JP2023136320A - Capacitor and capacitor manufacturing method - Google Patents

Abstract

To provide a capacitor that allows positioning of each component while solving design constraints caused by a jig.SOLUTION: A capacitor includes a capacitor element 2, an insulating member 4, and a bus bar 3, and the insulating member 4 includes capacitor element positioning means for positioning the capacitor element 2, and bus bar positioning means for positioning the bus bar, and the capacitor element positioning means is a loading unit 41 that can perform positioning by loading the capacitor elements 2, and the bus bar positioning means is a fixing unit 42 that can perform positioning and fixing by fixing the bus bar 3.SELECTED DRAWING: Figure 1

Description

The present invention relates to a capacitor including an insulating member and a method for manufacturing the capacitor.

Capacitors are usually manufactured by complex combinations of capacitor elements, bus bars, insulating members, etc., and therefore a jig is used to position each component (for example, see Patent Document 1).

Japanese Patent Application Publication No. 2017-226079

However, it must be designed on the premise that each component will be positioned on a jig, and there are many design constraints. In particular, busbars have to be connected to the electrode surfaces of capacitor elements while avoiding jigs, which poses problems in that they cannot be made into complex shapes and the area must be reduced.

An object of the present invention is to provide a capacitor that allows positioning of each component while solving design constraints caused by jigs, and a method for manufacturing the capacitor.

That is, the capacitor of the present invention includes a capacitor element 2, an insulating member 4, and a bus bar 3, and the insulating member 4 serves as a capacitor element positioning means for positioning the capacitor element 2 and a bus bar 3 for positioning. The bus bar positioning means is characterized in that it is provided with a bus bar positioning means.

The capacitor element positioning means is a loading part 41 that can perform positioning by loading the capacitor element 2, and the busbar positioning means is a fixing part 42 that can perform positioning and fixing by fixing the busbar 3. It is preferable that

Further, it is preferable that the insulating member 4 is entirely embedded in the filling resin 6 that covers the capacitor element 2.

In the capacitor manufacturing method of the present invention, after positioning the capacitor element 2 using the capacitor element positioning means of the insulating member 4, positioning the bus bar 3 using the bus bar positioning means of the insulating member 4, and then positioning the bus bar 3 at the element connecting portion 34 of the bus bar 3 ( 38) is connected to the electrode surface 2a (2b) of the capacitor element 2.

Another method for manufacturing a capacitor of the present invention is to load the capacitor elements 2 on the loading portion 41 of the insulating member 4 and position them, and then fix the bus bar 3 to the fixing portion 42 of the insulating member 4 and position it. A feature is that the element connecting portion 34 (38) of the bus bar 3 is connected to the electrode surface 2a (2b) of the capacitor element 2.

In the capacitor of the present invention, the capacitor element and the bus bar can be positioned relative to each other by the insulating member.

In the above capacitor, the capacitor element positioning means is a loading part that can perform positioning by loading the capacitor elements, and the busbar positioning means is a fixing part that can perform positioning and fixing by fixing the busbar. 42, the capacitor element and the bus bar can be positioned relative to each other with a simple configuration.

When the insulating member is completely embedded in the filled resin covering the capacitor element, cracks on the surface of the filled resin due to the insulating member protruding from the filled resin can be prevented.

In the capacitor manufacturing method of the present invention, the capacitor element and the bus bar can be positioned relative to each other by the insulating member.

FIG. 1 is an exploded perspective view showing a capacitor according to an embodiment of the invention. FIG. 3 is a perspective view showing a state in which capacitor elements are loaded on an insulating member. FIG. 3 is a perspective view showing a state in which a first bus bar is connected to a capacitor element. FIG. 3 is a perspective view showing a state in which a second bus bar is connected to a capacitor element. FIG. 3 is a cross-sectional view of a capacitor. FIG. 7 is a schematic plan view showing a modification of the insulating member.

