Low-noise capacitor for starting operation of fan motor

Abstract

The utility model relates to the technical field of capacitors, and discloses a low-noise capacitor for starting and operating a fan motor, which comprises a thin film A. The outer wall of the thin film A is wound with a thin film B through a winding needle, and the tail ends of the thin film A and the thin film B are provided with metal cleaning layers with specific lengths through electrode short-circuit cleaning of a winding machine. An outer wrapping film is pasted on the outer wall of the metal cleaning layer, the film A is a polypropylene film, the thickness of the film A ranges from 6 micrometers to 8 micrometers, good insulation performance can be provided, zinc-aluminum alloy is evaporated on the surface of the film A, the evaporation thickness is the square resistance value of 6-15 omega / square, the film A is used for improving the self-healing capacity and bearing higher voltage, and the film B is a polypropylene film and is used for improving the self-healing capacity and bearing higher voltage. And the heat resistance of the capacitor is enhanced. According to the utility model, by adopting a base film evaporation plasma treatment technical means, the problems that the PP film is a non-polar material, the surface tension is low, and the film layer fitting effect is poor are effectively solved.

Description

TECHNICAL FIELD

[0001] The utility model relates to a capacitor technical field especially relates to a low noise fan motor starting operation capacitor. BACKGROUND

[0002] The metallized polypropylene film capacitor, especially the CBB61 type capacitor, plays a key role in the starting and running of the fan motor. The CBB61 type capacitor is designed specifically for single-phase induction motors and has excellent electrical performance, reliability, and durability. The main function of the CBB61 type capacitor is to provide additional power boost during the motor starting phase, helping to overcome inertia and resistance during the starting process, ensuring smooth and reliable operation. It is an indispensable component of the fan motor starting and running.

[0003] The traditional CBB61 capacitor structure is a rectangle form, and the core after winding is processed by flattening and heat setting. Due to the flattening process of the core, the tension between the original film layers changes after the circular core is flattened into a rectangular shape. After the heat setting treatment of the capacitor core, the film layer adhesion effect of the winding section becomes poor. Under the action of the alternating current field, due to the poor adhesion effect between the film layers, there are film layer relaxation and void phenomena, and vibration occurs between the film layers, which makes the capacitor emit noise. Therefore, a low noise fan motor starting operation capacitor is proposed. SUMMARY

[0004] In order to make up for the above shortcomings, the utility model provides a low noise fan motor starting operation capacitor, which aims at improving the problem of poor adhesion effect between the film layers, film layer relaxation and void phenomenon, and vibration between the film layers, which makes the capacitor emit noise in the prior art.

[0005] In order to achieve the above purpose, the utility model adopts the following technical scheme: a low noise fan motor starting operation capacitor, comprising a film A, the film A is wound with a film B through a winding needle, the ends of the film A and the film B are short-circuited and cleaned with a metal cleaning layer of a certain length through the electrode of the winding machine, and the outer wall of the metal cleaning layer is pasted with an outer wrapping film.

[0006] As a further description of the above technical scheme:

[0007] The film A is a polypropylene film with a thickness of 6-8μm, which can provide good insulation performance, and its surface is coated with zinc-aluminum alloy with a coating thickness of 6-15Ω / □, which is used to improve the self-healing ability and withstand higher voltage.

[0008] As a further description of the above technical scheme:

[0009] The film B is a polypropylene film, which has the function of enhancing the heat resistance of the capacitor.

[0010] As a further description of the above technical solution:

[0011] The metal cleaning layer is a metal cleaning layer of a specific length formed by short-circuiting the ends of thin film A and thin film B through the electrodes of the winding machine, used to improve dielectric properties and structural stability.

[0012] As a further description of the above technical solution:

[0013] The outer film is made of polypropylene, which has a good adhesion effect and a thickness of 10μm to 20μm, so as to provide better wrapping and sealing of the outer film of the core.

[0014] As a further description of the above technical solution:

[0015] The film A, film B, metal cleaning layer and outer coating are wound together in a stacked manner to form a cylindrical structure with an overall diameter of 10mm to 20mm and a height of 30mm to 50mm.

[0016] As a further description of the above technical solution:

[0017] By optimizing the combined design of film A, film B, and the metal cleaning layer, the noise generated during the operation of the fan motor is reduced to less than 70% of the original level, improving overall user comfort.

[0018] This utility model has the following beneficial effects:

[0019] 1. In this utility model, by adopting the base film evaporation plasma treatment technology, the problem that polypropylene PP film is a non-polar material with low surface energy and poor film layer bonding effect is effectively solved.

[0020] 2. In this utility model, by using specific metal cleaning turns and outer wrapping turns, the bonding effect of the film layer of the capacitor core winding section is improved, and the side effect of increased capacitor noise caused by the curing characteristics of the anhydride epoxy potting compound is offset. Attached Figure Description

[0021] Figure 1 A side view of a low-noise capacitor for starting and operating a fan motor, as proposed in this utility model.

