Lightweight DC-Link capacitor

Abstract

The utility model discloses a lightweight DC-Link capacitor, which belongs to the technical field of capacitors and comprises an outer shell, the outer shell is formed by packaging a plurality of plates, a plurality of capacitor cores are arranged in the outer shell, extraction electrodes are arranged on the outer shell, and the capacitor cores are connected with busbars and are connected with the extraction electrodes through the busbars. The DC-Link capacitor can meet the use requirement in a high-temperature and high-humidity environment, can isolate the current leaked from the capacitor core, ensures the normal use of the capacitor core, can reduce the production cost, reduces the surplus during model selection, and achieves the light-weight arrangement.

Description

Technical Field

[0001] This utility model relates to the field of capacitor technology, specifically a lightweight DC-Link capacitor. Background Technology

[0002] DC-Link capacitors, also known as DC-supported capacitors, are a type of organic film capacitor. They have advantages such as self-healing properties, high voltage withstand capability, high current withstand capability, low impedance, low inductance, and safety and reliability, and are widely used in the power electronics industry.

[0003] However, in the use of existing DC-Link capacitors, in order to ensure that the temperature does not exceed the capacitor's operating temperature range, a large margin is generally left when selecting them. This leads to high product cost and large size. However, current DC-Link capacitors are required to develop in the direction of high power, high density and lightweight. Under such circumstances, the requirements for DC-Link capacitors are becoming higher and higher. Therefore, it is necessary to further improve them. Utility Model Content

[0004] The present invention aims to provide a lightweight DC-Link capacitor to overcome the shortcomings of the prior art.

[0005] A lightweight DC-Link capacitor designed for this purpose includes a housing, which is encapsulated by several plates and contains several capacitor cores. Lead electrodes are provided on the housing, and busbars are connected to the capacitor cores and connected to the lead electrodes through the busbars.

[0006] The outer casing includes a first end plate, a second end plate, an upper plate, and a lower plate. The first end plate and the second end plate are located at both ends of the capacitor core, respectively. A self-locking support rod is provided between the first end plate and the second end plate, and they are fixed to each other by the self-locking support rod. The upper plate is fixed to the top of the first end plate and the second end plate, and the lower plate is fixed to the bottom of the first end plate and the second end plate.

[0007] The lead-out electrodes are mounted on the upper plate.

[0008] The capacitor core is also equipped with a self-locking component at its end. Several capacitor cores are cylindrical and arranged in a crisscross pattern. A core winding hole is provided at the center of the capacitor core, and the self-locking component is connected to the core winding hole.

[0009] The busbar includes an upper stacked busbar and a lower stacked busbar. The upper stacked busbar is stacked on top of the lower stacked busbar. Conductive sheets are respectively provided on the upper stacked busbar and the lower stacked busbar, and are respectively connected to several capacitor cores through the conductive sheets.

[0010] The conductive sheet extends longitudinally and is connected to several longitudinally arranged capacitor cores.

[0011] An insulating plate is installed between the upper and lower stacked busbars.

[0012] A lightweight DC-Link capacitor manufacturing process, comprising the aforementioned lightweight DC-Link capacitor, wherein the manufacturing process includes the following steps:

[0013] Step 1: Use a heat-setting fixture to position the capacitor core to be manufactured, and after positioning, place it in an oven. Then, use a heat-setting method with gradual and slow heating to manufacture the capacitor core.

[0014] Step 2: After the capacitor core is heat-set, it is removed from the oven and cooled to room temperature before being removed from the heat-setting fixture.

[0015] Step 3: Heat shrink the capacitor core with two layers of heat shrink tubing. First, put on one layer and bake it in an 80-120℃ oven for 50-70 minutes. After heat shrinking one layer, put on the other layer and repeat the operation until only the gold plating layer of the capacitor core is exposed.

[0016] Step 4: Arrange several capacitor cores together horizontally and vertically, and assemble the self-locking parts on the core winding holes of several capacitor cores. Then, weld the lower stacked busbar to one end face of the capacitor core, place the insulating board on the lower stacked busbar, and then place the upper stacked busbar on the insulating board and weld it to the other end face of the capacitor core to form a capacitor core group.

