Capacitor with protective shell and preparation method thereof

Abstract

The invention discloses a capacitor with a protective shell and a preparation method thereof, the capacitor comprises an energy storage device, the protective shell and a shell, and the energy storage device is located in the protective shell; a first encapsulation part is arranged between the energy storage device and the protective shell, and a second encapsulation part is arranged between the protective shell and the shell; and a reinforcing rib is arranged on the outer side of the protective shell and is used for absorbing stress applied to the protective shell and the energy storage device by the second encapsulation part. By arranging the protective shell and the outer shell, the reinforcing ribs can effectively improve the structural stability of the protective shell, ensure that the protective shell can effectively absorb the shrinkage stress of the second encapsulation part in the curing process of the second encapsulation part, prevent the energy storage device from being stressed to generate vacuum discharge and damage to the capacitor, effectively simplify the production process of the capacitor, and improve the production efficiency. And the production efficiency and the yield of the capacitor with the protective shell are improved.

Description

Technical Field

[0001] This application relates to the field of capacitor technology, and in particular to a capacitor with a protective shell and a method for manufacturing the same. Background Technology

[0002] Capacitors used in filtering circuits are called filter capacitors. These capacitors are used in power supply filtering and various filter circuits to remove signals within a certain frequency band from the total signal. During the resin encapsulation process of capacitors with filter capacitors, differences in resin type and formulation can sometimes lead to excessive shrinkage stress. This stress can compress the filter capacitor, causing vacuum discharge between its electrodes and damaging both the filter capacitor and the main capacitor. Current technology aims to reduce shrinkage stress by adjusting the resin formulation or curing conditions to prevent damage during encapsulation. Some manufacturers also purchase filter capacitors with higher voltage ratings to improve the yield rate. Both methods significantly increase the production cost of capacitors, impacting production efficiency and yield. Summary of the Invention

[0003] This application provides a capacitor with a protective shell and a method for preparing the same. The protective shell can effectively absorb the shrinkage stress generated during the curing process of the second potting part, thereby improving the production efficiency and yield of the capacitor.

[0004] The technical solution adopted by this application to solve its problem is: In a first aspect, a capacitor with a protective shell includes: an energy storage device, a protective shell, and an outer shell, wherein the energy storage device is located inside the protective shell; a first potting portion is provided between the energy storage device and the protective shell, and a second potting portion is provided between the protective shell and the outer shell; a reinforcing rib is provided on the outer side of the protective shell, the reinforcing rib being used to absorb the stress exerted on the protective shell and the energy storage device by the second potting portion.

[0005] The aforementioned capacitor with a protective shell has at least the following beneficial effects: by setting a protective shell and an outer shell, the reinforcing ribs can effectively improve the structural stability of the protective shell, ensure that the protective shell can effectively absorb the shrinkage stress of the second potting part during the curing process of the second potting part, avoid the energy storage device from being subjected to vacuum discharge and causing damage to the capacitor, effectively simplify the capacitor production process, and improve the production efficiency and yield of capacitors with protective shells.

[0006] Furthermore, the reinforcing ribs are evenly distributed on the outer side of the protective shell. This structure ensures that the reinforcing ribs can uniformly and stably absorb the pressure applied by the second potting section, preventing the pressure applied by the second potting section from being transmitted to the energy storage device inside the protective shell, thereby improving the yield of the capacitor with the protective shell.

[0007] Furthermore, the reinforcing rib includes a first protrusion and a second protrusion, the first protrusion and the second protrusion being perpendicular to each other. By setting the first protrusion and the second protrusion, the reinforcing ribs are ensured to be evenly distributed on the outer side of the protective shell. The perpendicularity between the first protrusion and the second protrusion effectively improves the connection stability between the reinforcing ribs, avoids damage to the reinforcing ribs during the absorption of pressure applied by the second potting section, and improves the structural stability of the protective shell.

