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We all know that capacitor films are capacitors made by overlapping metal foils with plastic films such as polyethylene, polypropylene, polystyrene, or polycarbonate and winding them into a cylindrical shape. But do you know how capacitor film manufacturer made them? And what are the requirements during production? Let's talk about it with Safe Electronics.
Cutting the film for capacitor films
Cut the metal foil into the required width according to the product's design capacity using a film cutting machine. The cutting should be without burrs, with a clean appearance and no wrinkles.
Winding for capacitor films
According to the process requirements, select the core and metal foil, and wind them into a core using a winding machine. The requirements for capacitor film capacity should meet the design requirements, the core end should be flat, the film should be clean with appropriate tension, and the film should not be scratched.
Thermal compression for capacitor films
According to the process requirements, select appropriate thermal compression parameters (pressure, temperature, time) on the thermal press to flatten the core. The core should not loosen under slight external force, and the film should not delaminate.
Tape binding for capacitor films
According to the process requirements, select suitable adhesive tape and wind the core into a roll. The adhesive should be sticky with no coverage of the core end.
Spraying Gold for capacitor films
Spray metal layers onto the two ends of the core. According to the process requirements, select spraying gold distance, air pressure, wire drawing speed. The thickness and adhesion of the gold layer should meet the requirements.
Rolling the Edge for capacitor films
After gold spraying, dismantle the tape binding, and use a rolling machine to remove the residual edges after gold spraying and the excess metal dust adhering to the core surface. The rolling time and speed should refer to the process requirements. The core end should have no excess metal edges, and the surface should have no metal dust.
Vacuum Drying for capacitor films
According to the product requirements, choose the appropriate temperature, pressure, and time for the drying chamber to improve the electrical performance of the capacitor film products. The accuracy of the machine's set parameters should be guaranteed.
Charging for capacitor films
According to the characteristics of the capacitor film product, choose the appropriate increasing voltage to improve the electrical performance of the capacitor film product. The voltage should be set accurately.
Welding for capacitor films
Weld the pins on the core. The diameter and length of the wire should be correct, the position should be moderate, the welding current should be correct, the metal foil should not be burned, the solder joint should be smooth without burrs, and there should be no virtual welding.
Inserting for capacitor films
Insert the core into the plastic shell. The core should be located in the middle of the outer shell and fixed.
Encapsulation for capacitor films
Fill the encapsulation material into the plastic shell. The encapsulation material should be correctly proportioned, stirred evenly, and the lead-out end and shell surface should have no resin. The surface should have no bubbles, and the size should be accurate.
Printing for capacitor films
Print relevant information on the material surface. The capacitor film identification should be correct, the silk screen should be clear, centered, and not easy to fall off.
Outgoing Inspection for capacitor films
Performance sampling inspection (capacity, loss, withstand voltage, insulation resistance), and appearance inspection should be smooth, without scratches, burrs, resin, and other bad phenomena. The identification should be clear and correct, the ink should be even without breakage, incompleteness, or obvious deviation. The silk screen should not be easy to fall off, and the capacitor film size should meet the inspection document requirements.
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