[0022] Figure 2 This is a front view of a low-noise capacitor for starting and operating a fan motor, as proposed in this utility model.

[0023] Figure 3A schematic diagram of a slide rail for a low-noise fan motor starting capacitor proposed in this utility model.

[0024] Figure 4 This is a schematic diagram of the manufacturing process of the capacitor proposed in this utility model.

[0025] Legend:

[0026] 1. Film A; 2. Film B; 3. Metal cleaning layer; 4. Outer coating. Detailed Implementation

[0027] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0028] Example 1: Refer to Figures 1-3 A low-noise capacitor for starting and operating a fan motor includes a thin film A1, a thin film B2 wound around the outer wall of the thin film A1 by a winding needle, and a metal cleaning layer 3 of a specific length short-circuited and cleaned at the ends of the thin films A1 and B2 by the electrodes of the winding machine. An outer film 4 is attached to the outer wall of the metal cleaning layer 3. Through the above structure, the materials of each layer are tightly bonded to form an integral structure, effectively avoiding the possibility of loose bonding or gaps between layers, ensuring the structural stability and electrical performance reliability of the capacitor during use. At the same time, the outer film 4 further enhances the protective performance, enabling the capacitor to operate for a long time in relatively harsh working environments.

[0029] Reference Figures 1-3 Film A1 is a polypropylene film with a thickness of 6μm to 8μm, providing excellent insulation properties. Its surface is coated with a zinc-aluminum alloy with a sheet resistance of 6–15 Ω / □ to enhance self-healing capabilities and withstand higher voltages. By using polypropylene, film A1 provides superior insulation performance under high voltage, reducing the risk of leakage current during capacitor operation and thus improving equipment safety. Furthermore, the film's thickness range has been optimized to ensure insulation performance while effectively reducing the overall structural weight.

[0030] Reference Figures 1-3Film B2 is a polypropylene film. Polypropylene film plays a crucial role in the construction of capacitors, possessing excellent heat resistance and reinforcing properties. When the capacitor is in operation, especially in high-temperature environments, polypropylene film B(2) can effectively prevent heat from having an excessive negative impact on the internal structure and electrical performance of the capacitor. With its stable molecular structure and good thermal stability, it ensures that the capacitor can still operate stably under high-temperature conditions, maintaining its normal capacitance value, insulation performance and other key indicators, greatly extending the service life of the capacitor, improving the reliability and safety of the entire circuit system, and thus providing a solid guarantee for the stable and efficient operation of various electronic devices or power systems.

[0031] Reference Figures 1-3 The metal cleaning layer 3 is a specific length of metal cleaning layer formed by short-circuiting the ends of the thin film A1 and the thin film B2 through the electrodes of the winding machine. This metal cleaning layer 3 is used to improve dielectric properties and structural stability. The specific length of cleaned metal allows for better adhesion between the metal cleaning layer and the outer film 4, thereby improving the tightness of the core film layer. Simultaneously, the cleaned surface effectively reduces residual impurities, lowering the risk of internal short circuits in the capacitor and thus improving overall reliability.

[0032] Reference Figure 2 and 3 The outer film 4 is made of polypropylene, which has a good adhesion effect. Its thickness is 10μm to 20μm, which makes it better to wrap and seal the outer film of the core. Polypropylene gives the outer film (4) excellent shrinkage characteristics. When affected by specific temperature or other external conditions, it can shrink precisely according to the design requirements, so as to fit tightly on the outer film of the core.

[0033] Reference Figure 2 and 3 Thin film A1, thin film B2, metal cleaning layer 3, and outer coating film 4 are layered and wound together to form a cylindrical structure with an overall diameter of 10mm to 20mm and a height of 30mm to 50mm. This layering and winding method allows the capacitor to achieve maximum capacitance within a limited space while maintaining structural compactness. This design effectively reduces stress concentration within the capacitor, avoids performance degradation caused by material fatigue, and thus ensures the long-term reliability and consistency of the capacitor.

[0034] Reference Figures 1-3By optimizing the combined design of film A1, film B2, and metal cleaning layer 3, the noise generated during fan motor operation is reduced to below 70% of its original level, improving overall user comfort. Optimizing the combined thickness and material properties of film A1, film B2, and metal cleaning layer 3 effectively reduces vibration and noise caused by capacitor electromagnetic interference during fan motor operation. Simultaneously, the optimized structural design balances the mechanical strength and vibration absorption performance of the capacitor, significantly reducing overall noise levels and enhancing the user experience.

[0035] Reference Figure 4 A capacitor fabrication method based on Example 1 includes the following steps:

[0036] S1, Base film evaporation: Zinc-aluminum alloy is evaporated onto a polypropylene (PP) film under vacuum. During the film evaporation process, a plasma treatment process is used to modify the surface of the film.

