High voltage thin film capacitor with tab

Abstract

The application discloses a plug-in high-voltage thin film capacitor, which comprises an aluminum shell, a capacitor core is arranged in the aluminum shell, a conductive plug is electrically connected with the capacitor core, one end of the conductive plug is fixed to the end of the aluminum shell, and the conductive plug can be connected with an external circuit; and an insulating top cover which comprises a fixed part and a supporting part connected with each other, the fixed part is sleeved on the end of the aluminum shell, and the other end of the conductive plug is located in the inside of the supporting part after penetrating through the fixed part. Since the conductive plug can be connected with the external circuit, the capacitor is arranged in a plug-in structure through the arrangement of the conductive plug, the capacitor can be installed by hand plugging, the capacitor is convenient and fast to install and replace, and the installation and maintenance efficiency of the capacitor is improved. Since the insulating top cover is arranged, support is provided through the supporting part during plugging and using, the conductive plug is prevented from being damaged during plugging and using, and the conductive plug is prevented from being damaged during plugging and using.

Description

Technical Field

[0001] This application relates to the field of capacitor technology, and in particular to a plug-in high voltage film capacitor. Background Technology

[0002] High-voltage film capacitors are widely used in key areas such as new energy power generation (photovoltaic inverters, wind power converters), electric vehicle drive systems, industrial frequency converters, and high-voltage power supplies due to their excellent voltage withstand capability, low loss, and long lifespan. Existing high-voltage capacitors are generally installed using bolt fastening or lead soldering. However, bolt installation requires manual positioning, tightening, and torque verification, which is cumbersome and inconsistent. Lead soldering also makes maintenance and replacement procedures cumbersome. Summary of the Invention

[0003] This application provides a plug-in type high-voltage film capacitor to solve the technical problems of cumbersome installation steps and inconvenience in maintenance and replacement of high-voltage film capacitors in the prior art. The technical solution is as follows: This application provides a plug-in type high-voltage film capacitor in one embodiment, comprising: The aluminum casing houses the capacitor core. A conductive insert, one end of which is electrically connected to the capacitor core, is fixed to the end of the aluminum housing, and can be connected to an external circuit. An insulating top cover includes a fixed part and a supporting part connected together. The fixed part is sleeved on the end of the aluminum shell, and the other end of the conductive insert passes through the fixed part and is located inside the supporting part.

[0004] In one embodiment, the support portion has two receiving cavities, and there are two conductive inserts, each located within one of the two receiving cavities. The support portion has a partition in the middle, and the two receiving cavities are separated by the partition.

[0005] In one embodiment, the bottom of each of the two accommodating cavities is provided with a through hole for inserting a piece, and the other end of each of the two conductive inserts passes through the through hole and is located in the corresponding accommodating cavity.

[0006] In one embodiment, the top of the sidewall of the cavity has a semi-circular arc-shaped structure that is recessed towards the fixing part.

[0007] In one embodiment, the aluminum housing is encapsulated with epoxy resin, and the capacitor core, the aluminum housing, the conductive insert, and the insulating top cover are fixed by the epoxy resin.

[0008] In one embodiment, the capacitor core has a first end and a second end, wherein one of the conductive tabs is electrically connected to the first end via a wire, and the other conductive tab is electrically connected to the second end via a wire.

[0009] In one embodiment, a wire electrically connected to the second end passes through the central axis of the capacitor core.

[0010] In one embodiment, an upper insulating sleeve is installed at the first end of the capacitor core, and a lower insulating sleeve is installed at the second end of the capacitor core.

[0011] In one embodiment, a through hole is provided at the other end of the conductive insert.

[0012] In one embodiment, the conductive insert is made of copper sheet.

[0013] The advantages or beneficial effects of the above technical solutions include at least the following: The plug-in high-voltage film capacitor of this application embodiment includes an aluminum shell, conductive plugs, and an insulating top cover. Since the conductive plugs can connect to external circuits, the capacitor is designed as a plug-in type, allowing for manual insertion and removal, making installation and replacement convenient and quick, and improving installation and maintenance efficiency. Because of the insulating top cover, support is provided during insertion and removal, preventing the conductive plugs from having to perform both a connecting and fixing function, thus avoiding damage during insertion and removal. Attached Figure Description

[0014] In the accompanying drawings, unless otherwise specified, the same reference numerals throughout the various drawings denote the same or similar parts or elements. These drawings are not necessarily drawn to scale. It should be understood that these drawings depict only some embodiments disclosed in this application and should not be construed as limiting the scope of this application.