Next, one embodiment of the capacitor of the present invention will be described in detail based on the drawings. As shown in FIGS. 1 to 4, this capacitor 1 includes a capacitor element 2, a bus bar 3 connected to the capacitor element 2, and an insulating member 4 that insulates the capacitor element 2 and the bus bar 3. The device further includes a case 5 that accommodates the capacitor element 2, and a filling resin 6 that is filled into the case 5 (see FIG. 5). Each of the above parts will be explained below, but the concepts of "top and bottom," "left and right," and "front and back" are based on the top and bottom, left and right, and front and rear when loading the capacitor element 2 on the insulating member 4, and are not necessarily used. It does not specify whether the time is up or down. Note that in FIG. 5, unlike FIGS. 1 to 4, the top and bottom are reversed.

First, the insulating member 4 will be explained. As shown in FIG. 1, the insulating member 4 includes a flat bottom 41a, an edge 41b rising from the outer edge of the bottom 41a, and a partition wall 41c partitioning the inside of the edge 41b. The amount of rise of the edge portion 41b and the partition wall 41c is smaller than the axial length of the capacitor element 2, for example, approximately 1/5 to 6 of the axial length of the capacitor element 2. The longitudinal spacing between the longitudinal edges 41b, 41b, the lateral spacing between the short edge 41b and the partition wall 41c, and the lateral spacing between the partition walls 41c, 41c are all relative to the capacitor element 2. The outer size of the portion (end portion) loaded on the loading portion 41 is the same as or slightly smaller than the outer size of the portion (end portion) loaded on the loading portion 41. A portion surrounded by the edge portion 41b and the partition wall 41c becomes a loading portion 41 on which the capacitor elements 2 are loaded. In other words, it can be said that the loading portion 41 includes a bottom portion 41a, an edge portion 41b, and a partition wall 41c. A plurality of loading portions 41 are arranged in a row in the left-right direction in accordance with the number of capacitor elements 2, and the insulating member 4 as a whole has a substantially partition plate shape.

A plurality of protruding fixing parts 42 protruding horizontally (forward) are provided on the outer edge of the insulating member 4 on the longitudinal side. The fixing portion 42 is provided at the same position as the partition wall 41c in plan view. This fixing part 42 has the same width or a slightly larger width than a slit 32d of the first bus bar 31, which will be described later. (busbar positioning means) and positioning means (busbar positioning means). A window-like hole 41a1 is provided in the bottom portion 41a to expose the other electrode surface 2b of the capacitor element 2, which will be described later.

This insulating member 4 is made of insulating synthetic resin, and has a rigidity that does not substantially deform even when the capacitor elements 2 are loaded on all the loading sections 41, and maintains the first bus bar 31 attached via the fixing section 42. It has the strength to be able to Note that it can also be made of various insulating materials such as natural resin, rubber, and paper.

The capacitor element 2 is, for example, a film capacitor made by winding a metallized film in which metal is vapor-deposited on an insulating film, and electrode surfaces 2a and 2b are provided at both ends in the axial direction. This capacitor element 2 has a barrel shape when viewed from the axial direction, specifically, R (R) is provided at the four corners, and has a flat portion 2c1 and a curved surface portion 2c2 on the axial outer peripheral surface 2c. ing.

The bus bar 3 is constructed by appropriately bending a conductive metal plate such as copper. The bus bar 3 includes a first bus bar 31 connected to one electrode surface 2a of the capacitor element 2, and a second bus bar 35 connected to the other electrode surface 2b.

The first bus bar 31 includes a base portion 32 that is substantially U-shaped in side view in order to route one electrode surface 2a of the capacitor element 2 toward the other electrode surface 2b. A tongue-shaped element connecting portion 34 connected to one electrode surface 2a of the capacitor element 2 is provided on the upper horizontal portion 32a. From the lower horizontal portion 32b, an external connection portion 33 for connection with an external device extends downward and to the right. A plurality of slits 32d extending in the vertical direction are provided in the vertical portion 32c that connects the upper and lower horizontal portions 32a and 32b. The position of the slit 32d in the left-right direction is adjusted so that the first bus bar 31 is at a desired position relative to the insulating member 4 when the fixing part 42 is fitted into the slit 32d.

