Multi-element integrated high-voltage capacitor

Abstract

The utility model discloses a kind of multi-element integrated high-voltage capacitor, it is related to capacitor technical field, the utility model includes shell, baffle and limit strip are respectively fixed in shell inner wall, baffle is provided in shell inside, and two or more than two capacitor elements are provided in baffle top, and lead wire is fixed in the both ends of capacitor element, glue injection hole is opened in baffle bottom, and sealant is filled in the gap of shell inside.The utility model is provided with shell, capacitor element and lead wire, shell and baffle cover capacitor element, capacitor element lead wire is stretched out from baffle and shell bottom, forms a capacitor, two or more than two capacitor elements in shell inside, connect using parallel or series connection mode;When customer installs and uses, multiple capacitors on circuit board need not be carried out in series-parallel connection, just install this multi-element integrated high-voltage capacitor, simplify customer operation, and compared with multiple capacitors in series-parallel connection on circuit board, it is small to occupy PCB board space, reduce equipment volume.

Description

Technical Field

[0001] This utility model relates to the field of capacitor technology, specifically to a multi-element integrated high-voltage capacitor. Background Technology

[0002] In the early 19th century, humans began to use electricity. In order to make better use of electricity, capacitors, as an indispensable electronic component for the rational use of electricity, have also been updated and replaced. With the advancement of technology, some special new energy fields, such as rail transportation, medical equipment, mining machinery, aerospace and other fields, have increasingly higher requirements for the relevant characteristics of capacitors, such as high voltage resistance, high current, small size, low impedance, and high surge resistance.

[0003] Traditional high-voltage capacitors employ an internal series diaphragm structure design. In some specialized equipment (high-power ultra-high voltage) applications, customers need to perform detailed calculations based on the required capacitance and voltage rating to determine the necessary number of capacitors. They also need to calculate the number of capacitors in parallel and series, as well as other space-related parameters. This iterative calculation process is tedious, complex, and time-consuming. Furthermore, the large number of capacitors in parallel and series necessitates soldering, which is inconvenient. The increased number of capacitors in parallel and series increases the overall impedance of the module, and the lateral lead-out design occupies space on the PCB. Additionally, the commonly used Mylar tape encapsulation is unsuitable for outdoor environments and has relatively low voltage ratings. Utility Model Content

[0004] Therefore, the purpose of this utility model is to provide a multi-element integrated high-voltage capacitor to solve the technical problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a multi-element integrated high-voltage capacitor, comprising a housing, wherein a partition and a limiting strip are respectively fixed on the inner wall of the housing, a baffle is provided inside the housing, and two or more capacitor elements are provided on the top of the baffle, and leads are fixed at both ends of the capacitor elements, an injection hole is provided at the bottom of the baffle, and the gaps inside the housing are filled with sealant.

