drying effect. This effectively overcomes the environmental boiling point limitation; in a vacuum environment, the boiling point of water drops dramatically. For example, at a vacuum level of -0.095 MPa, the boiling point of water may drop to 40-50℃, or even 100-120℃, providing ample thermal energy. The dual atmosphere of negative pressure and high temperature is not simply a combination of technologies, but an effective integration that allows liquid water deep within the substrate, including between thin film layers and within the micropores of the dielectric, to rapidly vaporize and be extracted—something that atmospheric pressure drying cannot achieve. Dehumidification and drying under these dual conditions of high temperature and vacuum profoundly alters the microstructure and electrical properties of the aluminum foil material within the substrate, thereby significantly improving the ultimate performance of the capacitor.

[0050] The impregnation device 4 includes a cylinder 401, a negative pressure port 402, a liquid injection port 403, and a coil 404. The negative pressure port 402 is connected to the cylinder 401 and is used to adjust the air pressure intensity inside the cylinder 401. The liquid injection port 403 is connected to the cylinder 401 and is used to inject the impregnation liquid. The coil 404 is located on the inner wall of the cylinder 401 and is used to adjust the temperature of the cylinder 401.

[0051] Specifically, the impregnation device 4 employs an impregnation cylinder. The cylinder body 401 is connected to the storage tank 8 via the injection port 403. The storage tank 8 is used to inject the impregnation solution and electrolyte into the cylinder body 401 and maintain a preset liquid level to ensure that the raw materials are fully impregnated. The negative pressure port 402 is connected to the cylinder body 401, and a negative pressure state is created inside the cylinder body 401 by drawing negative pressure. The coil 404 is a heating or cooling pipe surrounding the cylinder body 401, used to apply different temperatures to different stages of impregnation, so that the raw materials achieve a more thorough impregnation effect.

[0052] Under negative pressure, not only is macroscopic air eliminated, but even microscopic gas molecules adsorbed on the surface of the element material are removed. This allows the impregnating agent and electrolyte to penetrate to every atomic level corner of the element. The negative pressure drives the electrolyte to fill every microscopic pore in the element with extremely high efficiency, maximizing the contact area between the electrolyte and the electrode, minimizing the resistance of the ion conduction path, and reducing the equivalent series resistance (ESR) by 20%. Consequently, lower ESR directly means lower impedance of the capacitor at high frequencies and better filtering performance.

[0053] Furthermore, by eliminating all air bubbles through negative pressure impregnation, it is ensured that while air has a relative permittivity of approximately 1, its dielectric strength (approximately 3 kV / mm) is significantly lower than that of a high-quality electrolyte oxide film (>10 kV / mm) or the solid dielectric itself. This ensures that under high electric fields in the capacitor, the voltage is uniformly borne by the dielectric oxide film with higher dielectric strength, preventing ionization breakdown from occurring first at weak air bubbles. This directly and significantly improves the rated operating voltage and breakdown voltage of the capacitor product.

[0054] The dehumidification mechanism 5 includes a drying component 501, an air inlet pipe 502, an air outlet 503, and an exhaust pipe 504. The air inlet pipe 502 and the exhaust pipe 504 are connected to the outside of the casing 1, and the air outlet 503 is connected to the process chamber 105. One end of the air inlet pipe 502, the air outlet 503, and the exhaust pipe 504 are all connected to the drying component 501 to form a circulating dehumidification air duct.

