Capacitor element and method of encapsulating a capacitor base body

The present disclosure relates to a capacitor element and, in particular, to an encapsulation of a capacitor element. Such a capacitor may be used as a motor run capacitor in electric motor driven equipments such as refrigerators and washing machines, for example.

It is the aim of the present invention to provide a cost- effective encapsulated capacitor element and a method of manufacturing such an encapsulated capacitor element.

A capacitor element comprising a capacitor base body and an encapsulation of the base body is provided. The encapsulation is injection-molded directly onto the base body. The basebody may be designed as a film capacitor comprising dielectric films. Electrode layers may be provided in the form of metallizations applied to the dielectric films.

Preferably, the dielectric films comprise a plastic material. In particular, the dielectric films may comprise

polypropylene or polyester. Preferably, the metallized dielectric films are wound together, for example in a

cylindrical fashion.

Preferably, a manufacturing process of encapsulating the base body comprises the steps of inserting the capacitor base body in a mold and injecting a molding material into the mold, whereby an encapsulated capacitor element is formed. After that, the encapsulated capacitor element can be separated from the mold. The encapsulation may comprise a plastic material. In

particular, the encapsulation may comprise at least one of polypropylene, polybutylene terephthalate (PBT) , nylon, a high density polyethylene (HDPE) or a low density

polyethylene (LDPE) .

In a preferred embodiment, the base body and the

encapsulation may consist of or may comprise a common

material. The common material may be a main material

component of both the base body and the encapsulation. In particular, the main material may be the material of the active dielectric part of the base body. As an example, both the dielectric films of the base body and the encapsulation may comprise polypropylene.

In a further embodiment, the base body and the encapsulation may consist of or may comprise different materials. In particular, a main material of the base body may be different from a main material of the encapsulation. For example, the encapsulation material may be different from the dielectric material of dielectric films of the base body.

In a preferred embodiment, a main component of the

encapsulation is free from epoxy resin. In particular, the encapsulation may be completely free from epoxy resin.

Preferably, the encapsulation comprises a material,

preferably a material forming the main component of the encapsulation, which is more environmentally friendly than epoxy resin.

In one embodiment, the encapsulation comprises a coating of a resin, for example a coating of epoxy resin. Preferably, the coating consists of a fast curing resin, for example a fast curing epoxy resin. The coating may have a thickness in the range of 0.3 to 0.8 mm. Preferably, the thickness is less than 0.5 mm. Preferably, the coating is configured such that it can be coated online within a time range of minutes. In the cases that the encapsulation is resin-free or does comprise fast curing resins, only a short curing time, in particular much shorter than an hour is required. Thus, in the manufacturing process, no storage of a semi-finished product may be required. Preferably, the encapsulation is enabled to be manufactured in the time range of seconds or minutes .

By an encapsulation being injection-molded directly onto the base body, a close fit between the encapsulation and the base body can be achieved. Preferably, the capacitor element is free from gaps, such as air gaps, between the base body and the encapsulation. Thereby, the occurrence of local

temperature fluctuations in the capacitor element can be prevented. Moreover, by the close fit of the encapsulation and the base body, a favorable temperature dissipation can be achieved .

Preferably, the injection-molded encapsulation directly adjoins a main material of the base body. In particular, the encapsulation material may directly adjoin the dielectric material of the capacitor base body. Preferably, the base body is free from any coating or protective layer comprising a material different from the main material of the base body. In this case, a very cost effective encapsulation of the base body can be achieved, because the number of materials is kept low .

Preferably, the base body is free from any coating or any protective layer. In this case, only the encapsulation material injection-molded on the base body is used for protecting the capacitor element.

In a preferred embodiment, the encapsulation is formed by a single piece, being free from joints.

In this case, the encapsulation can be formed in a single injection process. Thereby, the manufacturing process may be free from the steps of connecting several parts of an

encapsulation such as connecting a top part to a main part of an encapsulation. Thereby, a cost-effective manufacturing process can be achieved.

