Capacitors and dc support capacitors

Abstract

The application discloses a capacitor and a direct-current support capacitor. The capacitor comprises a capacitor winding core and a busbar. The busbar is made of aluminum material, which can greatly reduce the cost of the capacitor compared with copper material in the prior art. The application further provides the relationship between the busbar and the capacitor winding core, and the specification parameters of the busbar. The ratio of the covering area of the busbar to the area of the connecting surface is greater than or equal to 80%, and the thickness of the busbar is greater than or equal to 0.5 mm. Based on the above, on the one hand, the busbar made of aluminum material can fully utilize the space of the connecting surface of the capacitor winding core, so that the busbar has a large enough area, and the thickness of the busbar is appropriately increased, thereby guaranteeing the performance of the busbar made of aluminum material, guaranteeing that the conductive performance of the busbar made of aluminum material is close to or better than that of the copper busbar, thereby reducing the cost of the capacitor, and guaranteeing the reliability of the capacitor.

Description

Technical Field

[0001] This utility model relates to the field of capacitor assembly technology, and in particular to a capacitor and a DC support capacitor. Background Technology

[0002] Currently, existing capacitors are widely used in new energy vehicles, electronic and electrical equipment, DC power transmission and distribution, electric locomotives, wind power, solar power grid connection and other fields. A capacitor usually consists of a capacitor busbar and a capacitor core. The capacitor busbar is connected to the capacitor core. Most existing capacitor busbars are made of copper. In order to ensure current carrying capacity, the capacitor busbar usually has a large area and a thickness of 0.5-3mm. The material cost is relatively high, which is one of the main factors leading to the high cost of capacitors. Utility Model Content

[0003] The description of the utility model introduces a series of simplified concepts, which will be further explained in detail in the detailed description section. This part of the utility model is not intended to limit the key features and essential technical features of the claimed technical solution, nor is it intended to determine the scope of protection of the claimed technical solution.

[0004] The present invention aims to solve at least one of the technical problems existing in the prior art or related technologies.

[0005] Therefore, the first aspect of this utility model provides a capacitor.

[0006] A second aspect of this invention provides a DC support capacitor.

[0007] In view of this, embodiments of this application propose a capacitor, comprising: Capacitor winding core; Busbar, the busbar is made of aluminum and is welded to the capacitor core; Wherein, the surface where the capacitor core is connected to the busbar is the connecting surface, the ratio of the area covered by the busbar on the connecting surface to the area of ​​the connecting surface is greater than or equal to 80%, and the thickness of the busbar is greater than or equal to 0.5mm.

[0008] In one feasible implementation, there are multiple capacitor cores, which are arranged at intervals, and the busbar is connected to the multiple capacitor cores. The busbar covers multiple capacitor cores in width.

[0009] In one feasible implementation, the busbar is connected to the capacitor core by laser welding.

[0010] In one feasible implementation, the busbar includes: Busbar body; Multiple channels are formed on the busbar body; Multiple welded components, the groove is formed on the periphery of the welded component, the welded component and the busbar body are an integral structure, and the welded component is connected to the capacitor core.

[0011] In one feasible implementation, the weldment is needle-shaped, and the ratio of the area of ​​the weldment to the area of ​​the groove is less than or equal to 0.1.

[0012] In one feasible implementation, the welded part is planar, and the ratio of the area of ​​the welded part to the area of ​​the tank is greater than or equal to 0.8.

[0013] In one feasible implementation, the capacitor core includes: Core insertion; A metal film, which is wound around the core and inserted inside it; Wherein, the connection end of the welded component and the busbar is located away from the core insertion, and the welded component at least covers a portion of the core insertion area.

[0014] In one feasible implementation, each of the capacitor cores includes two connecting surfaces, each of which is connected to a busbar.

[0015] In one feasible implementation, the capacitor further includes: Busbar terminals, wherein the busbar terminals are connected to the busbar; Wherein, the busbar terminals are made of a material with a higher conductivity than the busbar, and the busbar terminals are laser-welded to the busbar; or The busbar terminals are made of the same material as the busbar, and the busbar terminals and the busbar are an integral structure.

[0016] In one feasible implementation, there are multiple busbar terminals, and the ratio of the sum of the widths of the multiple busbar terminals to the length of the busbar is greater than or equal to 50%.

[0017] A second aspect of the embodiments of this application provides a DC support capacitor, comprising: The capacitor as described in any of the above technical solutions; An aluminum electrode busbar, the aluminum electrode busbar being connected to the capacitor; The magnetic core through which the aluminum electrode array passes; Safety capacitors, connected to the aluminum electrode busbar, are arranged on the side of the magnetic core.

