10kv capacitive coupler for broadband carrier communication

Abstract

The application relates to a 10kV capacitor coupler for broadband carrier communication, and relates to the field of power communication equipment parts, which comprises a negative metal cover, a negative copper column, a circuit board, a magnetic tank, a high-voltage ceramic capacitor, a fuse, a positive epoxy cover, a positive stud, and a positive metal cover which are sequentially arranged from bottom to top; the negative metal cover is connected with the negative copper column through a first screw; the magnetic tank, the circuit board, and the negative copper column are fixed in the axial direction through a nylon screw rod and a nylon nut; a knurled nut is connected to the top of the nylon screw rod; the top of the knurled nut is connected with the high-voltage ceramic capacitor through a second screw; the fuse is connected with the high-voltage ceramic capacitor through a third screw below; an epoxy sleeve is arranged between the negative metal cover and the positive metal cover, and the epoxy sleeve is filled with pouring silica gel for packaging and fixing. The application has the effect of improving the stability and reliability of the 10kV capacitor coupler for carrier communication.

Description

Technical Field

[0001] This application relates to the field of power communication equipment components, and in particular to a 10kV capacitive coupler for broadband carrier communication. Background Technology

[0002] Currently, medium-voltage power line carrier communication is widely used in marketing data collection and distribution network data transmission. With the continuous development of smart grids, the requirements for data transmission communication rates are increasing. This trend is driving medium-voltage power line carrier communication towards high speed and high efficiency, which is of great significance for improving the intelligent management level and service quality of the power grid. As a key component of medium-voltage power line carrier communication, the performance of the 10kV capacitive coupler directly affects the quality and overall performance of the carrier communication.

[0003] In the field of medium-voltage power line carrier communication, 10kV capacitive couplers, as a key component, were initially mainly used for narrowband medium-voltage power line carrier communication. At that time, traditional 10kV capacitive couplers were mostly focused on narrowband low-frequency applications, with a relatively narrow communication frequency range. In terms of internal structural design, the magnetic ring coil material, wire selection, and winding turns ratio were all configured based on the requirements of narrowband communication. In terms of packaging, traditional 10kV capacitive couplers typically had a hard epoxy resin directly encapsulated on the outer layer to fix the internal core component, the high-voltage ceramic capacitor.

[0004] However, these traditional technologies have significant limitations. As communication demands shift towards broadband, traditional narrowband 10kV capacitive couplers are ill-suited to the requirements of broadband carrier communication. Their superior performance is only evident in the narrowband low-frequency band, performing poorly in high-frequency broadband applications. Furthermore, traditional packaging prevents the release of stress generated by the high-voltage ceramic capacitor under different voltage surges, easily leading to the 10kV capacitive coupler exploding and affecting the stability and reliability of carrier communication. Utility Model Content

[0005] To improve the stability and reliability of 10kV capacitive couplers for carrier communication, this application provides a 10kV capacitive coupler for broadband carrier communication.

[0006] This application provides a 10kV capacitive coupler for broadband carrier communication, which adopts the following technical solution:

[0007] A 10kV capacitive coupler for broadband carrier communication includes, from bottom to top, a negative metal cap, a negative copper pillar, a circuit board, a magnetic can, a high-voltage ceramic capacitor, a fuse, a positive epoxy cap, a positive stud, and a positive metal cap.

[0008] The negative electrode metal cap is connected to the negative electrode copper pillar via a first screw; the magnetic can, circuit board, and negative electrode copper pillar are axially fixed by nylon screws and nylon nuts; a knurled nut is connected to the top of the nylon screw, and the top of the knurled nut is connected to the high-voltage ceramic capacitor via a second screw; the fuse is connected to the high-voltage ceramic capacitor below via a third screw, and electrically connected to the positive electrode epoxy cap above via a copper connecting wire; the positive electrode stud is connected to the positive electrode metal cap above via a fourth screw, and connected to the positive electrode epoxy cap below via a fifth screw;

[0009] An epoxy sleeve is provided between the negative electrode metal cap and the positive electrode metal cap. The fuse, high-voltage ceramic capacitor, and epoxy resin insulating column are all located inside the epoxy sleeve. The epoxy sleeve is filled with potting silicone for encapsulation and fixation.