[0008] Furthermore, the reinforcing rib extends outward from the outer surface of the protective shell. The reinforcing rib is integrally formed with the protective shell, preventing displacement of the rib during pressure absorption and improving the connection stability between the rib and the protective shell.

[0009] Furthermore, the protective shell has a rectangular cross-section. This structure ensures that the protective shell can completely enclose the energy storage device, improving the buffering performance of the protective shell on the energy storage device and increasing the yield of capacitors with protective shells.

[0010] Furthermore, the distance between the inner wall surfaces of the protective shell is consistent with the length of the energy storage device. This structure ensures that the energy storage device can fit snugly against the inner wall surface of the protective shell, effectively reducing the size of the first potting portion and preventing pressure generated during the curing process of the first potting portion from damaging the energy storage device.

[0011] Furthermore, the first potting section and the second potting section are made of the same material. Making the first potting section and the second potting section of the same material effectively avoids the complexity of the process caused by using multiple potting materials, shortens the curing time, and improves the production efficiency of capacitors with protective shells.

[0012] Furthermore, the energy storage device is a filter capacitor. A filter capacitor is an electronic device installed at both ends of a rectifier circuit to reduce the AC ripple coefficient and improve the efficiency and smoothness of DC output. Using a filter capacitor as an energy storage device can effectively ensure the filtering performance of the capacitor.

[0013] Furthermore, the positive and negative terminals of the energy storage device are connected to the outside of the protective casing via lead terminals. By providing lead terminals, it is convenient to connect the positive and negative terminals of the energy storage device to external devices, thereby improving the ease of use of the capacitor with the protective casing.

[0014] A second aspect of this application discloses a method for manufacturing a capacitor with a protective casing, comprising the following steps: An energy storage device and a protective housing are provided, and the energy storage device is placed inside the protective housing, wherein the outer side of the protective housing is provided with reinforcing ribs; Provide an outer casing, and place the protective casing inside the outer casing; The prepared potting material is injected into the outer shell. After a preset curing time, a first potting portion is formed between the energy storage device and the protective shell, and a second potting portion is formed between the protective shell and the outer shell. The reinforcing rib absorbs the stress applied to the protective shell and the energy storage device by the second potting portion.

[0015] The beneficial effects of the above-mentioned capacitor with protective shell and its preparation method are as follows: by setting a protective shell and an outer shell, the reinforcing ribs can effectively improve the structural stability of the protective shell, ensure that the protective shell can effectively absorb the shrinkage stress of the second potting part during the curing process of the second potting part, avoid the energy storage device from being subjected to vacuum discharge and causing damage to the capacitor, effectively simplify the capacitor production process, and improve the production efficiency and yield of capacitors with protective shells.

[0016] Other features and advantages of this application will be set forth in the following description and will be apparent in part from the description or may be learned by practicing the application. The objectives and other advantages of this application may be realized and obtained by means of the structures particularly pointed out in the description and the accompanying drawings. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of a capacitor with a protective shell according to an embodiment of this application; Figure 2 This is an exploded view of a capacitor with a protective casing according to an embodiment of this application; Figure 3 for Figure 2 Enlarged view of the structure in the image; Figure 4 This is a flowchart illustrating a method for preparing a capacitor with a protective casing according to an embodiment of this application. Detailed Implementation

[0018] The embodiments of this application are described in detail below. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0019] Reference Figures 1 to 3 This application provides a capacitor with a protective shell, including: an energy storage device 100, a protective shell 200, and an outer shell 300. The energy storage device 100 is located inside the protective shell 200. A first potting portion 110 is provided between the energy storage device 100 and the protective shell 200, and a second potting portion 210 is provided between the protective shell 200 and the outer shell 300. A reinforcing rib 220 is provided on the outer side of the protective shell 200, and the reinforcing rib 220 is used to absorb the stress applied to the protective shell 200 and the energy storage device 100 by the second potting portion 210.