[0018] Compared with the prior art, the present invention has at least the following beneficial effects: The capacitor provided in this application includes a capacitor core and a busbar. The busbar is made of aluminum. Compared to copper in traditional technology, copper and aluminum of the same area and thickness can have a cost difference of about 14 times due to differences in density and unit price. Therefore, this application can significantly reduce the cost of the capacitor. Furthermore, considering that copper has significantly better conductivity than aluminum, this application further provides the relationship between the busbar and the capacitor core, and provides the specifications of the busbar. The ratio of the busbar's coverage area to the area of ​​the connection surface is greater than or equal to 80%, and the thickness of the busbar is greater than or equal to 0.5 mm. This allows the aluminum-made busbar to fully utilize the space of the capacitor core's connection surface, resulting in a sufficiently large busbar area. The increased thickness of the busbar also ensures the performance of the aluminum-made busbar, guaranteeing that its conductivity is close to or better than that of a copper busbar. This reduces the cost of the capacitor while ensuring its reliable operation.

[0019] The capacitor provided in this application embodiment is based on the following principle: during the capacitor's operation, the busbar and the capacitor core work together to complete the transfer and storage of charge. During the charging phase, the current from the external circuit first flows into the busbar (the positive busbar receives positive charge, and the negative busbar receives negative charge). The busbar acts as a conductive hub, evenly distributing the current to the capacitor core. The capacitor core, as the charge storage core, ensures that the charge is stably stored within it. During the discharging phase, the charge stored in the capacitor core is transferred to the busbar. The busbar collects the current from the capacitor core and sends it to the external circuit, thereby releasing electrical energy. Throughout this process, the busbar distributes and collects the current, while the core is used for charge storage and release.

[0020] The above description is merely an overview of the technical solution of this utility model. In order to better understand the technical means of this utility model and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this utility model more obvious and understandable, specific embodiments of this utility model are given below. Attached Figure Description

[0021] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this application. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings: Figure 1 A schematic structural diagram of a capacitor according to an embodiment of this application; Figure 2A schematic structural diagram of the busbar of a capacitor according to one embodiment of this application; Figure 3 A schematic structural diagram of the capacitor core of a capacitor according to one embodiment of this application; Figure 4 A schematic structural diagram of a capacitor according to an embodiment of this application; Figure 5 A schematic structural diagram of the busbar of a capacitor according to one embodiment of this application; Figure 6 This is a schematic structural diagram of a DC support capacitor provided in one embodiment of this application.

[0022] in, Figures 1 to 6 The correspondence between the reference numerals and component names in the attached drawings is as follows: 110 capacitor winding core, 120 busbar, 130 busbar terminals; 111 Connecting surface, 112 Core insert, 113 Metal film, 121 Busbar body, 122 Channel, 123 Welded parts; 210 aluminum electrode busbar, 220 safety capacitor, 230 magnetic core. Detailed Implementation

[0023] The following description provides numerous specific details to offer a more thorough understanding of the technical solutions provided by this invention. However, it will be apparent to those skilled in the art that the technical solutions provided by this invention can be implemented without one or more of these details.

[0024] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to the present invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms “comprising” and / or “including” are used in this specification, they indicate the presence of features, integrals, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or combinations thereof.

[0025] Exemplary embodiments according to the present invention will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of the present invention is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art.

[0026] like Figures 1 to 5As shown in the embodiment of this application, a capacitor is proposed, including: a capacitor core 110; a busbar 120, the busbar 120 being made of aluminum and welded to the capacitor core 110; wherein, the surface where the capacitor core 110 and the busbar 120 are connected is the connecting surface 111, the ratio of the area covered by the busbar 120 on the connecting surface 111 to the area of ​​the connecting surface 111 is greater than or equal to 80%, and the thickness of the busbar 120 is greater than or equal to 0.5 mm.

[0027] The capacitor provided in this application includes a capacitor core 110 and a busbar 120. The busbar 120 is made of aluminum. Compared with copper in the conventional technology, copper and aluminum of the same area and thickness can have a cost difference of about 14 times due to differences in density and unit price. Based on this, the implementation of this application can greatly reduce the cost of the capacitor. Considering that copper has significantly better conductivity than aluminum, this application further provides the relationship between the busbar 120 and the capacitor core 110, and provides the specifications of the busbar 120. The ratio of the area covered by the busbar 120 to the area of ​​the connection surface 111 is greater than or equal to 80%, and the thickness of the busbar 120 is greater than or equal to 0.5 mm. Based on this, on the one hand, the aluminum-made busbar 120 can make full use of the space of the connection surface 111 of the capacitor core 110, so that the busbar 120 has a sufficiently large area. At the same time, the thickness of the busbar 120 is appropriately increased, thereby ensuring the performance of the aluminum-made busbar 120. This ensures that the conductivity of the aluminum-made busbar 120 is close to or better than that of the copper-made busbar 120, thereby reducing the cost of the capacitor and ensuring the reliability of the capacitor operation.