[0055] The dehumidification mechanism 5 can be one of a rotary dehumidifier, a cooling dehumidifier, or a solution dehumidifier, as long as it achieves the desired dehumidification effect. No specific limitation is made; however, in this embodiment, a rotary dehumidifier is preferred. Specifically, the dehumidification mechanism 5 is installed inside the casing 1, while the air inlet duct 502 and exhaust duct 504 are located at different positions outside the casing 1. The air outlet 503 communicates with the process chamber 105 inside the casing 1. The air inlet duct 502 draws in external air, which is then absorbed by the dehumidifying impeller in the drying assembly 501. The resulting dry air is then discharged into the process chamber 105 through the air outlet 503. Simultaneously, the regeneration zone in the drying assembly 501 draws in humid air from the process chamber 105, which is then heated and dehumidified before being discharged outside the casing 1 through the exhaust duct 504. One end of the air inlet duct 502, the air outlet 503, and the exhaust duct 504 are all connected to the drying assembly 501 to form a circulating dehumidification air duct. This continuously supplies dry gas into the process chamber 105, performing micro-positive pressure dehumidification, which prevents external gas from entering and exhausts humid gas, thereby regulating and maintaining the air humidity in the closed process chamber 105 within a predetermined low dew point drying range.

[0056] In some implementations, the dehumidification unit 5 employs a dual-rotor series connection or a combination of rotors and cooling dehumidification to form a more powerful dehumidification system, consisting of a first stage for pre-deep dehumidification and a second stage for extreme adsorption dehumidification. The rotors are divided into a treatment zone and a regeneration zone. The silica gel rotor in the treatment zone is used for dehumidification of moderate humidity, achieving a dew point of -10°C. The molecular sieve rotor has extremely strong adsorption capacity for very low concentrations of moisture, which is key to achieving a dew point below -70°C. Humid air is dehumidified as it passes through the treatment zone, while another portion of heated, high-temperature regeneration air passes through the regeneration zone to remove the adsorbed moisture and restore the desiccant's activity. This is a continuous dynamic process, thus enabling the continuous production of ultra-low dew point dry air.

[0057] In this embodiment, the adjustable dew point range is -30°C to -70°C. More preferably, it can be adjusted to -50°C to -70°C. A dehumidification mechanism 5 is used in the sealed process chamber 105 to maintain the air dew point at a long-term stable range of -30°C to -70°C. The micro-positive pressure range is 5%-20% higher than the standard atmospheric pressure. When the micro-positive pressure inside the process chamber 105 is 5%-20% higher than the standard atmospheric pressure, the dew point at -30°C is equivalent to 370 ppm, at -50°C it is equivalent to 39 ppm, and at -70°C it is equivalent to 4 ppm. The dehumidification mechanism 5 controls the air humidity inside the sealed process chamber 105 to be between 4 ppm and 370 ppm. The dew point of the air humidity is specifically adjusted according to the type of capacitor element, preferably between 4 ppm and 10 ppm, providing a dry environment for the element drying and impregnation processes.

[0058] The process chamber 105 and the dehumidification mechanism 5 are combined to form a circulating dehumidification air duct, which is used to maintain a slightly positive pressure dry environment inside the process chamber 105.

[0059] The material transfer mechanism 6 includes a clamp 601 and a sliding track 602. The clamp 601 is slidably mounted on the sliding track 602, which extends along the X and Y axes in a horizontal plane. The clamp 601 moves on the sliding track 602 to transfer capacitor elements. The working range of the material transfer mechanism 6 can cover the drying device 3 and the impregnation device 4. The repeatability is ±0.5mm. Its end effector is a customized servo motor clamp, which can stably grip the carrier elements.

[0060] The dehumidification and drying processes for the raw materials, as well as the impregnation process, are both integrated within a humidity-controlled process chamber 105. This completely eliminates any exposure risk to the raw materials during the most vulnerable stage—the transition from drying to impregnation—ensuring a seamless transition from the dried to the impregnated state within a consistently controlled, closed drying environment. This effectively solves the problem of traditional processes where drying is completed in one device, followed by exposure to air, and then transfer to another device for impregnation. Even a short transfer process is sufficient to allow the highly active, dried raw materials to come into contact with air, leading to the reabsorption of moisture and oxygen and secondary damping. Furthermore, this technical solution seamlessly integrates negative pressure high-temperature dehydration and negative pressure impregnation electrolyte processing, resulting in effects far exceeding those of traditional methods that perform these two processes in separate steps.