[0006] By adopting the above technical solution, customers can calculate and select the number or connection method of capacitor elements according to their needs. For example, when the total volume needs to be increased, multiple capacitor elements are connected in parallel; when the total withstand voltage needs to be increased, multiple capacitor elements are connected in series. The larger the required total volume or voltage, the more capacitor elements are needed. After determining the number and connection method of capacitor elements, the arrangement method of capacitor elements is selected, such as horizontal arrangement, vertical arrangement, rectangular distribution, etc. After determining the arrangement method, the dimensions of the outer casing and baffle are set. The size of the outer casing is larger than the combined size of the capacitor elements. The dimensions are designed to facilitate subsequent sealant application. The gap between the capacitor elements and the casing, as well as the thickness of the casing and baffle, are determined according to insulation requirements. For voltages greater than 100KV, the casing, baffle, and sealant thickness should be at least 15 mm. Epoxy resins with better insulation properties, such as alicyclic epoxy resins, can reduce the sealant thickness. The baffle is interference-fitted to the inner wall of the casing, and its position separates multiple capacitor elements. This type of high-voltage capacitor facilitates customer selection, allowing for customized design based on customer needs. The capacitor's characteristic parameters are intuitive, eliminating the need for complex calculations. Customers only need to specify the capacitor's specifications. The capacitance, DF, ESR, Irms, and other parameters of the capacitor are calculated cumulatively. When customers install this capacitor on a circuit board, instead of multiple traditional capacitors connected in parallel or series, only one traditional capacitor needs to be installed using this multi-element integrated high-voltage capacitor, reducing the complexity of the installation process. After the casing and other components are manufactured, the workers place the capacitor element with soldered leads on the baffle, with the two leads at the end of the series or parallel connection extending from the inclined side of the baffle. The workers then insert the baffle into the casing, at which point one end of the two leads extends to the bottom of the casing. The baffle is then placed inside the casing. The inner baffle is limited by a limiting strip to restrict its insertion depth. This prevents the baffle from being placed too deep, which would result in an insufficient gap between the capacitor element and the upper part of the inner casing, and also prevents the baffle from pressing down on the capacitor element and causing damage. Finally, the operator injects sealant into the inner casing through the injection hole and the gap between the side slope of the baffle and the inner wall of the casing. After the sealant cures, it completely isolates the capacitor element from the outside air, greatly improving the capacitor's moisture resistance and extending its service life in harsh outdoor environments. Furthermore, the high resistance of the sealant increases the capacitor's voltage withstand range.

[0007] Furthermore, both sides of the back of the baffle and one side of the outer surface are sloped.

[0008] By adopting the above technical solution, after the production of components such as the outer casing, the workers place the capacitor element with the soldered leads on the baffle, and the two leads at the end of the series or parallel group are led out from the inclined side of the baffle. Then the workers insert the baffle into the outer casing, at which point one end of the two leads extends to the bottom of the outer casing.

[0009] Furthermore, the top of the baffle abuts against the partition and the limiting strip.

[0010] By adopting the above technical solution, after the baffle is placed inside the shell, the baffle is limited by the limiting strip to limit the depth of the baffle. This avoids the baffle being placed too deep, which would cause the gap between the capacitor element and the upper part of the shell to be too small, and also avoids the baffle and the upper part of the shell pressing down on the capacitor element, which would damage the capacitor element.

[0011] Furthermore, there are two injection holes, and the two injection holes are symmetrically distributed.

[0012] By adopting the above technical solution, sealant is injected into the shell through the gap formed by the inclined surface of the baffle side and the injection hole. After the sealant cures, it completely isolates the capacitor elements from the outside air, greatly improving the capacitor's resistance to moisture and extending the capacitor's operating life in harsh outdoor environments.

[0013] Furthermore, multiple leads are provided, and two or more capacitor elements are connected in series or in parallel through the leads, wherein one end of two leads extends to both sides of the bottom of the outer casing.

[0014] By adopting the above technical solution, the series and parallel structure of the leads realizes the flexible configuration of the capacitor's electrical parameters, making it convenient for customers to select the right model. The characteristic parameters of the capacitor are intuitive, eliminating the need for complicated decomposition calculations. Customers can simply add up the capacitor's capacitance, DF, ESR, Irms, and other parameters.

[0015] Furthermore, the lead wire is made of tin-plated copper, and one or both ends of the lead wire are welded and fixed to the capacitor element.

[0016] By adopting the above technical solution, the tin-plated copper leads are welded and fixed to the capacitor elements. Combined with the high weldability and oxidation resistance of the tin plating layer, the long-term stability of the electrical connection is ensured.

[0017] Furthermore, the sealant is made of epoxy material.