[0028] Specifically, the copper busbar 120 and the busbar 120 provided in the embodiments of this application can be compared in the table below, taking into account that the resistivity of copper is 1.68 × 10⁻⁶. -8 Ω m, the resistivity of aluminum is 2.65 × 10⁻⁶ m. -8 Ω m, which means that the resistivity of copper is 62.5% of that of aluminum. Based on this and in conjunction with Table 1 below, this application can ensure the conductivity of the capacitor by controlling the coverage area of ​​the busbar 120 on the capacitor core 110 and combining it with the thickness of the busbar 120, while not increasing the volume of the capacitor too much, and thus greatly reducing the cost of the capacitor.

[0029] Table 1 Comparison of Copper Busbars and Aluminum Busbars

[0030] The capacitor provided in this application embodiment, based on this, achieves charge transfer and storage through functional cooperation between the busbar 120 and the capacitor core 110 during capacitor operation: During the charging phase, current from the external circuit first flows into the busbar 120 (the positive busbar receives positive charge, and the negative busbar receives negative charge). The busbar 120 acts as a conductive hub, evenly distributing the current to the capacitor core 110; the capacitor core 110 acts as the charge storage core, ensuring stable charge storage within the capacitor core 110. During the discharging phase, the charge stored in the capacitor core 110 is transferred to the busbar 120. The busbar 120 collects the current from the capacitor core 110 and transmits it to the external circuit, thereby releasing electrical energy. Throughout this process, the busbar 120 distributes and collects the current, while the core is used for charge storage and release.

[0031] like Figures 1 to 5 As shown, in one feasible embodiment, there are multiple capacitor cores 110, which are arranged at intervals, and a busbar 120 is connected to the multiple capacitor cores 110; wherein, the busbar 120 covers the multiple capacitor cores 110 in width.

[0032] In this technical solution, the number of capacitor winding cores 110 is further provided. Considering that a single capacitor winding core 110 may not meet the upper limit of capacity requirements, there can be multiple capacitor winding cores 110, and the busbar 120 is connected to multiple capacitor winding cores 110 at the same time. Based on this, the capacitor can meet the requirements of large capacity, while also improving the current carrying capacity and ensuring the performance of the capacitor.

[0033] In this technical solution, the busbar 120 covers multiple capacitor cores 110 in width. Based on this, the space of the end faces of the multiple capacitor cores 110 can be fully utilized, so that the busbar 120 can have a sufficiently large area to meet the conductivity requirements.

[0034] like Figures 1 to 5 As shown, in one feasible embodiment, the busbar 120 is connected to the capacitor core 110 by laser welding.

[0035] This technical solution further provides a connection method between the busbar 120 and the capacitor core 110. When the busbar 120 and the capacitor core 110 are welded, a laser can provide heat energy to the aluminum busbar 120. A portion of the aluminum busbar 120 melts to form a molten pool. After the molten pool solidifies, the busbar 120 can establish a connection with the capacitor core 110. The laser welding method replaces the traditional tin soldering process, making the connection between the aluminum busbar 120 and the capacitor core 110 more reliable and more tightly fixed. This ensures efficient conductivity between the capacitor core 110 and the busbar 120, reducing capacitor costs while ensuring or even improving capacitor performance.

[0036] like Figures 1 to 5 As shown, in one feasible embodiment, the busbar 120 includes: a busbar body 121; a plurality of grooves 122 formed on the busbar body 121; and a plurality of welded parts 123, wherein the grooves 122 are formed on the periphery of the welded parts 123, the welded parts 123 and the busbar body 121 are integrally formed, and the welded parts 123 are connected to the capacitor core 110.

[0037] In this technical solution, considering that there may be multiple capacitor cores 110, the connection surfaces 111 of the multiple capacitor cores 110 may not be on the same plane when they are arranged. If there is only one capacitor core 110, the connection surface 111 of the capacitor core 110 may not be on the same plane either. Based on this, a structure of busbar 120 is further provided. Busbar 120 may include busbar body 121, multiple slots 122 and welding parts 123. During the processing of busbar 120, slots 122 can be formed by punching and milling on busbar body 121. A part of the aluminum structure is retained in the slot 122. This structure can serve as welding parts 123, so that welding parts 123 can be directly located in the slots 122, which is convenient for the production and processing of busbar 120. During the welding process, welding parts 123 can be pressed to make welding parts 123 more fully contact with capacitor cores 110, thereby facilitating a stable connection between busbar 120 and capacitor cores 110.