[0017] Step 5: Place the capacitor core assembly into a vacuum chamber for moisture-proof sealing treatment;

[0018] Step 6: Assemble the capacitor core assembly with the upper plate, then assemble the first end plate and the lower plate in sequence, and finally use the self-locking support rod to fix the second end plate to the first end plate;

[0019] Step 7: Place the assembled product in a tooling fixture, and then put it into a vacuum oven for vacuum potting. The vacuum potting sequence is left end face, right end face, top, bottom. After each side is potted, it needs to be cured in the vacuum oven before potting the next side, so as to finally produce a DC-Link capacitor.

[0020] The temperature control process in step one is as follows:

[0021] Heat from room temperature to 60℃ and hold for 3 hours, with the heating time taking 10 minutes;

[0022] Heat to 65℃ and maintain for 5 hours; heating time is 30 minutes.

[0023] Heat to 70℃ and hold for 30 minutes; heating time is 10 minutes.

[0024] Heat to 75℃ and hold for 30 minutes; heating time is 10 minutes.

[0025] Heat to 80℃ and hold for 30 minutes; heating time is 10 minutes.

[0026] Heat to 85℃ and hold for 30 minutes; heating time is 10 minutes.

[0027] Heat to 90℃ and hold for 30 minutes; heating time is 10 minutes.

[0028] Heat to 95℃ and hold for 30 minutes; heating time is 10 minutes.

[0029] Heat to 100℃ and hold for 30 minutes; heating time is 10 minutes.

[0030] Heat to 105℃ and hold for 10 hours; heating time is 60 minutes.

[0031] Heat to 110℃ and hold for 5 hours, with a heating time of 60 minutes.

[0032] The materials used in step five (moisture-proof sealing) and step seven (vacuum potting) include one or more combinations of two-component epoxy resin protective coatings, self-spraying conformal coatings, and high-voltage cable insulation waterproof and anti-corrosion coatings.

[0033] This invention, through structural improvements, utilizes a combination of moisture-proof sealing and vacuum potting to meet the requirements of DC-Link capacitors for use in high-temperature and high-humidity environments. An insulating plate is provided between the upper and lower stacked busbars to isolate the leakage current from the capacitor core, ensuring its normal operation. By encapsulating the upper and lower stacked busbars, the insulating plate, and several capacitor cores using multiple plates, the production cost can be effectively reduced, and the margin during selection can be decreased, enabling a lightweight design for DC-Link capacitors. Attached Figure Description

[0034] Figure 1 This is an exploded view of the DC-Link capacitor according to an embodiment of the present invention.

[0035] Figure 2 This is an exploded view of the tooling fixture according to an embodiment of the present invention. Detailed Implementation

[0036] To make the above-mentioned objects, features, and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a full understanding of this utility model. However, this utility model can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed below.

[0037] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0038] See Figure 1 , Figure 2 This lightweight DC-Link capacitor includes a housing, which is encapsulated by several plates and contains several capacitor cores 10. Lead-out electrodes 5 are provided on the housing, and busbars are connected to the capacitor cores 10 and connected to the lead-out electrodes 5 through the busbars.

[0039] The outer casing includes a first end plate 1, a second end plate 17, an upper plate 2, and a lower plate 3. The first end plate 1 and the second end plate 17 are located at both ends of the capacitor core 10, and a self-locking support rod 4 is provided between the first end plate 1 and the second end plate 17 and they are fixed to each other by the self-locking support rod 4. The upper plate 2 is fixed to the top of the first end plate 1 and the second end plate 17, and the lower plate 3 is fixed to the bottom of the first end plate 1 and the second end plate 17.

[0040] In this embodiment, four self-locking support rods 4 are provided, and are respectively located at the four corners of the first end plate 1 and the second end plate 17. Fixing holes are provided at the four corners of the first end plate 1 and the second end plate 17. The self-locking support rods 4 are connected to the fixing holes to achieve the fixation between the first end plate 1 and the second end plate 17.

[0041] Lead-out electrode 5 is mounted on the upper plate 2.

[0042] In this embodiment, there are several lead-out electrodes 5, which are spaced apart along the long dimension of the upper plate 2.

[0043] The capacitor core 10 is also provided with a self-locking member 16 at its end. Several capacitor cores 10 are cylindrical and are arranged in a lateral and longitudinal manner to reduce space occupancy. A core winding hole 15 is provided at the center of the capacitor core 10, and the self-locking member 16 is connected to the core winding hole 15.

[0044] In this embodiment, the self-locking member 16 extends laterally, and the number of self-locking members 16 corresponds to the number of rows of capacitor cores 10 arranged vertically. The self-locking member 16 also has a number of self-locking posts corresponding to the number of horizontally arranged capacitor cores 10. The self-locking posts are connected to the core roll hole 15 to achieve the positioning of several capacitor cores 10.