[0018] By adopting the above technical solution, the epoxy resin achieves high bonding strength after curing, far exceeding the requirements of general sealants. This ensures that the internal components of the capacitor form a rigid whole with the outer shell, resisting vibration and impact. Simultaneously, its low shrinkage rate avoids sealing gaps caused by shrinkage, preventing the intrusion of external moisture and dust. Due to the PBT material outer shell, the volume resistivity and breakdown strength of the insulation performance are effectively blocked, preventing leakage paths from the high voltage inside the capacitor to the outside and reducing the occurrence of breakdown and short circuits. The surface is not easily carbonized under high-voltage arcing, maintaining most of the insulation performance and reducing the risk of insulation aging during long-term use. It has good anti-aging and weather resistance, allowing for long-term use. It also features resistance to high operating temperatures, chemical corrosion, and water vapor penetration, effectively protecting the capacitor elements and preventing the sealant from melting due to high capacitor element operating conditions.

[0019] Furthermore, the sealant uses an epoxy material consisting of 65% epoxy resin, 25% aluminum oxide, and 10% boron nitride, and the surfaces of the aluminum oxide and boron nitride are treated with a silane coupling agent.

[0020] By adopting the above technical solution, boron nitride and alumina are compounded and treated with a silane coupling agent to reduce the interfacial tension between alumina and boron nitride and epoxy resin, reducing interfacial bubbles. The lamellar structure of boron nitride forms a layered heat conduction path, and the spherical particles of alumina fill the pores, constructing a three-dimensional heat conduction network. Compared with pure epoxy resin, its heat dissipation is effectively improved, and its coefficient of thermal expansion is similar to that of PBT materials used in the shell, reducing stress cracking. Furthermore, both alumina and boron nitride are insulating materials, reducing the negative impact on the insulation of the sealant.

[0021] Furthermore, the outer shell, partition, limiting strip, and baffle are all made of PBT material, and the outer shell, partition, and limiting strip are integrally injection molded.

[0022] By adopting the above technical solution, PBT achieves a high volume resistivity, typically ≥10¹⁰. 5 With a strength of Ω·cm, far exceeding the requirements of general insulation materials, PBT can effectively block the risk of leakage from the high voltage inside the capacitor to the outside. Furthermore, PBT's breakdown strength is ≥18kV / mm, enabling it to withstand the strong electric field during capacitor operation. Simultaneously, PBT's surface resistance is ≥10¹³Ω, making it less prone to static charge accumulation and reducing surface discharge or corona phenomena under high voltage. This makes it particularly suitable for the long-term stable operation of high-voltage capacitors. In addition to its excellent insulation performance, PBT's balance of rigidity and impact resistance provides mechanical protection for internal capacitor elements, resisting vibration and impact during transportation or installation. It also exhibits good creep resistance and is not easily deformed. Furthermore, PBT's low coefficient of linear expansion reduces the occurrence of sealing failures caused by thermal expansion and contraction, and minimizes the compression of capacitor elements due to deformation.

[0023] Furthermore, the PBT material used for the outer shell, partition, limiting strip, and baffle consists of 60% PBT, 30% alumina, and 10% aluminum nitride, and the surfaces of the alumina and aluminum nitride are treated with a silane coupling agent.

[0024] By adopting the above technical solution, alumina and aluminum nitride are also treated with silane coupling agent to enhance the interfacial bonding force with PBT and avoid local insulation weaknesses caused by filler agglomeration. Aluminum nitride acts as a thermally conductive bridge agent to fill the gaps between alumina particles and build a continuous thermally conductive network, thereby increasing the heat dissipation capacity of the shell. This allows the capacitor element to dissipate heat not only through the leads but also through the shell and sealant to meet some of the heat dissipation requirements.