[0038] like Figures 1 to 3 As shown, in one feasible embodiment, the weldment 123 is needle-shaped, and the ratio of the area of ​​the weldment 123 to the area of ​​the groove 122 is less than or equal to 0.1.

[0039] In this technical solution, the style of the welding part 123 is further provided. The ratio of the area of ​​the welding part 123 to the area of ​​the groove 122 is less than or equal to 0.1, so that the welding part 123 can be needle-shaped, which makes it easier to adjust the position of the welding part 123 and press the welding part 123, so that the welding part 123 can make better contact with the capacitor busbar 120.

[0040] like Figures 4 to 5 As shown, in one feasible embodiment, the weldment 123 is planar, and the ratio of the area of ​​the weldment 123 to the area of ​​the tank 122 is greater than or equal to 0.8.

[0041] In this technical solution, another style of welding component 123 is provided. The ratio of the area of ​​welding component 123 to the area of ​​tank 122 is greater than or equal to 0.8, so that welding component 123 can be planar. Based on this, a welding component 123 and capacitor core 110 can have a larger contact area, and a welding component 123 and capacitor core 110 can have more solder joints, thereby improving the reliability of the electrical connection between busbar 120 and capacitor core 110.

[0042] In one feasible embodiment, the capacitor core 110 includes: a core insert 112; a metal film 113 wound around the core insert 112; wherein the connection end of the welded part 123 and the busbar 120 is disposed away from the core insert 112, and the welded part 123 covers at least a portion of the core insert 112.

[0043] In this technical solution, the structural composition of the capacitor core 110 is further provided. The capacitor core 110 may include a core insert 112 and a metal film 113 wound on the core insert 112 to ensure the mechanical strength of the capacitor core 110. The connection end of the welded part 123 and the busbar 120 is located away from the core insert 112, and the welded part 123 covers at least a part of the core insert 112, so that a larger area of ​​the welded part 123 covers the gold spray layer of the capacitor core 110, which can further increase the connection area 111 between the capacitor core 110 and the busbar 120.

[0044] In one feasible implementation, each capacitor core 110 includes two connecting surfaces 111, each of which is connected to a busbar 120. This arrangement facilitates the charging and discharging of the capacitor core 110.

[0045] In one feasible embodiment, the capacitor further includes a busbar terminal 130 connected to the busbar 120. This arrangement facilitates the input and output of electrical energy.

[0046] In one feasible implementation, the busbar terminal 130 is made of a material with a higher conductivity than the busbar 120, and the busbar terminal 130 is laser welded to the busbar 120.

[0047] In this technical solution, considering that the width and size of the busbar terminal 130 will inevitably be smaller than the size of the busbar 120, the busbar terminal 130 can also be made of a different material than the busbar 120, such as copper, which can ensure efficient input and output of electrical energy. By welding the busbar terminal 130 to the busbar 120, the reliability of the connection between the two can be ensured.

[0048] In one feasible implementation, the busbar terminal 130 and the busbar 120 are made of the same material, and the busbar terminal 130 and the busbar 120 are an integral structure. This arrangement allows for the simultaneous fabrication of the busbar 120 and the busbar terminal 130, further reducing the production cost of the capacitor. Simultaneously, the integral molding of the busbar terminal 130 and the busbar 120 further improves conductivity.

[0049] In one feasible implementation, there are multiple busbar terminals 130, and the ratio of the sum of the widths of the multiple busbar terminals 130 to the length of the busbar 120 is greater than or equal to 50%. The arrangement of multiple busbar terminals 130 facilitates the input and output of electrical energy. Furthermore, the ratio of the sum of the widths of the multiple busbar terminals 130 to the length of the busbar 120 being greater than or equal to 50% ensures good electrical conductivity between the busbar terminals 130 and the busbar 120.

[0050] like Figure 6 As shown, a DC support capacitor is provided according to a second aspect of the embodiments of this application, comprising: a capacitor as described in any of the above technical solutions; an aluminum electrode busbar 210 connected to the capacitor; a magnetic core 230 through which the aluminum electrode busbar 210 passes; and a safety capacitor 220 connected to the aluminum electrode busbar 210 and arranged on the side of the magnetic core 230.

[0051] The DC support capacitor provided in this application embodiment includes capacitors as described in any of the above technical solutions, and therefore possesses all the beneficial effects of capacitors in the above technical solutions.