[0061] Specifically, after dehydration under negative pressure and high temperature, a complete and dense alumina dielectric film (aluminum oxide) has formed on the surface of the anode foil in the capacitor. This film is the insulating core of the capacitor, and it is microscopically porous with extremely high chemical activity.

[0062] Through the above process, almost no foreign moisture or impurities are introduced into the interface at the instant the dry oxide film surface comes into contact with the electrolyte. Unexpectedly, this makes the formed electric double layer more stable, and the channels for ion migration are blocked to a maximum extent. The capacitors produced in this way have extremely low initial leakage current, and the increase in leakage current is extremely slow throughout the entire life cycle, thus extending the service life.

[0063] In addition, since the dryness of the process chamber 105 is controllable, it can effectively prevent the elements from re-adsorbing moisture and oxygen to form secondary humidity. In turn, it can prevent the oxide film from absorbing moisture. The dry oxide film can effectively prevent these water molecules from ionizing under electric field and temperature during subsequent processes such as welding and aging, producing hydrogen ions with extremely small radii that can penetrate the oxide film lattice and react with aluminum. This process will corrode and thin the oxide film, leading to increased leakage current and decreased withstand voltage. Example 2

[0064] The cavity 301 is provided with a first carrier 303 and a second carrier 304 for loading capacitor elements. The outside of the cavity 301 is provided with a power component 305 for driving the first carrier 303 to move. The power component 305 passes through the cavity 301 and is connected to the first carrier 303. The first carrier 303 and the second carrier 304 can perform the action of overlapping and separating each other.

[0065] Specifically, the power assembly 305 includes a connecting rod 3051, a power arm 3052, and a power unit. The power unit is one of a servo motor, a cylinder, or a hydraulic shaft. In this embodiment, a servo motor is preferred. The power output end of the power unit is screwed to the power arm 3052 via a transmission screw to form a power transmission structure. Connecting rods 3051 are provided on both sides of the upper end of the power arm 3052. One end of the connecting rod 3051 passes through the cavity 301 and is fixedly connected to the first carrier 303. Driven by the power unit, the power arm 3052 drives the connecting rod 3051 to perform vertical extension and retraction movements. In turn, the connecting rod 3051 drives the first carrier 303 to perform lifting and lowering movements, causing the first carrier 303 to move closer to or away from the second carrier 304, thereby realizing the overlapping and separation of the first carrier 303 and the second carrier 304.

[0066] Specifically, it consists of a liftable first carrier 303 and a relatively fixed second carrier 304. The first carrier 303 and the second carrier 304 are arranged parallel to the bottom surface of the cavity 301, with the first carrier 303 and the second carrier 304 located in the middle of the cavity 301. When the first carrier 303 descends, it approaches the second carrier 304 to form an overlapping state; when the first carrier 303 rises, it separates from the second carrier 304 to form a staggered state.

[0067] The upper surface of the first carrier 303 is provided with a plurality of first carrier seats 3031 arranged at intervals, and a first through groove 3032 is provided between adjacent first carrier seats 3031. The second carrier 304 is provided with a plurality of second carrier seats 3041 arranged at intervals and protruding upwards, and a second through groove 3042 is provided between adjacent second carrier seats 3041. The first carrier seats 3031 are used to load arranged elements. When the first carrier 303 and the second carrier 304 are stacked, the second carrier 304 passes through the first through groove 3032 and is flush with the first carrier seats 3031 on the same horizontal plane for loading arranged elements.