In an alternative embodiment, the encapsulation may be formed by several, for example two injection molding steps. In particular, the manufacturing process may comprise a first injection molding step for forming the first piece and a subsequent second injection molding step for forming the second piece. Preferably, the second piece is directly injection molded onto the first piece such that no additional joining process is required.

In one embodiment, the encapsulation is formed by two pieces being free from multiple joints.

By an encapsulation being free from joints or being free from multiple joints, a reliable protection of the base body can be achieved as the risk of existing or arising gaps in the encapsulation is lower than in an encapsulation comprising several parts joint together.

Preferably, the encapsulation fully encloses the base body. In this case, the encapsulation is free from openings through which the base body is directly accessible from the outside. In a preferred embodiment, the encapsulation hermetically encloses the base body.

In a preferred embodiment, the outer shape of the

encapsulation is adapted to the outer shape of the base body.

As an example, in the case that the base body has a

cylindrical shape, also the encapsulation has a cylindrical shape being slightly larger than the base body. Preferably, the outer contour of the encapsulation follows the outer contour of the base body. Thereby, the amount of material needed for the encapsulation can be kept low. In addition to that, a capacitor element having a small size and, thus, requiring a minimum amount of space can be provided.

The encapsulation may have a uniform thickness. In

particular, a local thickness of the encapsulation may not strongly deviate from the average thickness of the

encapsulation. Preferably, the thickness of the encapsulation does not deviate from the average thickness by more than 50 % of the average thickness.

As an example, the thickness of the encapsulation is in the range of 1.0 mm to 2.0 mm.

The encapsulation may comprise an injection-molded marking.

Preferably, the injection-molded marking is formed in the step of injection-molding the encapsulation. Thereby, a time- and cost-saving process is provided, as no additional step for marking the encapsulation is needed.

Preferably, a mold used in the injection-molding process comprises a pattern for forming a marking of the capacitor element. As an example, the marking may be formed as an indention or an elevation in the encapsulation. Preferably, a visible marking is formed. Moreover, the capacitor element may comprise at least one electric terminal for electrically contacting the base body.

As an example, the terminal may be a fast-on terminal fixed to the base body.

The fast-on terminals may comprise as a base material at least one of the materials brass, copper or mild steel. The base material may have a plating suitable for establishing good electrical contacts. The fast-on terminals may comprise means to provide good mechanical and electrical connections with matching receptacles.

In a further embodiment, the terminal may be configured as an insulated wire terminal, for example a single core or a dual core insulated wire terminal.

Preferably, the encapsulation encloses also the side of the base body where the terminal is attached and more preferably, hermetically encloses the base body.

In a preferred embodiment, the terminal comprises a single piece which is attached to the base body and leads through the encapsulation. In this case, during the manufacturing process, only a single step may be required for providing the capacitor element with a terminal. In particular, after the encapsulation process, no additional step of providing the capacitor element with outer terminals electrically connected to terminals inside the encapsulation may be required.

Preferably, the terminals are attached to the base body before the encapsulation is formed. The base body with attached terminals may be encapsulated such that the

terminals are enclosed by the encapsulation in a region adjacent to the base body. In this case, the terminals may be mechanically stabilized by the encapsulation. Preferably, a close fit of the encapsulation and the terminals is achieved such that the encapsulation is free from gaps and fully encloses the base body.

Other features will become apparent from the following detailed description when considered in conjunction with the accompanying drawings .

Figure 1 shows a capacitor element comprising an injection- molded encapsulation,

Figures 2A, 2B, 2C and 2D show steps of manufacturing a capacitor element,

Figures 3A, 3B, 3C and 3D show, in a cross-sectional view, steps of encapsulating a capacitor element.