[0025] In summary, the present invention has the following main advantages: 1. This utility model utilizes a casing, capacitor elements, and leads. The casing and partitions enclose the capacitor elements, and the capacitor element leads extend from the partitions and the bottom of the casing to form a capacitor. Two or more capacitor elements are connected in parallel or series inside the casing. The number of capacitor elements, the connection method between them, the arrangement of them, the casing size, and the partition size are customized according to customer requirements. For example, if the customer requires two capacitor elements in series, it is shown in the figure. Customer selection is convenient, and the capacitor's characteristic parameters are intuitive, eliminating the need for complex calculations. Customers simply add up the capacitor's capacitance, DF, ESR, Irms, and other parameters, select the number of capacitor elements and the connection method between them, and then select the arrangement of them, the casing size, and the partition size. During installation, customers do not need to connect multiple capacitors in series or parallel on the circuit board; they only need to install this multi-element integrated high-voltage capacitor, simplifying the customer's work. Compared to connecting multiple capacitors in series or parallel on the circuit board, it occupies less PCB space and reduces the overall size of the equipment. 2. This utility model, through the setting of a shell, limiting strip and baffle, places the capacitor element on the top of the baffle. The limiting strip limits the insertion depth of the baffle to prevent the baffle from squeezing the capacitor element against the inner wall of the shell. The shell and partition form a shell to wrap several capacitor elements, which facilitates subsequent glue injection; the encapsulation provides coarse protection for the capacitor elements. 3. This utility model, through the setting of the injection hole and sealant, injects sealant into the shell through the gap formed by the inclined surface of the side of the baffle and the injection hole. After the sealant cures, it completely isolates the capacitor elements from the outside air, greatly improving the capacitor's resistance to moisture and extending its service life in harsh outdoor environments. In addition, the sealant has high resistance, which improves the capacitor's voltage withstand range. It has a wide range of applications and can work normally even in outdoor environments. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a schematic diagram of the exploded structure of this utility model; Figure 3 This is a cross-sectional structural diagram of the present invention; Figure 4 This is a bottom view schematic diagram of the baffle structure of this utility model; Figure 5 This is a schematic diagram of the capacitor element structure of this utility model.

[0027] In the diagram: 1. Outer shell; 2. Partition plate; 3. Limiting strip; 4. Baffle plate; 5. Injection hole; 6. Capacitor element; 7. Lead wire; 8. Sealant. Detailed Implementation

[0028] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0029] The embodiments of this utility model will be described below based on its overall structure.

[0030] Example 1: A multi-element integrated high-voltage capacitor, such as Figures 1-5 As shown, the device includes an outer shell 1. A partition 2 and a limiting strip 3 are fixed to the inner wall of the outer shell 1. A baffle 4 is installed inside the outer shell 1. The outer shell 1, partition 2, limiting strip 3, and baffle 4 are all made of PBT material. The outer shell 1, partition 2, and limiting strip 3 are integrally injection molded. The back sides and one side of the outer surface of the baffle 4 are sloped. The top of the baffle 4 abuts against the partition 2 and the limiting strip 3. Two or more capacitor elements 6 are installed on the top of the baffle 4. Leads 7 are fixed to both ends of each capacitor element 6. Multiple leads 7 are provided. The leads 7 are made of tin-plated copper. One or both ends of the leads 7 are welded to the capacitor elements 6. Two or more capacitor elements 6 are connected in series or parallel through the leads 7. One end of two leads 7 extends to the bottom sides of the outer shell 1. The customer calculates and selects the number or connection method of capacitor elements 6 according to their needs. For example, when the total volume needs to be increased, multiple capacitor elements 6 are used... The capacitor elements 6 are connected in parallel. When the total withstand voltage needs to be increased, multiple capacitor elements 6 are connected in series. The larger the required total volume or total voltage, the more capacitor elements 6 are needed. After determining the number and connection method of capacitor elements 6, the arrangement method of capacitor elements 6 is selected, such as horizontal arrangement, vertical arrangement, rectangular distribution, etc. After determining the arrangement method, the size of the outer shell 1 and the baffle 4 is set. The size of the outer shell 1 is larger than the size of the combined capacitor elements 6 to facilitate the subsequent injection of sealant 8. The gap between capacitor elements 6 and outer shell 1, as well as the thickness of outer shell 1 and baffle 4, are determined according to the insulation requirements. If it is required to be greater than 100KV, the thickness of outer shell 1, baffle 4, and sealant 8 should be at least 15 mm. Epoxy resin with better insulation properties, such as alicyclic epoxy resin, can reduce the thickness of sealant 8. The baffle 4 is interference-fitted with the inner wall of outer shell 1, and the position of the partition 2 can separate multiple capacitor elements 6.