[0068] In this embodiment, the clamp 601 of the material transfer mechanism 6 uses a staggered loading and unloading mechanism to load and unload materials. Specifically, when placing materials into the cavity 301, the second carrier 304 is loaded with materials first. The clamp 601 installs several rows of neatly arranged materials to be dried onto the second carrier 304. After the second carrier 304 is fully loaded, the first carrier 303 is raised to a preset height by the power component 305. Then, the clamp 601 installs several rows of neatly arranged materials to be dried onto the first carrier 303. After the first carrier 303 is fully loaded, the first carrier 303 is lowered by the power component 305 to overlap with the second carrier 304, so that the materials in the first carrier 303 and the second carrier 304 are interspersed on the same horizontal plane, and no space needs to be left between each row for the clamp 601 to move. Therefore, the spacing between each row is reduced to 1-3mm. In conventional technology, at least 8mm of space is reserved for the movement of the fixture 601 when arranging the elements. This solution can greatly improve the loading capacity of the cavity 301, achieve precise and dense installation of elements, and improve loading and unloading efficiency by staggered installation of elements, thus achieving the effect of dense installation. This allows more elements to be baked in the same size drying space. The staggered loading and unloading of elements by the first carrier 303 and the second carrier 304 increases the loading capacity of the cavity 301 by 50%, thereby improving the utilization rate of space.

[0069] On the other hand, when the drying device 3 is baking the seeds, the power component 305 can also drive the first carrier 303 and the second carrier 304 to move away from each other and closer to each other intermittently, so that the seeds arranged in the middle are alternately changed in position, and the seeds in the middle position receive sufficient heat radiation, avoiding uneven heating of the middle seeds, further promoting the evaporation of moisture inside the seeds, and effectively solving the problem of uniform drying of the seeds. Example 3

[0070] Working Process: The operator feeds the raw materials into the housing 1 through the sealed transfer window 106. The material transfer mechanism 6 picks up the raw materials, opens the sealing cover 302 of the drying device 3 cavity 301, and places them inside. The drying device 3 dries the raw materials according to a preset program, such as 105℃ / 2h-125℃ / 2h followed by vacuuming at 105℃ / 2h. After drying, the material transfer mechanism 6 removes the raw materials from the drying device 3 cavity 301. At this time, the entire raw material is in a drying protective atmosphere with a dew point of -30℃ to -70℃. The material transfer mechanism 6 transfers the dried raw materials into the pre-vacuumed impregnation device 4. After the impregnation device 4 cylinder 401 is closed, the standard impregnation procedure, including vacuuming, liquid injection, soaking, and vacuum breaking, is executed.

[0071] The following is a detailed implementation of the integrated process method. This embodiment describes in detail a process method for producing aluminum electrolytic capacitor elements using the equipment of Embodiment 1 and Embodiment 2 for drying and impregnation. The specific steps are as follows: S1: Preparation and Placement. The wound aluminum electrolytic capacitor elements are fed into the equipment through the sealed transfer window 106. The material transfer mechanism 6 places them into the drying device 3.

[0072] S2: Drying and dehumidification. Start the drying device 3 and execute the gradient temperature increase drying program, raising the temperature from room temperature to 80°C for 30 minutes and holding for 1 hour; then raise the temperature to 120°C for 30 minutes and hold for 2 hours; finally, evacuate to a low vacuum of approximately 100 Pa and continue drying at 120°C for 1 hour. Throughout the drying process, the dehumidification mechanism 5 continuously operates to ensure that the dew point in the process chamber 106 remains stable below -30°C.

[0073] S3: After the closed transfer and drying process, the drying device 3 is ventilated. The material transfer mechanism 6 opens the sealing cover 302 of the drying device 3 and removes the dried raw materials. At this time, they are not immediately placed into the impregnation tank. Instead, the material basket is placed on the buffer rack inside the machine housing 1 and allowed to cool naturally for 30 minutes in a low dew point environment, so that the raw material temperature drops to about 60℃~75℃, which is conducive to impregnation. After cooling, the material transfer mechanism 6 transfers the raw materials and places them into the cylinder 401 of the vacuum impregnation device 3. This step requires a reasonable cooling program to ensure a smooth transition from the high temperature of drying to the optimal impregnation temperature. Drying requires high temperature to completely remove moisture, while impregnation requires a specific temperature to ensure the activity of the electrolyte. The process design for this step needs to find the optimal balance between the two.