[0010] By adopting the above technical solution, during encapsulation, the negative electrode metal cover is first connected to the negative electrode copper pillar with the first screw. The magnetic can, circuit board, and negative electrode copper pillar are then axially fixed with nylon screws and nylon nuts. Next, the bottom of the knurled nut is connected to the nylon screw, and the top is connected to the high-voltage ceramic capacitor with the second screw. The fuse is connected to the high-voltage ceramic capacitor below with the third screw, and electrically connected to the positive electrode epoxy cover above with a copper connecting wire. Then, the positive electrode stud is connected to the positive electrode metal cover above with the fourth screw, and to the positive electrode epoxy cover below with the fifth screw. An epoxy sleeve is then placed between the negative and positive electrode metal covers, so that the fuse, high-voltage ceramic capacitor, and epoxy resin insulating pillar are all located inside the epoxy sleeve. Finally, potting silicone is filled into the epoxy sleeve for encapsulation and fixation. The potting silicone absorbs mechanical stress and alleviates deformation caused by voltage surges, preventing the high-voltage ceramic capacitor from bursting due to stress caused by different thermal effects and expansion coefficients under different voltages. This significantly enhances the product's resistance to voltage surges, thereby ensuring the product's stability and reliability.

[0011] Optionally, the magnetic jar is a GU48 type magnetic jar made of high magnetic permeability composite material.

[0012] By adopting the above technical solution, the magnetic can is selected from the GU48 model with high permeability. During signal transmission, the magnetic can can better sense and transmit high-frequency signals by virtue of its high permeability. Compared with traditional magnetic ring materials, it can efficiently process high-frequency signals by utilizing its own material advantages in high-frequency environments, reduce signal loss, and thus improve the high-frequency permeability of the product. This allows the product to have more stable impedance matching and lower insertion loss over a wide frequency range, enabling the product to work more stably over a wide frequency range and improving the high-frequency signal transmission characteristics.

[0013] Optionally, the turns ratio of the primary winding to the secondary winding of the coil inside the magnetic jar is 7:12, and the coil wire is made of low-loss silver-plated copper wire.

[0014] By adopting the above technical solution, the low-loss silver-plated copper wire can reduce signal loss during signal transmission, transmitting signals with less energy loss. At the same time, the specific 7:12 turns ratio enables the primary and secondary windings to better achieve signal conversion and transmission during electromagnetic induction, giving the product more stable impedance matching and lower insertion loss over a wide frequency range. For example, it has good performance in the 9kHz to 12MHz bandwidth range, with the primary winding impedance in the range of 100Ω-400Ω and the secondary winding impedance in the range of 50Ω-100Ω. When a 75Ω resistor is connected to the primary winding, the secondary winding impedance is stably maintained at around 300Ω within a certain frequency range, and when a 300Ω resistor is connected to the secondary winding, the primary winding impedance is maintained at around 75Ω within a certain frequency range.

[0015] Optionally, the magnetic can, circuit board, and negative electrode copper pillar are encapsulated and fixed by epoxy resin insulating pillars, which extend axially along the nylon screw and contact the bottom of the negative electrode metal cap.

[0016] By adopting the above technical solution, the magnetic can, circuit board and negative copper pillar are encapsulated and fixed on the outside by epoxy resin insulating pillars, and the magnetic can, circuit board and negative copper pillar are stably combined together. This can ensure the stability of the connection between the magnetic can, circuit board and negative copper pillar, and avoid loosening or displacement during use. This improves the reliability of the 10kV capacitive coupler used for broadband carrier communication and extends the service life of the equipment.

[0017] Optionally, an outer protective shell is fitted on the outside of the epoxy sleeve, and an umbrella skirt is fixedly fitted on the outside of the outer protective shell.

[0018] By adopting the above technical solutions, the outer protective shell can further enhance the protection of the internal structure, prevent external factors such as physical collisions and chemical corrosion from damaging the inside of the coupler, and the umbrella skirt is used to increase the creepage distance, improve electrical insulation performance, reduce safety accidents such as leakage, and ensure the safe and stable operation of the capacitor coupler in complex environments.

[0019] Optionally, the outer protective shell is composed of an outer silicone rubber layer and an inner glass fiber layer laminated together.

[0020] By adopting the above technical solution, the outer silicone rubber layer in the outer protective shell has good flexibility, insulation and weather resistance, and can resist the erosion of the external environment, such as ultraviolet radiation and humidity; the glass fiber layer has high strength and good rigidity, which can enhance the overall strength and stability of the outer protective shell. The structural combination enables the outer protective shell to adapt to various complex outdoor environmental conditions, and also provides reliable protection for the internal capacitive coupler components, ensuring the stable operation of broadband carrier communication.

[0021] Optionally, the bottom of the negative copper post is provided with an aviation plug interface, which is connected to the internal conductive channel of the negative copper post through a threaded connector.