[0052] The DC support capacitor provided in this embodiment integrates filtering functionality. When the DC support capacitor is working, external circuit power is first transferred to the core aluminum busbar 120 capacitor via the aluminum electrode busbar 210. During the charging phase, the aluminum busbar 120 evenly distributes the current to each capacitor core 110, where the core stores charge. During the discharging phase, the charge released by the core is collected by the busbar 120 and then transported to the external circuit via the aluminum electrode busbar 210. In this process, the aluminum electrode busbar 210 passes through the magnetic core 230, which filters interference signals in the current. Simultaneously, the safety capacitor 220 on the side further absorbs residual noise. This dual action ensures the stability of the output current, guaranteeing the coordinated operation of power support and interference suppression by the DC support capacitor in the circuit. The DC support capacitor balances cost, performance, and functional integration. First, the core capacitor uses an aluminum busbar 120 combined with aluminum electrode busbars 210, both made of aluminum, saving over 85% of material costs compared to traditional copper busbars. The lightweight nature of aluminum also reduces overall weight, making it suitable for cost- and weight-sensitive applications such as new energy vehicles. Second, the aluminum busbar 120, through optimization of its coverage area, thickness, and cross-sectional area, achieves conductivity close to or better than copper busbars, ensuring efficient power transmission. Third, the integrated magnetic core 230 and safety capacitor 220 eliminate the need for additional external filter components, simplifying the circuit structure and saving installation space. Simultaneously, the dual-filter design effectively suppresses current interference, improving circuit reliability and meeting the high stability requirements of DC power transmission and distribution, wind power conversion, and other fields.

[0053] In this utility model, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance; the term "multiple" refers to two or more unless otherwise explicitly defined. The terms "install," "connect," "join," and "fix" should be interpreted broadly. For example, "connect" can be a fixed connection, a detachable connection, or an integral connection; "join" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0054] In the description of this utility model, it should be understood that the terms "upper", "lower", "left", "right", "front", "rear", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or unit referred to must have a specific orientation or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0055] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0056] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A capacitor, characterized in that, include: Capacitor winding core; Busbar, the busbar is made of aluminum and is welded to the capacitor core; Wherein, the surface where the capacitor core is connected to the busbar is the connecting surface, the ratio of the area covered by the busbar on the connecting surface to the area of ​​the connecting surface is greater than or equal to 80%, and the thickness of the busbar is greater than or equal to 0.5mm.

2. The capacitor according to claim 1, characterized in that, The capacitor winding core is a plurality of capacitor winding cores, which are arranged at intervals, and the busbar is connected to the plurality of capacitor winding cores; The busbar covers multiple capacitor cores in width.

3. The capacitor according to claim 1, characterized in that, The busbar is connected to the capacitor core by laser welding.

4. The capacitor according to claim 3, characterized in that, The busbar includes: Busbar body; Multiple channels are formed on the busbar body; Multiple welded components, the groove is formed on the periphery of the welded component, the welded component and the busbar body are an integral structure, and the welded component is connected to the capacitor core.

5. The capacitor according to claim 4, characterized in that, The welded part is needle-shaped, and the ratio of the area of ​​the welded part to the area of ​​the tank is less than or equal to 0.

1.

6. The capacitor according to claim 4, characterized in that, The welded part is planar, and the ratio of the area of ​​the welded part to the area of ​​the tank is greater than or equal to 0.

8.

7. The capacitor according to claim 4, characterized in that, The capacitor core includes: Core insertion; A metal film, which is wound around the core and inserted inside it; Wherein, the connection end of the welded component and the busbar is located away from the core insertion, and the welded component at least covers a portion of the core insertion area.

8. The capacitor according to any one of claims 1 to 7, characterized in that, Each of the capacitor cores includes two connecting surfaces, and each connecting surface is connected to a busbar.

9. The capacitor according to any one of claims 1 to 7, characterized in that, Also includes: Busbar terminals, wherein the busbar terminals are connected to the busbar; Wherein, the busbar terminals are made of a material with a higher conductivity than the busbar, and the busbar terminals are laser-welded to the busbar; or The busbar terminals are made of the same material as the busbar, and the busbar terminals and the busbar are an integral structure; The busbar terminals are multiple, and the ratio of the sum of the widths of the multiple busbar terminals to the length of the busbar is greater than or equal to 50%.

10. A DC-supported capacitor, characterized in that, include: The capacitor as described in any one of claims 1 to 9; An aluminum electrode busbar, the aluminum electrode busbar being connected to the capacitor; Magnetic core, through which the aluminum electrode array passes; Safety capacitors, connected to the aluminum electrode busbar, are arranged on the side of the magnetic core.

Images