[0020] By setting up a protective shell 200 and an outer shell 300, the reinforcing rib 220 can effectively improve the structural stability of the protective shell 200, ensuring that the protective shell 200 can effectively absorb the shrinkage stress of the second potting part 210 during the curing process of the second potting part 210, avoiding vacuum discharge of the energy storage device 100 under stress, which would damage the capacitor. It can effectively simplify the capacitor production process and improve the production efficiency and yield of capacitors with protective shells.

[0021] In some embodiments, the reinforcing ribs 220 are evenly distributed on the outer side of the protective shell 200. This structure ensures that the reinforcing ribs 220 can absorb the pressure applied by the second potting portion 210 evenly and stably, preventing the pressure applied by the second potting portion 210 from being transmitted to the energy storage device 100 inside the protective shell 200, thereby improving the yield of the capacitor with the protective shell.

[0022] In some embodiments, the reinforcing rib 220 includes a first protrusion 221 and a second protrusion 222, with the first protrusion 221 and the second protrusion 222 perpendicular to each other. By providing the first protrusion 221 and the second protrusion 222, the reinforcing rib 220 is ensured to be evenly distributed on the outer side of the protective shell 200. The perpendicularity between the first protrusion 221 and the second protrusion 222 effectively improves the connection stability between the reinforcing ribs 220, preventing damage to the reinforcing ribs 220 during the absorption of pressure applied by the second potting portion 210, and improving the structural stability of the protective shell 200.

[0023] In some embodiments, the reinforcing rib 220 extends outward from the outer surface of the protective shell 200. The reinforcing rib 220 is integrally formed with the protective shell 200 to prevent displacement of the reinforcing rib 220 during pressure absorption and to improve the connection stability between the reinforcing rib 220 and the protective shell 200.

[0024] In some embodiments, the protective shell 200 has a rectangular cross-section. This structure ensures that the protective shell 200 can completely enclose the energy storage device 100, improves the buffering performance of the protective shell 200 on the energy storage device 100, and increases the yield of capacitors with protective shells.

[0025] In some embodiments, the distance between the inner wall surfaces of the protective shell 200 is consistent with the length of the energy storage device 100. This structure ensures that the energy storage device 100 can fit against the inner wall surface of the protective shell 200, effectively reducing the size of the first potting portion 110 and preventing the pressure generated during the curing process of the first potting portion 110 from damaging the energy storage device 100.

[0026] In some embodiments, the first potting portion 110 and the second potting portion 210 are made of the same material. Making the first potting portion 110 and the second potting portion 210 of the same material can effectively avoid the complexity of the process caused by multiple potting materials, shorten the curing time, and improve the production efficiency of capacitors with protective shells.

[0027] In some embodiments, the energy storage device 100 is a filter capacitor. A filter capacitor is an electronic device installed at both ends of a rectifier circuit to reduce the AC ripple coefficient and improve the efficiency and smoothness of DC output. The energy storage device 100 being a filter capacitor can effectively ensure the filtering performance of the capacitor.

[0028] In some embodiments, the positive and negative terminals of the energy storage device 100 are connected to the outside of the protective housing 200 via lead terminals 120. By providing lead terminals 120, it is convenient to connect the positive and negative terminals of the energy storage device 100 to external devices, thereby improving the ease of use of the capacitor with the protective housing.

[0029] Reference Figure 4 This application also provides a method for manufacturing a capacitor with a protective casing. For example... Figure 4 As shown, the method for manufacturing a capacitor with a protective shell provided in this application embodiment includes at least the following steps: S1000 provides an energy storage device 100 and a protective shell 200, with the energy storage device 100 placed inside the protective shell 200, wherein the outer side of the protective shell 200 is provided with reinforcing ribs 220.

[0030] It is understandable that by setting a protective shell 200 on the outside of the energy storage device 100 before potting, the protective performance of the energy storage device 100 can be effectively improved, and the vacuum discharge phenomenon can be avoided when the energy storage device 100 is subjected to external force. In the actual production process, the energy storage device 100 is accurately and quickly fixed in the protective shell 200 by automatic assembly equipment, which is the existing technology and will not be described in detail here.