Figure 4 shows a further embodiment of a capacitor element comprising an injection-molded encapsulation, Figure 5 shows a further embodiment of a capacitor element comprising an injection-molded encapsulation. Figure 1 shows a capacitor element 1 comprising a capacitor base body (not visible here) encapsulated by an injection- molded encapsulation 3. The base-body is designed as a film capacitor comprising wound metallized dielectric films. The dielectric films comprise polypropylene or polyester. In the depicted

embodiment, the base body has a round cylindrical shape. In other embodiments, the base body may have a different shape, for example a cuboidal shape.

The encapsulation 3 is injection-molded directly onto the base body such that a close fit of the encapsulation 3 and the base body is established. The encapsulation 3 encloses the base body allover and, in particular, hermetically encloses the base body. The encapsulation 3 comprises a plastic material such as polypropylene and is free from epoxy resin . The capacitor element 1 comprises two electric terminals 5 for electrically contacting the base body. The terminals 5 are fixed, for example, soldered or welded to the base body and lead through the encapsulation 5. Preferably, the

terminals 5 are welded to the base body such that the base body is free from any soldering agents. The encapsulation 3 encloses the terminals 5 in regions 53 adjacent to the base body .

The terminals 5 are configured as fast-on terminals 52, comprising means for establishing a good mechanical and electrical connection. In particular, the terminals 53 comprise a dimple or detent. As examples, the terminals 52 may have dimensions of 6.3 mm x 0.8 mm, 4.75 mm x 0.5 mm, 4.75 mm x 0.8 mm, 2.8 mm x 0.5 mm and 2.8 mm x 0.8 mm. The capacitor element 1 comprises mounting means 6 for mounting the capacitor to its application environment. The mounting means 6 are an integral part of the encapsulation 3 and are formed in the same injection-molded process as the encapsulation 3.

Furthermore, the capacitor element 1 comprises a marking 4, being an indentation in the encapsulation 3. The marking is formed during the process of injection-molding the

encapsulation 3 and show the characteristic values of the capacitor element.

As examples, the capacitor element may have a capacitance in the range of 2 yF to 6 yF at a working voltage of 400 V to 450 V or a capacitance of 5 yF to 20 yF at a working voltage of 210 V to 250 V.

Figures 2A, 2B, 2C and 2D show several steps in the

manufacturing process of a capacitor element 1, starting from a capacitor base body 2.

Figure 2A shows a first, optional step, whereby the capacitor base body 2 is oil-impregnated in a basin 8. Here, several base bodies 2 are processed together. Figure 2B shows the step of attaching electric terminals 5 to the base body 2. The terminals 5 may be soldered or welded to the base body 2.

In this embodiment, the terminals 5 are attached to the front face of the cylindrical base body 2. In other embodiments, for example in the embodiment shown in Figure 1, the

terminals 5 may be attached to the side face of the base body 2. After that, the base body 2 is encapsulated in an injection- molded process. Here, the injection-molding material is directly injected onto the base body 2 as can be seen in Figures 3A to 3D.

Figure 2C shows the capacitor element 1 after the step of encapsulating the base body 2. The terminals 5 fixed to the base body lead through the encapsulation 3 such that they can be directly used for electrically contacting the capacitor element 1. The encapsulation 3 comprises markings 4 formed during the injection-molding process.

Figure 2D shows the final step of testing the capacitor element 1.

By the shown process, a time-saving and cost-effective manufacturing of an encapsulated capacitor element can be achieved. In particular, the injection-molded process requires a low number of process steps and can be carried out during a time-scale of seconds.

Figures 3A, 3B, 3C and 3D show several steps in the process of encapsulating a capacitor element 1, which can be carried out after the manufacturing step shown in Figure 2B.

Figure 3A shows, in a cross-sectional view, the base body 3 inserted into a cavity 74 of a lower part 71 of a mold 7. The shape of the cavity 74 is adapted to the cylindrical outer shape of the base body 3.