[0022] By adopting the above technical solution, when electrical connection is required, the compatible aviation plug can be inserted into the aviation plug interface at the bottom of the negative copper post to achieve reliable transmission of current or signal. The aviation plug interface facilitates quick plugging and unplugging operations, improves the convenience of equipment installation and disassembly, and can realize complete broadband carrier communication functions.

[0023] In summary, this application includes at least one of the following beneficial technical effects:

[0024] 1. A customized epoxy sleeve is used as the outer fixing structure. The inside of the sleeve is filled with soft silicone for encapsulation and fixation. This can absorb mechanical stress and alleviate deformation caused by voltage impact. It avoids the problem of cracking caused by the inability to release stress due to the different thermal effects and expansion coefficients of high voltage ceramic capacitors under different voltages. This significantly enhances the product's tolerance to voltage impact, thereby ensuring the product's stability and reliability.

[0025] 2. By reselecting the internal magnetic ring coil material, wire selection, and re-ratio and design of the winding turns ratio, and by using the GU48 magnetic can with high permeability, the high-frequency permeability was improved. The primary-to-secondary winding turns ratio was redesigned to 7:12, which enabled the product to have more stable impedance matching and lower insertion loss over a wide frequency range. It also exhibits good performance in the bandwidth range of 40kHz to 12MHz signal source input frequency, and better senses and transmits high-frequency signals.

[0026] 3. By using epoxy resin insulating pillars to encapsulate and fix the magnetic can, circuit board, and negative copper pillar to the outside, the magnetic can, circuit board, and negative copper pillar are stably combined together. This ensures the stability of the connection between the magnetic can, circuit board, and negative copper pillar, and avoids loosening or displacement during use. This improves the reliability of the 10kV capacitive coupler used for broadband carrier communication and extends the service life of the equipment. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the 10kV capacitive coupler used for broadband carrier communication in this application;

[0028] Figure 2 This is an exploded view of a 10kV capacitive coupler used for broadband carrier communication.

[0029] Figure 3 This is a partial cross-sectional view of a 10kV capacitive coupler used for broadband carrier communication.

[0030] Explanation of reference numerals in the attached diagram: 1. Negative electrode metal cap; 2. Negative electrode copper pillar; 3. Circuit board; 4. Magnetic can; 5. High-voltage ceramic capacitor; 6. Fuse; 7. Positive electrode epoxy cap; 8. Positive electrode stud; 9. Positive electrode metal cap; 10. Epoxy resin insulating pillar; 11. Knurled nut; 12. Epoxy sleeve; 13. Potting silicone; 14. Outer protective shell; 15. Umbrella skirt; 16. Aviation connector. Detailed Implementation

[0031] The following is in conjunction with the appendix Figures 1-3 This application will be described in further detail.

[0032] This application discloses a 10kV capacitive coupler for broadband carrier communication. (Refer to...) Figure 1 and Figure 2 The 10kV capacitive coupler for broadband carrier communication includes, from bottom to top, a negative metal cover 1, a negative copper pillar 2, a circuit board 3, a magnetic can 4, a high-voltage ceramic capacitor 5, a fuse 6, a positive epoxy cover 7, a positive stud 8, and a positive metal cover 9. These components are sequentially connected to form a complete electrical structure, enabling the smooth transmission of electrical energy from the negative to the positive terminal. Furthermore, the various components cooperate to process and regulate the signal, ensuring the normal operation of broadband carrier communication.

[0033] Specifically, refer to Figure 2 and Figure 3 The negative electrode metal cap 1 and the positive electrode metal cap 9 are typically made of metals such as copper or aluminum, and are generally circular in shape. The bottom of the negative electrode metal cap 1 has a screw hole, which connects to the negative electrode copper pillar 2 via a first screw. The negative electrode copper pillar 2 is a cylinder made of copper, and its top is adjacent to the circuit board 3, forming an electrical connection with it. The circuit board 3 is the control core of the entire coupler, housing various electronic components such as resistors, capacitors, and inductors, and featuring a multi-layer wiring structure to achieve complex circuit functions. The magnetic can 4, the circuit board 3, and the negative electrode copper pillar 2 are axially fixed by nylon screws and nylon nuts, and further encapsulated and fixed by epoxy resin insulating pillars 10, which extend axially along the nylon screws and contact the bottom of the negative electrode metal cap 1. The nylon screw and nylon nut have insulating properties, which can avoid electrical interference. By tightening the nylon nut in conjunction with the epoxy resin insulating post 10, the magnetic can 4, the circuit board 3 and the negative copper post 2 can be firmly encapsulated and fixed, ensuring the stability of the connection between the magnetic can 4, the circuit board 3 and the negative copper post 2, and preventing loosening or displacement during use, thereby improving the reliability of the entire 10kV capacitive coupler used for broadband carrier communication.

