Custom Water Cooled Capacitors for Induction Heating & Melting Factory

For water-cooled induction heating and melting capacitors, how to ensure that their electrical performance and heat dissipation performance are not affected under different ambient temperatures (such as -20℃ to +50℃)?

Electrical performance
Material selection: The water-cooled induction heating and melting capacitors produced by Jiande Antai Power Capacitor Co., Ltd. use polypropylene film as the dielectric and high-purity aluminum foil as the electrode. Polypropylene film has good electrical insulation performance, low dielectric loss and high breakdown field strength, and can maintain stable electrical performance at different temperatures. High-purity aluminum foil has excellent conductivity and stability, which helps to reduce resistance loss and reduce electrical parameter fluctuations caused by temperature changes.
Vacuum impregnation process: During the company's capacitor production process, the winding components are placed in an extremely high vacuum environment and then impregnated with non-PCB electrical grade insulating oil. This process can effectively remove internal air and moisture, avoiding the degradation of insulation performance due to air ionization or moisture condensation. Insulating oil can maintain good insulation performance at different temperatures and has certain temperature adaptability. It can maintain fluidity at low temperatures and will not volatilize or decompose excessively at high temperatures, thereby ensuring that the capacitor maintains stable electrical performance within the ambient temperature range of -20℃ to 50℃.
Electrical connection design: The electrical connection part of the capacitor adopts a reliable welding process to ensure a firm connection and low contact resistance. At different temperatures, the thermal expansion and contraction of metal materials may affect the stability of the electrical connection. Therefore, a reasonable design of the connection structure and the use of connection materials with appropriate elasticity and thermal stability, such as some special alloy materials, can compensate for the dimensional changes caused by temperature changes and prevent the degradation of electrical performance caused by poor contact.

Heat dissipation performance
Water cooling system design
Efficient water cooling pipeline: Jiande Antai Power Capacitor Co., Ltd. equips the capacitor with a high thermal conductivity copper tube to promote the flow of cooling water. The copper tube has good thermal conductivity and can quickly transfer the heat generated inside the capacitor to the cooling water. At different ambient temperatures, by reasonably designing the layout and diameter of the water cooling pipeline, it is ensured that the cooling water can flow evenly through all parts of the capacitor to achieve efficient heat dissipation. For example, in a low-temperature environment, appropriately increasing the flow of cooling water can prevent the capacitor temperature from being too low; in a high-temperature environment, increasing the flow and increasing the cooling water flow rate can enhance the heat dissipation effect.
Temperature control device: Install a temperature sensor to monitor the temperature of the capacitor in real time, and automatically adjust the flow and temperature of the cooling water according to the ambient temperature and the actual temperature of the capacitor. In a low-temperature environment, the temperature of the cooling water can be appropriately increased by the heating device to prevent the pipe from freezing and the capacitor temperature from being too low; in a high-temperature environment, start the cooling equipment to reduce the cooling water temperature to ensure good heat dissipation of the capacitor. At the same time, it is equipped with an intelligent control system to automatically adjust the operating parameters of the cooling system according to the preset temperature threshold to achieve precise temperature control.
Heat dissipation structure optimization
Fin heat dissipation: Design heat dissipation fins on the capacitor shell to increase the heat dissipation area. The shape and size of the fins are optimized to improve the heat dissipation efficiency. In a low-temperature environment, the fins can dissipate heat to the surrounding air through natural convection; in a high-temperature environment, combined with a forced air cooling or water cooling system, the heat can be taken away more effectively. For example, the use of a zigzag or wavy fin structure can increase the contact area and disturbance between the air or cooling water and the fins, and improve the heat dissipation effect.
Air circulation design: Reasonably design the installation position and surrounding space of the capacitor to ensure that air can circulate freely. In low temperature environments, avoid the accumulation of cold air around the capacitor to cause local overcooling; in high temperature environments, good air circulation helps to remove heat and prevent heat accumulation. For example, when installing capacitors, leave enough gaps and vents so that the air can form a natural convection channel, or install fans for forced ventilation to enhance heat dissipation capacity.

Thermal management system
Thermal balance calculation: In the design stage, accurately evaluate the heat generation and heat dissipation of the capacitor at different ambient temperatures through thermal balance calculation, and optimize the parameters of the heat dissipation system according to the calculation results. Considering the loss of internal components of the capacitor, changes in ambient temperature, and the influence of heat dissipation methods, accurately calculate the required cooling water volume, heat dissipation area, etc., to ensure that the heat dissipation system can meet the heat dissipation requirements under different temperature conditions.
Maintenance and monitoring: Establish a complete thermal management system and regularly monitor and maintain the heat dissipation performance of the capacitor. Check whether there are leaks, blockages, and other problems in the pipes of the water cooling system, and clean the dust and debris on the heat dissipation fins in time to ensure that the heat dissipation channel is unobstructed. At the same time, monitor the temperature changes of the capacitor, find abnormalities in time and take corresponding measures, such as adjusting the cooling system parameters or repairing the capacitor.

Comprehensive measures
Shell material and insulation: Select a shell material with good thermal insulation performance to reduce the impact of the external ambient temperature on the capacitor. In a low temperature environment, an insulation layer can be added to the surface of the capacitor shell to prevent heat from dissipating too quickly; in a high temperature environment, the insulation material can reduce the transfer of external heat into the capacitor. For example, use polystyrene foam, polyurethane foam and other insulation materials as the insulation layer of the shell, and adjust the thickness of the insulation layer according to the ambient temperature and the heat dissipation requirements of the capacitor.
Adaptive design and testing: In the product design stage, fully consider the impact of different ambient temperatures and conduct adaptive design. By simulating the operation under different temperature conditions, the capacitor is strictly tested and verified to ensure that its electrical performance and heat dissipation performance can meet the requirements within the temperature range of -20℃ to 50℃. For example, high and low temperature cycle tests, thermal shock tests, etc. are carried out to test the performance stability of the capacitor when the temperature changes sharply, and to promptly discover and solve potential problems.
Jiande Antai Power Capacitor Co., Ltd., with its 40 years of professional experience, has taken a series of effective measures in product design, material selection, production process and quality control, etc., which can ensure that the electrical performance and heat dissipation performance of water-cooled induction heating and melting capacitors are not affected at different ambient temperatures from - 20℃ to 50℃, and provide customers with products with excellent performance and reliable quality to meet the application needs of induction heating and melting. Its products have passed ISO9001 and CE certification, and it has its own testing laboratory and advanced and complete testing equipment, as well as a strong R&D team and a complete production service system, which provide strong guarantees for the stable operation of products under different environmental conditions.