[0045] The busbar includes an upper stacked busbar 7 and a lower stacked busbar 8. The upper stacked busbar 7 is stacked on top of the lower stacked busbar 8. Conductive sheets 6 are respectively provided on the upper stacked busbar 7 and the lower stacked busbar 8, and are respectively connected to a number of capacitor cores 10 through the conductive sheets 6.

[0046] In this configuration, the conductive sheet 6 of the upper stacked busbar 7 is connected to one end face of several capacitor cores 10, and the conductive sheet 6 of the lower stacked busbar 8 is connected to one end face of several capacitor cores 10.

[0047] The conductive sheet 6 extends longitudinally and is connected in conjunction with several longitudinally arranged capacitor cores 10.

[0048] In this embodiment, the upper stacked busbar 7 and the conductive sheet 6 are integrally formed, and the lower stacked busbar 8 and the conductive sheet 6 are integrally formed.

[0049] An insulating plate 9 is provided between the upper stacked busbar 7 and the lower stacked busbar 8.

[0050] In this embodiment, a combination of moisture-proof sealing and vacuum potting is used to meet the requirements of DC-Link capacitors for use in high-temperature and high-humidity environments. An insulating plate 9 is provided between the upper stacked busbar 7 and the lower stacked busbar 8 to isolate the leakage current of the capacitor core 10, thereby ensuring the normal use of the capacitor core 10. By using several plates to encapsulate the upper stacked busbar 7, the lower stacked busbar 8, the insulating plate 9, and several capacitor cores 10, the production cost of the product can be effectively reduced, and the margin during selection can be reduced, thus achieving a lightweight design of the DC-Link capacitor.

[0051] The manufacturing process for the aforementioned lightweight DC-Link capacitor includes the following steps:

[0052] Step 1: Use a heat-setting fixture to position the capacitor core 10 to be manufactured, and place it in an oven after positioning. Then, use a heat-setting method with gradual and slow heating to manufacture the capacitor core 10.

[0053] Step 2: After the capacitor core 10 is heat-set, it is removed from the oven and cooled to room temperature before being removed from the heat-setting fixture.

[0054] Step 3: Heat shrink the capacitor core 10 with two layers of heat shrink tubing. First, put on one layer and bake it in an 80-120℃ oven for 50-70 minutes. After heat shrinking one layer, put on the other layer and repeat the operation until only the gold plating layer of the capacitor core 10 is exposed.

[0055] Step 4: Arrange several capacitor cores 10 together in a crisscross pattern, and assemble the self-locking component 16 onto the core winding hole 15 of several capacitor cores 10. Then, weld the lower stacked busbar 8 to one end face of the capacitor core 10, place the insulating plate 9 on the lower stacked busbar 8, and then place the upper stacked busbar 7 on the insulating plate 9 and weld it to the other end face of the capacitor core 10 to form a capacitor core group.

[0056] Step 5: Place the capacitor core assembly into a vacuum chamber for moisture-proof sealing treatment;

[0057] Step 6: Assemble the capacitor core assembly with the upper plate 2, then assemble the first end plate 1 and the lower plate 3 in sequence, and then use the self-locking support rod 4 to fix the second end plate 17 to the first end plate 1.

[0058] Step 7: Place the assembled product in a tooling fixture, and then put it into a vacuum oven for vacuum potting. The vacuum potting sequence is left end face, right end face, top, bottom. After each side is potted, it needs to be cured in the vacuum oven before potting the next side, so as to finally produce a DC-Link capacitor.

[0059] The temperature control process in step one is as follows:

[0060] Heat from room temperature to 60℃ and hold for 3 hours, with the heating time taking 10 minutes;

[0061] Heat to 65℃ and maintain for 5 hours; heating time is 30 minutes.

[0062] Heat to 70℃ and hold for 30 minutes; heating time is 10 minutes.

[0063] Heat to 75℃ and hold for 30 minutes; heating time is 10 minutes.

[0064] Heat to 80℃ and hold for 30 minutes; heating time is 10 minutes.

[0065] Heat to 85℃ and hold for 30 minutes; heating time is 10 minutes.

[0066] Heat to 90℃ and hold for 30 minutes; heating time is 10 minutes.

[0067] Heat to 95℃ and hold for 30 minutes; heating time is 10 minutes.