[0074] S4: Vacuum impregnation. After closing cylinder 401 of impregnation device 3, start the impregnation program to evacuate to 5 Pa and maintain it for 30 minutes; then inject pre-degassed electrolyte through a metering pump until the element is completely submerged; soak under 5 Pa vacuum for 60 minutes; finally, slowly reduce to atmospheric pressure and continue soaking for 30 minutes. After completion, material transfer mechanism 6 sends the element out of chassis 1 through sealed transfer window 106 for subsequent assembly processes.

[0075] After thorough drying in a controlled vacuum environment, capacitor elements are directly transferred and injected into the electrolyte. This effectively avoids exposure to air after drying and before impregnation. Direct vacuum transfer after thorough drying avoids air contact and maintains the residual temperature of 60°C to 75°C, which is precisely the temperature between the activity and stability of the electrolyte (60°C to 75°C). The electrolyte viscosity decreases with increasing temperature, enhancing fluidity and allowing for deeper and faster filling of the complex etched pit structure of the anode foil. This is the foundation for forming effective capacitance, generating a dense oxide film (aluminum oxide), repairing defects, and thus significantly reducing leakage current and increasing breakdown voltage. This process ensures the effective dissolution and function of special additives while preventing thermal damage.

[0076] This method integrates the drying and impregnation processes within a controlled humidity-controlled, sealed space, achieving a seamless transition from drying to impregnation of the capacitor substrate. It effectively avoids atmospheric exposure during intermediate steps, completely eliminates secondary moisture absorption, and ensures the substrate is always in its optimal dry state before impregnation. Testing shows that the residual moisture content can be reduced to below 20 ppm, achieving deep dehydration. After dehumidification by this equipment, the capacitor substrate produced using this method exhibits extremely high dryness. During impregnation with a residual moisture content below 20 ppm, the electrolyte penetrates more fully and rapidly, powerfully driving the electrolyte into the depths of the micro-pores in the aluminum foil and expelling internal gases. The electrolyte fully fills oxide film defects, forming a more uniform conductive layer; the expelled gases prevent the breakage of conductive polymer chains at high temperatures, resulting in a denser and more stable oxide film. The breakdown voltage can be significantly increased from approximately 100V in conventional processes to over 600V; the equivalent series resistance (ESR) is significantly reduced; and the leakage current is decreased. The leakage current was reduced by 15% and the ESR value was reduced by 20%, which significantly optimized the key performance parameters of the final product, such as loss tangent and leakage current, and greatly improved product consistency and reliability.

[0077] It should be emphasized that the embodiments described in this invention are illustrative rather than limiting. Therefore, this invention is not limited to the embodiments described in the specific implementation. Any other implementation methods derived by those skilled in the art based on the technical solutions of this invention also fall within the scope of protection of this invention.

Claims

1. An integrated drying and impregnation device for capacitor elements, comprising a closed enclosure (1) formed by a top plate (101), side plates (102), and a bottom plate (103); characterized in that, The chassis (1) forms a process chamber (105) inside; the process chamber (105) is provided with a frame (2) for accommodating impregnation equipment; the impregnation equipment includes at least a drying device (3), an impregnation device (4), a dehumidification mechanism (5), and a material transfer mechanism (6); at least one of the drying devices (3) is disposed in the process chamber (105) for drying capacitor elements; at least one of the impregnation devices (4) is disposed in the process chamber (105) for impregnating capacitor elements dried by the drying device; the dehumidification mechanism (5) is used to adjust and maintain the air humidity in the process chamber (105) within a predetermined drying range; the material transfer mechanism (6) is disposed in the process chamber (105) for transferring the dried capacitor elements from the drying device (3) to the impregnation device (4); the drying and impregnation processes of the capacitor elements are both carried out in the process chamber (105) with a preset drying atmosphere.

