Polypropylene film for capacitors industry technology development status and trend analysis

Polypropylene film for capacitors industry technology overview

Our polypropylene film for capacitors industry product is divided into the base film and metalized film, base film including electronic film deposition and oil immersed electronic film, metalized film can be divided into aluminum metal electronic film, Aluminum Zinc alloy metalized film and metalized anti-explosion film (safety film). After nearly 20 years of development, industry product categories and the number of varieties have greater development, level has improved greatly. While some companies in some product quality has reached the international advanced level, but in the new product development and process innovation are still lagging behind in advanced foreign enterprises. There are about ten manufacturing enterprises in the domestic industry, their technical level is uneven. Most companies’ capacity is concentrated in the low-end market; some high-end products still rely on imports.

Situation of the polypropylene film for capacitors industry technology applications

Polypropylene film for capacitors industry is technology - intensive industry, the manufacture of thin film for capacitors started in the 1980s, its main equipment and production technology mainly rely on imports. After twenty years of development, the production technologies are gradually digested, absorbed and be innovative, but the thickness specifications mainly between 7-12μm. With the rapid replacement of electronic machine, the demand for ultra-thin films of electronic rapid expansion, to conform to market trends, some stronger film plant started to develop the production of ultra-thin electronic film 6μm below, and ultra-thin films for high precision equipment and technology requirements, conventional production techniques are difficult to overcome continuous automated production process and ensure frequent rupture problems inherent quality film and subsequent processing characteristics, resulting in poor product quality, higher cost of raw materials and large losses. Using high-precision production equipment and technology to explore the match in order to improve product yield and intrinsic characteristics and subsequent processing is the only way to use ultra-thin polypropylene film capacitor industry development. The technical features of the industry performance in understanding and technological innovation capability of the equipment, and the understanding of the capacitor applications and range of application.

As the core production line equipment and testing instruments are introduced from abroad, high degree of automation, the stability of equipment operation, equipment condition and suitability of the production process directly determines the stability and quality of product quality improvement, therefore, technology staff understanding and transformation capabilities of the device largely determines the level of the company's technology.

Film capacitors are widely used in different industries appliances, communications equipment, electronic machine, automotive electronics, new energy vehicles, solar energy, wind energy, etc., but in the same industry are different range of applications, performance indicators related to the film is also different, production and technical personnel to understand the extent of the capacitor applications and application scope, largely determines the degree of matching the performance of the company's products and customer needs.

Technology research and Trends

(1)  The ultra-thin

Ultra-thin polypropylene film for capacitors is high-end products, as opposed to conventional film, use it to make the capacitor, capacitance per unit volume significantly increased, which helps to save raw materials and reducing the element volume, and has broad market prospects.

       Film capacitor capacity, miniaturization trend prompted polypropylene film for capacitor to develop in the direction of ultra-thin as a whole, made with thin polypropylene film capacitors, which significantly increased the capacitance per unit volume, which helps to save raw materials and reducing element volume. Polypropylene film quality continues to improve so that the indicators include thickness uniformity, overall performance, including electricians are greatly improved; coupled with advances in manufacturing technology manufacturers, so that each micron film withstand voltage has been significantly improved. In a polypropylene film reliability is guaranteed premise capacitor manufacturers in order to reduce cost and reduce the volume of the capacitor, starts to move towards the use of thinner films of polypropylene waves. Since the unit cost of film capacitors consumed × Unit Price = film capacitor film consumption, and therefore the consumption of the unit capacitor film capacitors great influence on the costs. In the manufacture of the same film capacitors store electrical energy using a smaller film thickness specifications to manufacture cost advantages are obvious and which are smaller. Currently, most manufacturing a thin film capacitor using 7μm film part is 6μm and the following thin film manufacturing. 6μm and the use of the following films are increasing year by year, in general, is the development trend of ultra-thin polypropylene film.

(2) The high temperature resistance

High temperature heat resistance polypropylene film for capacitors is much better than ordinary polypropylene film for capacitors, with its production of capacitors, high reliability, long-term work in a relatively harsh thermal environment, a wide range of application, such as power capacitors, electrical equipment capacitors, electric locomotive capacitors, hybrid cars capacitors, automotive electronics capacitors, capacitors and other energy-saving lamps, high temperature polypropylene film for capacitors is another important development direction of the industry.