[0031] Understandably, the reinforcing rib 220 effectively improves the structural stability of the protective shell 200, ensuring that the protective shell 200 can effectively absorb the shrinkage stress of the second potting section 210 during the curing process, preventing vacuum discharge from the energy storage device 100 and thus avoiding damage to the capacitor. This effectively simplifies the capacitor production process and improves the production efficiency and yield of capacitors with protective shells. In actual production, to ensure the structural integrity and protective performance of the protective shell 200, it is made of a material with higher strength than the potting material, such as polycarbonate (PC) or nylon (PA).

[0032] S2000 provides a housing 300, and a protective case 200 is placed inside the housing 300.

[0033] Understandably, the casing 300 provides physical support for the capacitor's internal precision structure, preventing damage from mechanical shocks, vibrations, and external pressure during manufacturing, transportation, and use. The casing 300 also encapsulates the capacitor's external structural components, effectively isolating the energy storage device 100 and other charged parts from the outside environment, preventing leakage or short circuits. Simultaneously, the casing 300 isolates moisture, oxygen, and contaminants, preventing the energy storage device 100 from becoming damp, oxidized, and contaminated, thus avoiding performance degradation and extending the capacitor's lifespan. Furthermore, the casing 300 also serves a heat dissipation function, helping to dissipate the heat generated by the energy storage device 100 during operation to the outside, maintaining the capacitor within a suitable operating temperature range.

[0034] It should be noted that the material of the casing 300 can be adjusted according to the specifications of the capacitor. For capacitors that are exposed to high temperature and high pressure for a long time, a metal casing 300 is selected; for low voltage and small capacitance capacitors, a plastic casing 300 can be selected. The metal casing 300 can be made by cutting and forming the metal sheet to the required size through stamping or extrusion technology, and then performing surface treatment, such as anodizing or painting, to enhance corrosion resistance and aesthetics. The plastic casing 300 can be made by injection molding or blow molding to form the plastic into the casing shape, followed by cooling and curing, and then finishing processes such as trimming excess material, surface polishing, and applying a protective coating.

[0035] S3000, the prepared potting material is injected into the outer shell 300. After a preset hardening time, a first potting part 110 is formed between the energy storage device 100 and the protective shell 200, and a second potting part 210 is formed between the protective shell 200 and the outer shell 300. The reinforcing rib 220 absorbs the stress applied to the protective shell 200 and the energy storage device 100 by the second potting part 210.

[0036] Understandably, when a pre-prepared potting material, such as a single-material resin, is potted into a capacitor, the resin is divided into a first potting portion 110 inside the protective shell 200 and a second potting portion 210 outside the protective shell 200 due to the presence of the protective shell 200. The shrinkage stress generated during the curing process of the second potting portion 210 is applied to the protective shell 200. Because the protective shell 200 is reinforced with ribs 220, its structural rigidity is enhanced, preventing the resin shrinkage stress from being fully transferred to the energy storage device 100. Since the energy storage device 100 is only subjected to the shrinkage stress of the first potting portion 110, the resin shrinkage stress on the energy storage device 100 is greatly reduced, thereby lowering the probability of vacuum discharge in the energy storage device 100.

[0037] It should be noted that since the first potting section 110 and the second potting section 210 can be made of the same material, no additional resin material or formulation is required, effectively saving procurement costs. Simultaneously, during the R&D process, since there is no need to conduct matching experiments between different resin materials, only a protective shell 200 with sufficient rigidity needs to be designed, reducing trial-and-error costs. Due to the uniformity of the resin material, there is no need to extend the curing time of the first potting section 110 and the second potting section 210, effectively shortening the production cycle and improving capacitor production efficiency. Furthermore, since there is no need to manage different resin materials separately, it avoids confusion with other capacitor production lines, saving management costs; it also allows the use of the same resin piping with other capacitors without a protective shell 200, improving the versatility of the production line.