The second bus bar 35 includes a flat base 36 that extends along the other electrode surface 2b of the capacitor element 2. The base portion 36 is provided with an element connecting portion 38 that is approximately T-shaped in plan view and is connected to the other electrode surface 2b of the capacitor element 2. An external connection portion 37 for connection to an external device extends downward from the longitudinal outer edge of the base portion 36. The external connection portion 37 overlaps with the external connection portion 33 of the first bus bar 31 mainly on the proximal end side. Therefore, a spacer 7 is provided between the external connection parts 33 and 37 to prevent electrical connection between the external connection parts 33 and 37.

The spacer 7 has a plate shape, and is appropriately provided with a rising portion 71 so as to border the outer edge. This rising portion 71 is for increasing the creepage distance between the external connection portions 33 and 37. The spacer 7 is made of insulating synthetic resin. It may be made of the same material as the insulating member 4. However, high rigidity and strength like the insulating member 4 are not necessarily required.

The case 5 has a hollow rectangular parallelepiped shape, and has a bottom surface 51 and side surfaces 52, as shown in FIG. An opening 53 is provided on the surface facing the bottom surface 51 for accommodating the capacitor element 2 therein and for drawing out the external connections 33 and 37 to the outside. The case 5 is made of synthetic resin, but may be made of metal or the like, regardless of whether it is conductive or not.

The filling resin 6 is an insulating resin. Thermosetting resins and photocurable resins are preferred, such as epoxy resins, urethane resins, and silicone resins.

Next, a method for manufacturing capacitor 1 will be explained. First, as shown in FIG. 2, with one electrode surface 2a of the capacitor element 2 facing up and the other electrode surface 2b facing down, place the end of the capacitor element 2 on the side where the other electrode surface 2b is provided on the loading section. 41, and the capacitor element 2 is mounted on the insulating member 4. Thereby, the capacitor element 2 is positioned with respect to the insulating member 4 at the same time as being fixed. Specifically, the bottom portion 41a performs positioning in the vertical direction, and the edge portion 41b and the partition wall 41c performs positioning in the front, rear, left, and right directions. In short, the edge 41b and the partition wall 41c function as means for fixing the capacitor element 2 (capacitor element fixing means), and also function as positioning means in the front, rear, left and right directions (capacitor element positioning means). Although most of the other electrode surface 2b is covered by the bottom 41a by attachment to the insulating member 4, a portion is exposed to the outside through a window-like hole 41a1 provided in the bottom 41a (see FIG. 5).

After loading and fixing one capacitor element 2 on each of the loading sections 41, the first bus bar 31 is then attached. Specifically, the capacitor element 2 and the insulating member 4 are placed between the upper and lower horizontal parts 32a and 32b with the vertical part 32c of the first bus bar 31 facing the side surface of the plurality of capacitor elements 2 arranged in a row. Attach it by inserting it. At this time, as shown in FIG. 3, by fitting the fixing portion 42 into the slit 32d, the first bus bar 31 is positioned with respect to the insulating member 4 in the left-right direction. In short, the fixing part 42 functions as a positioning means in the left-right direction. Note that the vertical positioning is performed by the upper and lower horizontal parts 32a and 32b. After positioning, the element connecting portion 34 of the first bus bar 31 is connected to one electrode surface 2a of the capacitor element 2 by soldering or the like. Since both the capacitor element 2 and the first bus bar 31 are fixed and positioned to the same insulating member 4, the connection work can be performed easily and accurately. Although the lower horizontal portion 32b is located on the other electrode surface 2b side, insulation is mainly ensured by the bottom portion 41a of the insulating member 4 (see FIG. 5).

Next, the element connecting portion 38 of the second bus bar 35 is connected to the other electrode surface 2b of the capacitor element 2 by soldering or the like. At this time, as shown in FIGS. 3 and 4, a spacer 7 is interposed between the external connection parts 33 and 37. Furthermore, although the external connection parts 33 and 37 are facing downward in FIGS. 1 to 4, it is preferable to perform soldering after inverting them upside down as shown in FIG. This completes the capacitor module.