(3) Metalized safety film technology

Metalized film explosion of electronic security (safety film) is deposited by electron film on the surface may have a special pattern deposited metal electrode layer capacitor electrodes achieved, media, explosion-proof mechanism in one of the three composite products. Its outstanding feature is the high security and reliability, and long life. Metalized safety film is an electrode and dielectric materials for safety explosion-proof capacitor. This film is widely used in air conditioners, refrigerator compressor capacitors, hybrid cars capacitors and other areas with high security requirements of the explosion. Because metalized safety film processing complex, high technology content, improved its production costs, has not yet been used in a large area of the country. As security certification standards to improve safety awareness, electrical products and other electrical facilities will increasingly high proportion of applications that will enable security film expanded. At present,China's exports of home appliances in Europe andAmericafor all air conditioners, refrigerators and other compressor capacitors have been forced to use safety film capacitors.

Metalized safety film technology is proposed in the early 1990s by the German Steiner Limited (Steiner GmbH & Co.KG), a patented product to market, and gradually in order to meet the development trend of ultra-thin capacitor industry. The product of the composition of the capacitor dielectric, an electrode, a composite three-proof mechanism in one, its high-quality polypropylene film as dielectric substrate under high vacuum (2 × 10-4mbar) condition of the electrode metal evaporated, and precipitated in the film surface, to form a specific pattern, from the explosion effects (thickness only tens of nanometers) thin electrode coatings, fabrication can be rolled directly into the explosion of the capacitor element "metalized safety film."

      The proof mechanism is: the production of an electrode coating is divided into a number of insulated electrodes of the network into small cell block; each cell block has four micro-contact with the surrounding adjacent cell blocks communication from the fuse effect; each such micro-fuse square meter safety film 2 to 40,000 as much. Metalized film capacitors security layer structure of this electrode made of the work in case the voltage is too high, or the media film a certain point and breakdown voltage is not enough, at this point of the electrode around a small unit of four small junction breakdown current fuse is melted to evaporate, so that breakdown of the cell isolation portion surrounding the capacitor precursor remained normal work. Due to ensure that its work is very sensitive miniature fuse is designed so that the breakdown current size is limited, to the adjacent film does not produce effects in the spread of self-protection action.

      Use metalized polypropylene film manufacturing explosion safety capacitors, in the face of over-voltage capacitor breakdown, reliable self-healing, both explosion-proof effect, but also to extend the working life of the capacitor, so that the safety and reliability of the capacitor on a new stepped on explosion mechanism is a revolutionary progress. The product is manufactured AC capacitors, power capacitors, capacitor locomotive urgent need of new materials, and increasingly widely used in hybrid cars capacitor to replace aluminum electrolytic capacitors.

      China is also back in the late 1990s began to use imported trial explosion safety film capacitors. Domestic manufacturers have been also developed ultra-thin metalized safety film, but because of the immaturity equipment, process control difficulties, poor quality precision reasons beyond the actual use, ultra-thin metalized safety film production is still in a blank state . Some well-known domestic enterprises and foreign-funded enterprises in the production of high-security equipment explosion capacitors, had from Germany Steiner Limited (Steiner GmbH & Co.KG) buying large quantities of imported metalized safety film, but expensive, the impact of this promote the use of term technologies.

      October 8, 2008, AQSIQ, GB Commission jointly issued the "limit consumption of household refrigerators and energy efficiency rating (GB12021.2-2008) standards", and in May 1, 2009 implemented. In order to achieve the energy standards, since 2009, all refrigerators for sale on the domestic market were required to install energy-saving devices. If you do this on every refrigerator installation requires the use of metalized capacitors safety film 20 to 40 grams, according to the 2010 production of 75.46 million units nationwide refrigerators, is estimated demand for the metal will grow Safety Film 1509-3018 tons.

(4) Materials modification technology

The dielectric constant of the polypropylene material is not very high, which is an inherent characteristic of polypropylene. In order to achieve the same capacity, and other electrical performance of the same volume of the smaller object, the development of a high dielectric constant material is a polypropylene effective direction, nanotechnology, cross linking, grafting, coating and other technology has made silicon oxide this idea a big step forward. Once the implementation of this idea, polypropylene film capacitor miniaturization will be possible, but also means that the unit cost of electricity capacity will drop substantially, product gross margin will be increased dramatically.