2. The integrated drying and impregnation equipment for capacitor elements according to claim 1, characterized in that: The drying device (3) includes a cavity (301), a sealing cover plate (302), a heat source assembly (305), and a negative pressure assembly (307). The heat source assembly (305) is disposed on the inner wall of the cavity (301) to form a surrounding heat source for providing baking heat to the cavity (301). The negative pressure assembly (307) is connected to the cavity (301) and is used to adjust the air pressure in the cavity (301) within a predetermined negative pressure range.

3. The integrated drying and impregnation equipment for capacitor elements according to claim 2, characterized in that: The cavity (301) is provided with a first carrier (303) and a second carrier (304) for loading capacitor elements. The outside of the cavity (301) is provided with a power assembly (305) for driving the first carrier (303) to move. The power assembly (305) passes through the cavity (301) and is connected to the first carrier (303). The first carrier (303) and the second carrier (304) can overlap and separate with each other.

4. The integrated drying and impregnation equipment for capacitor elements according to claim 1, characterized in that: The impregnation device (4) includes a cylinder (401), a negative pressure port (402), a liquid injection port (403), and a coil (404). The negative pressure port (402) is connected to the cylinder (401) and is used to adjust the air pressure intensity inside the cylinder (401). The liquid injection port (403) is connected to the cylinder (401) and is used to inject impregnation liquid. The coil (404) is located on the inner wall of the cylinder (401) and is used to adjust the temperature of the cylinder (401).

5. The integrated drying and impregnation equipment for capacitor elements according to claim 1, characterized in that: The dehumidification mechanism (5) includes a drying component (501), an air inlet pipe (502), an air outlet (503), and an exhaust pipe (504). The air inlet pipe (502) and the exhaust pipe (504) are connected to the outside of the chassis (1), and the air outlet (503) is connected to the process chamber (105). One end of the air inlet pipe (502), the air outlet (503), and the exhaust pipe (504) are all connected to the drying component (501) to form a circulating dehumidification air duct.

6. The integrated drying and impregnation equipment for capacitor elements according to claim 1, characterized in that: The material transfer mechanism (6) includes a clamp (601) and a sliding track (602). The clamp (601) is slidably mounted on the sliding track (602), wherein the sliding track (602) extends along the X-axis and Y-axis directions on a horizontal plane. The clamp (601) moves on the sliding track (602) to transfer capacitor elements. The working range of the material transfer mechanism (6) can cover the drying device (3) and the impregnation device (4).

7. The integrated drying and impregnation equipment for capacitor elements according to claim 1, characterized in that: The frame (2) includes a support column (201) and a support plate (202). The support column (201) is used to fix the support plate (202). The upper end of the support plate (202) is provided with a number of mounting seats (2021) arranged at intervals. The mounting seats (2021) in different columns are used to install the drying device (3) and the impregnation tank (4).

8. The integrated drying and impregnation equipment for capacitor elements according to claim 1, characterized in that: The process chamber (105) and the dehumidification mechanism (5) are combined to form a circulating dehumidification air duct, which is used to maintain a slightly positive pressure dry environment inside the process chamber (105).

9. The integrated drying and impregnation equipment for capacitor elements according to claim 1, characterized in that: The preset dry atmosphere is the air humidity range corresponding to a low dew point of -30℃ to -70℃.

10. The integrated drying and impregnation equipment for capacitor elements according to claim 1, characterized in that: The drying and impregnation process includes the following steps: Step S1: Preparation and placement; Place the capacitor element into the drying device (3) inside the process chamber (104) of the enclosed chassis (1); Step S2: Drying and dehumidification; start the dehumidification mechanism (5) to maintain a low dew point dry environment in the process chamber (104); at the same time, start the drying device (3) to dry the raw materials; Step S3: Closed transfer; Under the premise of maintaining a low dew point dry environment in the process chamber (104), the dried capacitor elements are transferred to the impregnation device (4) through the material transfer mechanism (6); Step S4: Vacuum impregnation; The capacitor element is subjected to vacuum impregnation in the impregnation device (4).

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