[0031] See Figures 1-5In the above embodiment, the bottom of the baffle 4 is provided with two injection holes 5, which are symmetrically distributed. The gap inside the outer shell 1 is filled with sealant 8, which is made of epoxy material. The operator injects the sealant 8 into the inner wall of the outer shell 1 through the injection holes 5 and the gap between the side slope of the baffle 4 and the inner wall of the outer shell 1. After the sealant 8 is cured, it completely isolates the capacitor element 6 from the outside air, which greatly improves the moisture resistance of the capacitor and increases the service life of the capacitor in harsh outdoor environments. In addition, the sealant 8 has a high resistance, which improves the voltage withstand range of the capacitor.

[0032] Example 2: Based on the above embodiment 1, in order to increase the heat dissipation of sealant 8, the following settings are now implemented.

[0033] See Figure 1 and Figure 3 In the above embodiments, the epoxy material used in sealant 8 consists of 65% epoxy resin, 25% alumina, and 10% boron nitride. The surfaces of alumina and boron nitride are treated with a silane coupling agent. By compounding boron nitride with alumina and treating with a silane coupling agent, the interfacial tension between alumina and boron nitride and epoxy resin is reduced, reducing interfacial bubbles. The lamellar structure of boron nitride forms a layered heat conduction path, and the spherical particles of alumina fill the pores, constructing a three-dimensional heat conduction network. Compared with pure epoxy resin, its heat dissipation is effectively improved, and its coefficient of expansion is similar to that of PBT material such as shell 1, reducing stress cracking. Furthermore, both alumina and boron nitride are insulating materials, reducing the negative impact on the insulation of sealant 8.

[0034] Example 3: Based on the above embodiment 1, in order to increase the heat dissipation of the outer casing 1, the following settings are now implemented.

[0035] See Figures 1-5 In the above embodiments, the PBT material used for the outer shell 1, partition 2, limiting strip 3 and baffle 4 is composed of 60% PBT, 30% alumina and 10% aluminum nitride. Similarly, the alumina and aluminum nitride are treated with silane coupling agent to enhance the interfacial bonding with PBT and avoid local insulation weaknesses caused by filler agglomeration. Aluminum nitride acts as a thermally conductive bridge to fill the gaps between alumina particles and build a continuous thermally conductive network, thereby increasing the heat dissipation capacity of the outer shell 1. This allows the capacitor element 6 to dissipate heat not only by relying on the lead wire 7, but also by meeting some of the heat dissipation requirements through the outer shell 1 and sealant 8.