[0034] The magnetic can 4 is a key component affecting the high-frequency performance of the coupler. A GU48 model magnetic can 4 can be selected, which improves high-frequency permeability and enhances high-frequency signal transmission characteristics. The coil inside the magnetic can 4 acts as an electromagnetic converter. The turns ratio of the primary winding to the secondary winding is 7:12, which allows for more stable impedance matching and lower insertion loss over a wide frequency range. For example, it exhibits good performance in a bandwidth of 9kHz to 12MHz, with the primary winding impedance ranging from 100Ω to 400Ω and the secondary winding impedance from 50Ω to 100Ω. When a 75Ω resistor is connected to the primary winding, the secondary winding impedance remains stably around 300Ω within a certain frequency range; when a 300Ω resistor is connected to the secondary winding, the primary winding impedance remains around 75Ω within a certain frequency range. The coil conductor uses low-loss silver-plated copper wire, which has good conductivity and low resistance, reducing energy loss during signal transmission.

[0035] Reference Figure 2 and Figure 3 The epoxy resin insulating column 10 is equipped with a knurled nut 11. The bottom of the knurled nut 11 is connected to the nylon screw, and the top is connected to the high voltage ceramic capacitor 5 through a second screw. The high voltage ceramic capacitor 5 is the core energy storage element of the coupler and has a high voltage withstand capability.

[0036] Fuse 6 serves as overcurrent protection. When the current in the circuit is too high, fuse 6 will melt, cutting off the circuit and protecting other components from damage. Fuse 6 is connected to the high-voltage ceramic capacitor 5 at the bottom via a third screw, and to the positive epoxy cap 7 at the top via a copper connecting wire. The copper connecting wire has good conductivity, ensuring smooth power transmission.

[0037] Reference Figure 2 and Figure 3 The positive electrode epoxy cap 7 is made of epoxy resin material and has good insulation properties. Its top is connected to the positive electrode stud 8 by the fifth screw. The positive electrode stud 8 is made of copper cylinder and has good conductivity. Its top is connected to the positive electrode metal cap 9 by the fourth screw.

[0038] An epoxy sleeve 12 is provided between the negative electrode metal cap 1 and the positive electrode metal cap 9. The epoxy sleeve 12 is made of customized epoxy resin material. The fuse 6, the high-voltage ceramic capacitor 5, and the epoxy resin insulating column 10 are all located inside the epoxy sleeve 12. The epoxy sleeve 12 is filled with potting silicone 13 to encapsulate and fix the internal electrical components. The potting silicone 13 has good elasticity and insulation properties, which can absorb mechanical stress and alleviate deformation caused by voltage impact, thus preventing the high-voltage ceramic capacitor 5 from cracking due to stress not being released when subjected to different voltage impacts.

[0039] Reference Figure 2 and Figure 3An outer protective shell 14 is fitted around the epoxy sleeve 12. The outer protective shell 14 is composed of an outer silicone rubber layer and an inner fiberglass layer. The outer silicone rubber layer has good flexibility and waterproof performance, protecting the internal components from moisture and dust. The inner fiberglass layer has high strength and insulation performance, enhancing the structural strength of the outer protective shell 14. A skirt 15 is fixedly fitted around the outer protective shell 14. The skirt 15 has a ring structure and is made of insulating material, such as silicone rubber. The skirt 15 is used to increase the creepage distance, improve insulation performance, and prevent leakage.

[0040] The bottom of the negative copper post 2 is equipped with an aviation plug 16 interface, which is connected to the internal conductive channel of the negative copper post 2 through a threaded connector. The threaded connector can ensure the tightness and stability of the connection, and the aviation plug 16 interface facilitates electrical connection with external devices.