[0015] Figure 1 This is a schematic diagram of a plug-in type high-voltage film capacitor. Figure 2 This is a cross-sectional view of a chip-type high-voltage film capacitor. Explanation of reference numerals in the attached figures: 1. Aluminum shell; 2. Conductive insert; 3. Insulating top cover; 4. Capacitor core; 31. Fixing part; 32. Supporting part; 33. Receiving cavity; 34. Partition; 41. First end; 42. Second end; 5. UL wire; 6. Upper insulating sleeve; 7. Lower insulating sleeve; 8. Epoxy resin; 21. Through hole. Detailed Implementation

[0016] The invention will be described in detail below with reference to specific embodiments.

[0017] Existing high-voltage film capacitors typically use bolted connections or lead soldering for installation. Bolted installation requires manual positioning, tightening, and torque verification, which is cumbersome and inconsistent. Lead soldering can cause thermal stress damage, and repair and replacement are also quite complicated.

[0018] Therefore, as Figure 1 As shown in the figure, this application provides an insert-type high-voltage film capacitor to solve the above-mentioned problems.

[0019] like Figure 1 , Figure 2 As shown, the insert-type high-voltage film capacitor includes an aluminum casing 1, conductive inserts 2, and an insulating top cover 3. The aluminum casing 1 houses a capacitor core 4. One end of the conductive insert 2 is electrically connected to the capacitor core 4, and the conductive insert 2 is fixed to the end of the aluminum casing 1, allowing it to connect to an external circuit. The insulating top cover 3 includes a fixed portion 31 and a supporting portion 32 connected together. The fixed portion 31 is fitted onto the end of the aluminum casing 1, and the other end of the conductive insert 2 passes through the fixed portion 31 and is located inside the supporting portion 32.

[0020] The plug-in high-voltage film capacitor of this application embodiment includes an aluminum shell 1, conductive plugs 2, and an insulating top cover 3. Since the conductive plugs 2 can be connected to external circuits, the capacitor is designed as a plug-in type, allowing for manual insertion and removal, making installation and replacement convenient and quick, and improving installation and maintenance efficiency. Because of the insulating top cover 3, support is provided by the support part 32 during insertion and removal, preventing the conductive plugs 2 from having to simultaneously perform a connecting and fixing function, thus avoiding damage to the conductive plugs 2 during insertion and removal.

[0021] The capacitor core 4 in this embodiment is formed by winding an existing metallized polypropylene film, and has a metal sputtering layer (zinc or zinc alloy) on both ends of the capacitor core 4.

[0022] In one embodiment, such as Figure 2 As shown, the support portion 32 has two receiving cavities 33, and two conductive inserts 2 are respectively located in the two receiving cavities 33. A partition 34 is located in the middle of the support portion 32, separating the two receiving cavities 33. Insertion through holes are respectively opened at the bottom of the two receiving cavities 33, and the other ends of the two conductive inserts 2 pass through the insertion through holes and are located in the corresponding receiving cavity 33. The top of the sidewall of the receiving cavity 33 has a semi-circular arc-shaped structure that is recessed towards the fixing portion 31.

[0023] Because the capacitor is relatively small and there are only two conductive tabs 2, the creepage distance between the two conductive tabs 2 is small, posing a certain safety hazard. Therefore, in this embodiment, a partition 34 is provided between the two receiving cavities 33, and the top of the sidewalls of the two receiving cavities 33 are designed as a semi-circular arc-shaped structure recessed towards the fixing part 31. The above design of the support part 32 makes it a stepped insulating support part. Specifically, the two receiving cavities 33 themselves form a recessed depression, the sidewalls of the receiving cavities 33 form the vertical surface of the steps, and the partition 34 between the two receiving cavities 33 forms a vertical barrier. Through the above design, the creepage distance and electrical clearance between the two conductive tabs 2 can be increased, and the creepage distance can be increased by more than 40% under the same volume.