[0036] The implementation principle of this utility model is as follows: First, the customer calculates according to their needs and selects the number or connection method of capacitor elements 6; for example, when the total volume needs to be increased, multiple capacitor elements 6 are connected in parallel; when the total withstand voltage needs to be increased, multiple capacitor elements 6 are connected in series; the larger the required total volume or total voltage, the more capacitor elements 6 are needed; after determining the number and connection method of capacitor elements 6, the arrangement method of capacitor elements 6 is selected, such as horizontal arrangement, vertical arrangement, rectangular distribution, etc.; after determining the arrangement method, the dimensions of the outer shell 1 and the baffle 4 are set. The dimension of the outer shell 1 is larger than the dimension of the assembled capacitor elements 6 to facilitate the subsequent injection of sealant 8. The gap between the capacitor elements 6 and the outer shell 1, as well as the thickness of the outer shell 1 and the baffle 4, are determined according to the insulation requirements, such as... For voltages greater than 100KV, the thickness of the outer casing 1, baffle 4, and sealant 8 must be at least 15 mm. Using epoxy resin with better insulation, such as alicyclic epoxy resin, can reduce the thickness of sealant 8. The baffle 4 is interference-fitted with the inner wall of the outer casing 1, and the partition 2 can separate multiple capacitor elements 6. This type of high-voltage capacitor makes selection convenient for customers, allowing for customized design based on their needs. The capacitor's characteristic parameters are intuitive, eliminating the need for complex decomposition calculations. Customers only need to calculate the capacitance, DF, ESR, Irms, and other parameters. When installing this capacitor on a circuit board, where multiple traditional capacitors would normally require parallel or series connection, this multi-element integrated high-voltage capacitor only requires one installation, reducing the complexity of the installation process. After the outer casing 1 and other components are manufactured, the workers place the capacitor element 6 with the soldered leads 7 on the baffle 4, with the two leads 7 at the end of the series or parallel connection extending out from the inclined side of the baffle 4. Then, the workers insert the baffle 4 into the outer casing 1, at which point one end of the two leads 7 extends to the bottom of the outer casing 1. After the baffle 4 is inserted into the outer casing 1, the limiting strip 3 limits the depth of the baffle 4, preventing it from being placed too deep and causing the gap between the capacitor element 6 and the upper part of the inner casing 1 to be too small, and preventing the baffle 4 from pressing down on the capacitor element 6 and causing damage to it. Finally, the workers inject sealant 8 into the inner casing 1 through the injection hole 5 and the gap between the inclined side of the baffle 4 and the inner wall of the outer casing 1. After the sealant 8 cures, it completely isolates the capacitor element 6 from the outside air, greatly improving the capacitor's moisture resistance and extending its operating life in harsh outdoor environments. In addition, the sealant 8 has a high resistance, which improves the capacitor's voltage withstand range.

[0037] Although embodiments of the present invention have been shown and described, these specific embodiments are merely explanations of the present invention and are not intended to limit the invention. The specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. After reading this specification, those skilled in the art may make modifications, substitutions, and variations to the embodiments as needed without departing from the principles and spirit of the present invention, provided that such modifications, substitutions, and variations are within the scope of the claims of the present invention and are protected by patent law.

Claims

1. A multi-element integrated high-voltage capacitor, comprising a housing (1), characterized in that: The inner wall of the outer shell (1) is fixed with a partition (2) and a limiting strip (3). A baffle (4) is provided inside the outer shell (1), and two or more capacitor elements (6) are provided on the top of the baffle (4). Both ends of the capacitor elements (6) are fixed with leads (7). An injection hole (5) is opened at the bottom of the baffle (4). The gaps inside the outer shell (1) are filled with sealant (8).

2. The multi-element integrated high-voltage capacitor according to claim 1, characterized in that: The back sides and one side of the outer surface of the baffle (4) are all sloped.

3. The multi-element integrated high-voltage capacitor according to claim 2, characterized in that: The top of the baffle (4) abuts against the partition (2) and the limiting strip (3).

4. The multi-element integrated high-voltage capacitor according to claim 1, characterized in that: There are two injection holes (5), and the two injection holes (5) are symmetrically distributed.

5. The multi-element integrated high-voltage capacitor according to claim 1, characterized in that: The lead wire (7) is provided in multiple ways, and two or more capacitor elements (6) are connected in series or in parallel through the lead wire (7), wherein one end of two lead wires (7) extends to both sides of the bottom of the outer shell (1).

6. The multi-element integrated high-voltage capacitor according to claim 5, characterized in that: The lead wire (7) is made of tin-plated copper, and one or both ends of the lead wire (7) are welded and fixed to the capacitor element (6).

7. The multi-element integrated high-voltage capacitor according to claim 1, characterized in that: The sealant (8) is made of epoxy material.

8. The multi-element integrated high-voltage capacitor according to claim 1, characterized in that: The outer shell (1), partition (2) and limiting strip (3) are integrally injection molded.

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