[0068] Heat to 100℃ and hold for 30 minutes; heating time is 10 minutes.

[0069] Heat to 105℃ and hold for 10 hours; heating time is 60 minutes.

[0070] Heat to 110℃ and hold for 5 hours, with a heating time of 60 minutes.

[0071] The oven temperature for step three is 100℃, and the baking time is 60 minutes.

[0072] The materials used in step five (moisture-proof sealing) and step seven (vacuum potting) include one or more combinations of two-component epoxy resin protective coatings, self-spraying conformal coatings, and high-voltage cable insulation waterproof and anti-corrosion coatings.

[0073] The tooling fixture in step seven includes a front plate 11 and a rear plate 18. The front plate 11 and the rear plate 18 are respectively provided with fastening holes. The fastening holes of the front plate 11 and the fastening holes of the rear plate 18 correspond to each other, and a support rod 13 is provided between them. The two ends of the support rod 13 are respectively provided with threaded parts. After the threaded parts pass through the fastening holes, they are connected to fasteners 14, thereby fixing the front plate 11 and the rear plate 18. In addition, the front plate 11 and the rear plate 18 are also respectively provided with positioning grooves. The positioning grooves of the front plate 11 and the positioning grooves of the rear plate 18 correspond to each other, and a positioning block 12 is provided between them. The front plate 11 and the rear plate 18 are positioned by the positioning block 12.

[0074] In this embodiment, four support rods 13 are provided and are located at the four corners of the front end plate 11 and the rear end plate 18, respectively. Four positioning blocks 12 are provided and are located at the middle of the four edges of the front end plate 11 and the rear end plate 18, respectively, so as to effectively achieve a stable fit between the front end plate 11 and the rear end plate 18.

[0075] In use, the front end plate 11 and the rear end plate 18 are pre-fixed by the support rod 13. Then, the assembled outer shell, upper stacked busbar 7, lower stacked busbar 8, insulating plate 9, and several capacitor cores 10 are placed between the front end plate 11 and the rear end plate 18. Finally, the positioning is achieved by the positioning block 12.

[0076] The above describes the preferred embodiments of this utility model, illustrating and describing its basic principles, main features, and advantages. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made without departing from the spirit and scope of this utility model, and all such changes and modifications fall within the scope of protection of this utility model as defined by the appended claims and their equivalents.

Claims

1. A lightweight DC-Link capacitor comprising an outer housing, characterized in that: The outer casing is encapsulated by several plates and contains several capacitor cores (10). Lead-out electrodes (5) are provided on the outer casing. Busbars are connected to the capacitor cores (10) and connected to the lead-out electrodes (5) through the busbars.

2. The lightweight DC-link capacitor of claim 1, wherein: The outer casing includes a first end plate (1), a second end plate (17), an upper plate (2), and a lower plate (3). The first end plate (1) and the second end plate (17) are located at both ends of the capacitor core (10). A self-locking support rod (4) is provided between the first end plate (1) and the second end plate (17) and they are fixed to each other by the self-locking support rod (4). The upper plate (2) is fixed to the top of the first end plate (1) and the second end plate (17), and the lower plate (3) is fixed to the bottom of the first end plate (1) and the second end plate (17).

3. The lightweight DC-link capacitor of claim 2, wherein: The lead-out electrode (5) is set on the upper plate (2).

4. The lightweight DC-link capacitor of claim 3, wherein: The capacitor core (10) is also provided with a self-locking component (16) at its end. Several capacitor cores (10) are cylindrical and arranged in a lateral and longitudinal manner. A core winding hole (15) is provided at the center of the capacitor core (10). The self-locking component (16) is connected to the core winding hole (15).

5. The lightweight DC-link capacitor of claim 4, wherein: The busbar includes an upper stacked busbar (7) and a lower stacked busbar (8). The upper stacked busbar (7) is stacked on top of the lower stacked busbar (8). The upper stacked busbar (7) and the lower stacked busbar (8) are respectively provided with conductive sheets (6), and are respectively connected to several capacitor cores (10) through the conductive sheets (6).

6. The lightweight DC-Link capacitor of claim 5, wherein: The conductive sheet (6) extends longitudinally and is connected in conjunction with several longitudinally arranged capacitor cores (10).

7. The light-weight DC-Link capacitor according to claim 6, characterized in that: An insulating plate (9) is provided between the upper stacked busbar (7) and the lower stacked busbar (8).

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