[0024] The conductive insert 2 is made of an ultra-thin copper sheet. Preferably, the conductive insert 2 has a size of 6.3mm wide * 0.8mm thick. Copper sheets have good ductility, are easy to stamp, and have low resistivity. They still have conductivity after oxidation, and the conductive insert 2 can be directly stamped. In this embodiment, the conductive insert 2 made of copper sheet replaces the electrode, avoiding the problems of long procurement cycles and high costs associated with special electrodes. Since the conductive insert 2 enables capacitor installation through a plug-in method, it can be installed by hand without the need for tools or soldering. Installation and replacement can be completed within 5 minutes, improving installation efficiency. Compared with existing lead soldering, the capacitor in this embodiment avoids the risk of solder joint failure and contact impedance degradation. The contact resistance of the conductive insert 2 can be reduced by more than 60% compared to lead soldering, significantly reducing the temperature rise at the connection point.

[0025] To achieve electrical connection between the conductive insert 2 and the capacitor core 4, the capacitor core 4 has a first end 41 and a second end 42. One of the conductive inserts 2 is electrically connected to the gold-plated metal layer of the first end 41 via a wire, and the other conductive insert 2 is electrically connected to the gold-plated metal layer of the second end 42 via a wire. The aforementioned wire is a UL wire 5, which can be soldered to both the gold-plated metal layer and the conductive insert 2. The UL wire 5 connected to the gold-plated metal layer of the second end 42 passes through the central axis of the capacitor core 4.

[0026] Extending the conductive insert 2 directly to the first end 41 or the second end 42 of the capacitor core 4 to connect with the metal plating layer would consume a lot of materials. However, the conductive insert 2 can reduce costs by electrically connecting to the capacitor core 4 through the UL line 5.

[0027] In one embodiment, an upper insulating sleeve 6 is installed at the first end 41 of the capacitor core 4, and a lower insulating sleeve 7 is installed at the second end 42 of the capacitor core 4. The upper insulating sleeve 6 can be directly fitted onto the first end 41 of the capacitor core 4, and the lower insulating sleeve 7 can be directly fitted onto the second end 42 of the capacitor core 4. Additionally, an opening can be formed in the upper insulating sleeve 6, through which the UL wire 5 can pass.

[0028] To achieve a fixed connection between the capacitor core 4, the insulating top cover 3, and the aluminum shell 1, epoxy resin 8 can be potted inside the aluminum shell 1 under vacuum. The capacitor core 4, the aluminum shell 1, the conductive insert 2, and the insulating top cover 3 are fixed by the epoxy resin 8. This embodiment uses existing epoxy resin 8 to achieve a sealed fixation between the capacitor core 4, the conductive insert 2, the insulating top cover 3, and the aluminum shell 1. After curing, the epoxy resin 8 forms a dense protective layer, effectively preventing moisture and water from entering the capacitor. The epoxy resin 8 mentioned above is an existing material, and this application does not improve the epoxy resin material itself.

[0029] The capacitor in this embodiment can be mounted on a PCB board or other components. To mount the capacitor on the PCB board or other components, a mounting bracket can be installed on the PCB board or other components. Specifically, the bracket structure can be configured to match the capacitor. The bracket has pins, and the bracket can be soldered to the PCB board or other components through these pins. To facilitate insertion and removal of the capacitor, two insertion slots can be provided on the bracket. The inner wall of the insertion slots is provided with a flexible metal sheet (aluminum or copper sheet), and the flexible metal sheet can be connected to the pins through soldering or other methods.

[0030] When the capacitor is inserted into the socket, the conductive insert 2 is inserted into the insertion slot, and the two conductive inserts 2 are in close contact with the elastic metal pieces in the two insertion slots, thereby realizing the connection between the capacitor and the external circuit.