[0037] S2, Film roll slitting: The vapor-deposited zinc-aluminum metallized film roll is slitted into smaller film rolls of the required width according to specific unwinding tension and slitting speed.

[0038] S3, Core winding: The slit metallized film is wound into a core under specific process parameters such as winding tension, pressure roller pressure, number of metal cleaning turns, and number of outer wrap turns.

[0039] S4, Core Heat Treatment: The wound core undergoes heat treatment, which includes three stages: core pre-forming, core pressing, and core shaping. Core pre-forming includes first pressure, first temperature, and first time parameters; core pressing includes second pressure parameters; and core shaping includes second temperature, second time, third temperature, and third time parameters.

[0040] In step S1 above, the polypropylene base film used has a thickness of 6.8 micrometers, the plasma processing power is 0.5 to 5.5 kW, and the gas flow rate is 200 to 600 sccm.

[0041] In step S2 above, the unwinding tension of the film roll slitting is 35-45 N, and the slitting speed is 150 M / min-250 M / min.

[0042] In step S3 above, the specific winding tension is (film width mm * film thickness μm * tension coefficient k1), with a tension coefficient k1 value of 1.05 to 1.35; the specific pressure roller pressure is (film width mm * SQRT film thickness μm * 10) * pressure coefficient k2), with a tension coefficient k2 value of 0.95 to 1.3; the number of metal cleaning turns is 10 to 20 turns, and the number of outer wrapping turns is 15 to 30 turns.

[0043] In step S4 above, the first pressure is 4 MPa to 8 MPa, the first temperature is 85℃ to 100℃, and the first time parameter is 120S to 240S; the second pressure is 4 to 6 MPa; the second temperature is 80℃ to 100℃, the second time is 1h to 3h, the third temperature is 100℃ to 130℃, and the third time is 3h to 10h.

[0044] In step S1, since the polypropylene (PP) film is a non-polar material with low surface tension, plasma treatment during the base film deposition process can modify the film surface to increase surface tension, thereby improving the adhesion between film layers.

[0045] In step S2, slitting under specific unwinding tension and slitting speed conditions can increase the effect of heating temperature on the film during core heat setting, resulting in a uniform shrinkage polymerization effect.

[0046] In step S3, such as Figure 1 As shown, under specific winding tension and pressure roller parameters, the gap between film A and film B can be improved; Figure 2 As shown, under specific metal cleaning and wrapping cycles, the bonding effect of the film layer in the capacitor core winding section can be improved, and the side effect of increased capacitor noise caused by the curing characteristics of the anhydride epoxy potting compound can be offset.

[0047] In step S4, pre-forming under specific first pressure, first temperature, and first time conditions prevents the cores within the fixture from being squeezed during heat setting, ensuring uniform thermal shrinkage of the film and improving polymerization. Core compression under specific second pressure conditions improves the adhesion between film A and film B, reducing voids. Under specific second temperature, second time, third temperature, and third time conditions, the film achieves a uniform thermal shrinkage polymerization effect under the influence of temperature and time.

[0048] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A low-noise capacitor for starting and operating a fan motor, comprising a thin film A (1), characterized in that: The outer wall of the film A (1) is wound with film B (2) by a winding needle. The ends of film A (1) and film B (2) are short-circuited by the electrodes of the winding machine to clean a metal cleaning layer (3) of a specific length. The outer wall of the metal cleaning layer (3) is covered with an outer film (4).

2. The low-noise capacitor for starting and operating a fan motor according to claim 1, characterized in that: The film A (1) is a polypropylene film with a thickness of 6 μm to 8 μm, and its surface is coated with zinc-aluminum alloy with a sheet resistance of 6 to 15 Ω / □.

3. The low-noise capacitor for starting and operating a fan motor according to claim 1, characterized in that: The film B (2) is a polypropylene film.

4. The low-noise capacitor for starting and operating a fan motor according to claim 1, characterized in that: The metal cleaning layer (3) is a metal cleaning layer (3) of a specific length that is short-circuited and cleaned by the electrodes of the winding machine at the ends of the thin film A (1) and the thin film B (2).

5. The low-noise capacitor for starting and operating a fan motor according to claim 1, characterized in that: The outer membrane (4) is made of polypropylene and has a thickness of 10 μm to 20 μm.

6. The low-noise capacitor for starting and operating a fan motor according to claim 1, characterized in that: The thin film A (1), thin film B (2), metal cleaning layer (3) and outer film (4) are rolled together in a stacked manner to form a cylindrical structure with an overall diameter of 10 mm to 20 mm and a height of 30 mm to 50 mm.

7. The low-noise capacitor for starting and operating a fan motor according to claim 1, characterized in that: By optimizing the combined design of film A (1), film B (2) and metal cleaning layer (3), the noise generated during the operation of the fan motor is reduced to less than 70% of the original level.

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