In Figure 3B, an upper part 72 of the mold 7 is placed onto the lower part 71. The upper part 72 has an opening 73, through which the injection molding material can be injected into the mold 7. Figure 3C shows the base body 2 in the mold 7 after the injection molding material has been injected, whereby an encapsulation 3 of the base body 2 is formed. The

encapsulation 3 encloses the base body 2 on all sides, including the top and bottom faces.

The base body 2 can be separated from the mold 7 after a few seconds . Figure 3D shows the encapsulated capacitor element 1. Due to the shape of the mold 7, which is adapted to the outer shape of the base body 2, the encapsulation has a uniform thickness 31. Preferably, the thickness is in the range of 1.0 mm to 2.0 mm .

Preferably, during the whole injection molding process, the temperature is kept below 250 °C. Thereby, the risk of damaging the base body, for example a partially dissolving the dielectric films, can be reduced.

In particular, when using polypropylene as an injection molding material, a molding process may be enabled, wherein the temperature is kept below 250 °C. In a further

embodiment, additives may be added to the molding material to allow for injection processes where the temperature is kept below 250 °C. This may be particularly useful when using injection molding materials different from polypropylene.

In a further embodiment, the temperature in the injection process may be higher than 250 °C, for example up to 300 °C. In this case, the base body may be protected of the heat by a material coating. As an example, the active part of the base body may be enclosed by passive dielectric films. In

particular, the passive dielectric films may comprise or be of the same material as the dielectric material in the active part and may be free from a metallization. In a wound

capacitor coil, the material coating may comprise turns of unmetallized dielectric films, for example a number of 20 to 30 additional turns of these films. In this case, the base body may be protected by a coating comprising a material which is changing its state from one state to another state, as per latent heat principle, thereby storing heat and thus bringing down the temperature at the base body. Preferably, the encapsulation material directly adjoins the material of the passive dielectric films. In the case that the passive dielectric films comprise the same main material as the active dielectric films, the encapsulation directly adjoins a main material of the base body. Accordingly, the base body is free from any coating comprising a different material than the main material of the base body.

In a further embodiment, the base body is free from any protective layer, also when the injection molding process is carried out at temperatures above 250 °C. Preferably, in this case, the encapsulation directly adjoins the dielectric part of the capacitor base body, in particular active capacitor coils of the base body. In this case, a molding technique, wherein the injecting molding material is injection molded in free flow around the base body may be used in order to avoid damaging the base body.

Figures 4 and 5 show further embodiments of capacitor

elements 1 comprising a capacitor base body (not visible here) encapsulated by injection-molded encapsulations 3. The base body and the encapsulation 3 may be similar or equal to the base body and the encapsulation 3 of the capacitor element shown in Figure 1.

In Figure 4, the capacitor element 1 comprises terminals 5 in the form of single core wire terminals 56, 57. The wire terminals 56, 57 comprise a conductor 51, insulated by an insulating material 54. As an example, the conductor 51 may comprise a copper material, for example a copper wire. The conductor 51 may have a cross sectional area of 0.35 mm^ or larger. The insulating material 54 may comprise

polyvinylchloride or polypropylene, for example.

The encapsulation 3 encloses the terminals 5 in regions 53 adjacent to the base body. Thereby, the base body is hermetically enclosed by the encapsulation 3.

In Figure 5, the capacitor element 1 comprises a terminal 5 in the form of a dual core wire terminal. The terminal 5 comprises two single core wire terminals 56, 57 aligned side by side and insulated by a secondary layer 55 of insulating material. The insulating material may consist of

polyvinylchloride or polypropylene. The individual single core wires may comprise copper conductors having a cross section of at least 0.35 mm^ with polyvinylchloride or polypropylene insulation.

Reference numerals

1 capacitor element 2 base body

3 encapsulation

31 thickness 4 marking

5 electric terminal

51 conductor

52 fast-on terminal

53 regions of terminals adjacent to base body

54 insulating material

55 second layer of insulating material

56, 57 single core wire terminal 6 mounting means

7 mold

71 lower part of mold

72 upper part of mold

73 opening

8 basin

9 tool