[0041] The implementation principle of a 10kV capacitive coupler for broadband carrier communication according to an embodiment of this application is as follows: During encapsulation, the negative metal cover 1 is first connected to the negative copper pillar 2 by a first screw. The magnetic can 4, circuit board 3, and negative copper pillar 2 are axially fixed by nylon screws and nylon nuts. Then, the outer side of the magnetic can 4, circuit board 3, and negative copper pillar 2 is encapsulated and fixed by epoxy resin insulating pillar 10, so that the epoxy resin insulating pillar 10 extends axially along the nylon screw and contacts the bottom of the negative metal cover 1. Next, the bottom of the knurled nut 11 inside the epoxy resin insulating pillar 10 is connected to the nylon screw, and the top is connected to the high-voltage ceramic capacitor 5 by a second screw. The fuse 6 is connected to the high-voltage ceramic capacitor 5 below by a third screw, and electrically connected to the positive epoxy cover 7 above by a copper connecting wire. Finally, the positive stud 8 is connected to the positive epoxy cover 7 by a fourth screw. The capacitor coupler is connected to the positive metal cover 9 and then to the positive epoxy cover 7 via a fifth screw. An epoxy sleeve 12 is then placed between the negative metal cover 1 and the positive metal cover 9, housing the fuse 6, high-voltage ceramic capacitor 5, and epoxy resin insulating column 10 within the epoxy sleeve 12. The epoxy sleeve 12 is then filled with potting silicone 13 for encapsulation and fixation. Finally, an outer protective shell 14 and a skirt 15 are fitted over the epoxy sleeve 12 and secured with the positive and negative metal covers 9 and 1, completing the assembly. The potting silicone 13 absorbs mechanical stress and mitigates deformation caused by voltage surges, preventing the high-voltage ceramic capacitor 5 from bursting due to unreleased stress caused by varying thermal effects and expansion coefficients under different voltages. This significantly enhances the product's resistance to voltage surges, ensuring its stability and reliability. Furthermore, the bottom-up, sequential arrangement of components results in a compact and rational structure, facilitating installation and maintenance.

[0042] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A 10kV capacitive coupler for broadband carrier communication, characterized in that, The components, arranged from bottom to top, include a negative electrode metal cap (1), a negative electrode copper pillar (2), a circuit board (3), a magnetic can (4), a high-voltage ceramic capacitor (5), a fuse (6), a positive electrode epoxy cap (7), a positive electrode stud (8), and a positive electrode metal cap (9). The negative electrode metal cap (1) is connected to the negative electrode copper pillar (2) by a first screw; the magnetic can (4), circuit board (3) and negative electrode copper pillar (2) are fixed axially by nylon screws and nylon nuts; a knurled nut (11) is connected to the top of the nylon screw, and the top of the knurled nut (11) is connected to the high voltage ceramic capacitor (5) by a second screw; the fuse (6) is connected to the high voltage ceramic capacitor (5) below by a third screw, and is electrically connected to the positive electrode epoxy cap (7) above by a copper connecting wire; the positive electrode stud (8) is connected to the positive electrode metal cap (9) above by a fourth screw, and to the positive electrode epoxy cap (7) below by a fifth screw; An epoxy sleeve (12) is provided between the negative electrode metal cover (1) and the positive electrode metal cover (9). The fuse (6), the high-voltage ceramic capacitor (5), and the epoxy resin insulating column (10) are all located inside the epoxy sleeve (12). The epoxy sleeve (12) is filled with potting silicone (13) for encapsulation and fixation.

2. A 10kV capacitive coupler for broadband carrier communication according to claim 1, characterized in that, The magnetic container (4) is a GU48 type magnetic container (4) made of high magnetic permeability composite material.

3. A 10kV capacitive coupler for broadband carrier communication according to claim 2, characterized in that, The ratio of the number of turns of the primary winding to the number of turns of the secondary winding of the coil inside the magnetic jar (4) is 7:12, and the coil wire is made of low-loss silver-plated copper wire.

4. A 10kV capacitive coupler for broadband carrier communication according to claim 1, characterized in that, The magnetic can (4), circuit board (3) and negative electrode copper pillar (2) are encapsulated and fixed by epoxy resin insulating pillar (10), which extends along the axial direction of the nylon screw and contacts the bottom of the negative electrode metal cover (1).

5. A 10kV capacitive coupler for broadband carrier communication according to claim 1, characterized in that, An outer protective shell (14) is fitted on the outside of the epoxy sleeve (12), and an umbrella skirt (15) is fixedly fitted on the outside of the outer protective shell (14).

6. A 10kV capacitive coupler for broadband carrier communication according to claim 5, characterized in that, The outer protective shell (14) is composed of an outer silicone rubber layer and an inner glass fiber layer.

7. A 10kV capacitive coupler for broadband carrier communication according to claim 1, characterized in that, The bottom of the negative copper pillar (2) is provided with an aviation plug (16) interface, which is connected to the internal conductive channel of the negative copper pillar (2) through a threaded connector.

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