[0031] In one embodiment, a through hole 21 may be provided at the other end of the conductive insert 2. Since the surfaces of the conductive insert 2 and the insulating top cover 3 are flat and smooth, the friction between the conductive insert 2 and the elastic metal sheet, and between the insulating top cover 3 and the card holder, is insufficient to achieve good fixation of the capacitor when it is inserted into the card holder. Therefore, this application provides a through hole 21 on the conductive insert 2, and a spherical protrusion may be provided at the corresponding position of the elastic metal sheet. After the conductive insert 2 is inserted into the card holder, the protrusion can enter the through hole 21, increasing contact stability and thus achieving better fixation of the capacitor.

[0032] The design of the insulating top cover 3 and conductive insert 2 on the capacitor in this application solves the defects in efficiency, reliability, and space occupation of traditional capacitors that are fixed by welding or bolting. The capacitor of this application achieves plug-and-play installation through the conductive insert 2, saving space and reducing costs. It eliminates the need for bolts and other components, reduces size, makes it easier to miniaturize, and simplifies the manufacturing process.

[0033] The insulating top cover 3 can be made of existing plastic materials, and the fixing part 31, the supporting part 32, and the partition 34 can be an integrated structure. Through the design of the aluminum shell and the insulating top cover 3, the heat dissipation performance of the capacitor is ensured while allowing for free insertion and removal, thus comprehensively improving the reliability and installation efficiency of the capacitor.

[0034] It should be noted that this application embodiment does not protect the structure of the card holder; the shape and structure of the card holder can be adapted to the shape of the insulating top cover 3. The design of the card holder should ensure a tight fit with the insulating top cover 3 and the conductive insert 2, and that no interference occurs during insertion and removal. The material of the conductive insert 2 can also be replaced with other metal materials with good conductivity and mechanical properties, and is not limited to copper sheets.

[0035] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions created by the present invention, and are not intended to limit the scope of protection of the present invention. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions created by the present invention without departing from the essence and scope of the technical solutions created by the present invention.

Claims

1. A chip-type high-voltage film capacitor, characterized in that, include: The aluminum casing houses the capacitor core. A conductive insert, one end of which is electrically connected to the capacitor core, is fixed to the end of the aluminum housing, and can be connected to an external circuit. An insulating top cover includes a fixed part and a supporting part connected together. The fixed part is sleeved on the end of the aluminum shell, and the other end of the conductive insert passes through the fixed part and is located inside the supporting part.

2. The insert-type high-voltage film capacitor according to claim 1, characterized in that, The support has two accommodating cavities, and there are two conductive inserts, which are respectively located in the two accommodating cavities. The middle part of the support has a partition, and the two accommodating cavities are separated by the partition.

3. The insert-type high-voltage film capacitor according to claim 2, characterized in that, The bottom of each of the two accommodating cavities is provided with a through hole for inserting a piece, and the other end of each of the two conductive inserts passes through the through hole and is located in the corresponding accommodating cavity.

4. The insert-type high-voltage film capacitor according to claim 2, characterized in that, The top of the sidewall of the cavity has a semi-circular arc-shaped structure that is recessed towards the fixing part.

5. The insert-type high-voltage film capacitor according to claim 1, characterized in that, The aluminum casing is filled with epoxy resin, and the capacitor core, the aluminum casing, the conductive insert, and the insulating top cover are fixed by the epoxy resin.

6. The insert-type high-voltage film capacitor according to any one of claims 1 to 5, characterized in that, The capacitor core has a first end and a second end, one of the conductive inserts being electrically connected to the first end via a wire, and the other conductive insert being electrically connected to the second end via a wire.

7. The insert-type high-voltage film capacitor according to claim 6, characterized in that, The wire electrically connected to the second end passes through the central axis of the capacitor core.

8. The insert-type high-voltage film capacitor according to claim 6, characterized in that, The first end of the capacitor core is equipped with an upper insulating sleeve, and the second end of the capacitor core is equipped with a lower insulating sleeve.

9. The insert-type high-voltage film capacitor according to any one of claims 1 to 5, characterized in that, The other end of the conductive insert has a through hole.

10. The insert-type high-voltage film capacitor according to any one of claims 1 to 5, characterized in that, The conductive insert is made of copper sheet.

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