[0038] In actual production, the method for manufacturing a capacitor with a protective shell according to the embodiments of this application can effectively reduce the defect rate of the capacitor after injection molding. Specifically, by adding a protective shell 200, the defect rate of the capacitor's withstand voltage after injection molding is reduced from 10% to 6%, effectively saving the production cost of the capacitor.

[0039] As can be seen from the above description, the capacitor with a protective shell and its manufacturing method in this application embodiment, by setting the connecting part 200 and the cavity 300, and the contact block 210 fitting the potting part through the transition block 220, can effectively increase the contact area between the connecting part 200 and the potting part, reduce the pressure applied by the connecting part 200 to the potting part during vibration, avoid wear of the connecting part 200, and improve the working stability and service life of the capacitor; by setting the outer surface 110 and the connecting hole 111, it is easy to fix the main body 100, improving the convenience of using the capacitor; by setting the reinforcing rib 120, it is possible to prevent the outer surface 110 from deforming during use, thereby improving the structural stability of the capacitor.

[0040] In the several embodiments provided in this application, it should be understood that the disclosed systems, instruments, and methods can be implemented in other ways. For example, the instrument embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the shown or discussed mutual couplings, direct couplings, or communication connections may be through some interfaces; indirect couplings or communication connections between instruments or units may be electrical, mechanical, or other forms. Units described as separate components may or may not be physically separate, and components shown as units may or may not be physical units, i.e., they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0041] The above is a detailed description of the preferred embodiments of this application. However, this application is not limited to the above embodiments. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of this application. All such equivalent modifications or substitutions are included within the scope defined by the claims of this application.

Claims

1. A capacitor with a protective case, characterized by The application relates to a storage device, a protective shell and an outer shell, wherein the storage device is arranged in the protective shell; a first pouring sealing part is arranged between the storage device and the protective shell, a second pouring sealing part is arranged between the protective shell and the outer shell; reinforcing ribs are arranged on the outer side of the protective shell, and the reinforcing ribs are used for absorbing stress exerted by the second pouring sealing part on the protective shell and the storage device. The reinforcing ribs are uniformly distributed on the outer side of the protective shell.

2. The capacitor with protective housing according to claim 1, characterized in that The reinforcing ribs comprise first convex strips and second convex strips, and the first convex strips and the second convex strips are perpendicular to each other.

3. The capacitor with protective housing according to claim 2, characterized in that The reinforcing ribs are formed by extending outward from the outer surface of the protective shell.

4. The capacitor with protective casing according to claim 2, characterized in that The cross section of the protective shell is rectangular.

5. The capacitor with protective housing according to claim 1, characterized in that The distance between the inner walls of the protective shell is consistent with the length of the storage device.

6. The capacitor with protective casing according to claim 5, characterized in that The first pouring sealing part and the second pouring sealing part are made of the same material.

7. The capacitor with protective housing of claim 1 wherein, The storage device is a filter capacitor.

8. The capacitor with protective housing of claim 1 wherein, The positive and negative poles of the storage device are connected to the outside of the protective shell through lead terminals.

9. The capacitor with protective casing according to claim 8, characterized in that The application further relates to a method for manufacturing the storage device, the protective shell and the outer shell, and the method comprises the following steps:

10. A method of making a capacitor with a protective shell, characterized by, providing a storage device and a protective shell, and arranging the storage device in the protective shell, wherein reinforcing ribs are arranged on the outer side of the protective shell; providing an outer shell, and arranging the protective shell in the outer shell; injecting pouring sealing material into the outer shell, and forming a first pouring sealing part between the storage device and the protective shell and a second pouring sealing part between the protective shell and the outer shell after a preset hardening time, wherein the reinforcing ribs absorb stress exerted by the second pouring sealing part on the protective shell and the storage device. ​

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