Then, as shown in FIG. 5, the capacitor module which has been turned upside down is housed in the case 5 so that the external connection parts 33 and 37 are pulled out of the case 5 through the opening 53, and the capacitor element 2 is covered. In this manner, the case 5 is filled with the filling resin 6, and the filling resin 6 is cured, thereby completing the manufacturing of the capacitor 1. Note that the filling resin 6 is filled until the capacitor element 2 reaches an amount (thickness) that can ensure desired moisture resistance. It is preferable that the insulating member 4 is completely embedded in the filled resin 6.

In the capacitor 1 configured as described above, since the capacitor element 2 and the first bus bar 31 can be positioned by the insulating member 4, there is no need to separately provide a jig for positioning. In addition, since the positional relationship of the three components of capacitor element 2, insulating member 4, and first bus bar 31 is fixed, insulation between the other electrode surface 2b of capacitor element 2 and first bus bar 31 is ensured. can do. In addition, since the jig is intended to be reused, it must be made of a hard material to ensure durability, and there is a risk that the capacitor element 2 and bus bar 3 may be damaged when fixed to the jig, but the insulating member 4 Since it is only necessary to have enough strength for positioning, the jig can be made of a softer material than the jig, and damage to the capacitor element 2 and the bus bar during fixation can be suppressed.

FIG. 6 shows a different form of the insulating member 4. For example, a part of the edge 41b or the partition wall 41c may be cut out and provided only on all four sides of the capacitor element 2 in plan view (see FIG. 6A), or may be provided only on one side of the capacitor element 2 in plan view (see FIG. 6B). ).

In addition, instead of the edge 41b and the partition wall 41c, hemispherical or pin-shaped protrusions 41d are provided on all four sides (see FIG. 6C), three sides (see FIG. 6D), and two sides (see FIG. 6E) of the capacitor element 2. It may also be provided.

Further, instead of providing a partition wall 41c or a protrusion 41d as a positioning means between the capacitor elements 2, 2, positioning means are provided on all sides of a capacitor element group made up of a plurality of capacitor elements 2 (in short, the edge 41b (see FIG. 6F), the plurality of capacitor elements 2 may be divided into a plurality of groups, and a partition wall 41c may be provided between the groups (see FIG. 6G).

Further, the positioning means shown in each figure may be combined as appropriate. Engaging claws are provided on the edge 41b, the partition wall 41c, and the protrusion 41d so that they engage with the capacitor element 2 when the capacitor element 2 is loaded on the loading section 41, thereby making the capacitor element 2 more firmly fixed. Good too.

Although the embodiments of this invention have been described above, this invention is not limited to the above embodiments, and can be implemented with various changes within the scope of this invention. For example, although the edge portion 41b and the partition wall 41c functioned as a means for fixing the capacitor element 2, they may not function as a fixing means and may simply function as a positioning means. For example, if the amount of rise of the edge 41b or partition wall 41c is small or if the interval is slightly wider than the width of capacitor element 2, friction between the inner surface of edge 41b or partition wall 41c and the outer surface of capacitor element 2 may occur. The force is not large enough or does not occur to fix the capacitor element 2 to the insulating member 4, resulting in a state in which the capacitor element 2 can be positioned but cannot be fixed. In this case, it is preferable to provide a separate fixing means for fixing the capacitor element 2 to the insulating member 4. For example, attaching adhesive or adhesive tape to the upper surface of the bottom portion 41a serves as a fixing means.

Further, although the fixing portion 42 functions as a fixing means, it may not function as a fixing means and may simply function as a positioning means. For example, if the width of the fixing part 42 is slightly smaller than the width of the slit 32d, the frictional force between the outer surface of the fixing part 42 and the inner surface of the slit 32d is not large enough to fix the first bus bar 31, or This does not occur, and although positioning is possible, fixing is not possible. In this case, it is preferable to provide a separate fixing means for fixing the first bus bar 31 to the insulating member 4. For example, attaching adhesive or adhesive tape to the lower surface of the bottom portion 41a serves as a fixing means.

In the above embodiment, the first bus bar 31 is fixed to the insulating member 4 by fitting the fixing part 42 into the slit 32d (male/female type). 31 may be slid and inserted into the notch. That is, the notch may be used as the fixing portion 42. Further, the fixing portion 42 may be fixed more firmly by applying adhesive, adhesive tape, or the like.

Moreover, although the first bus bar 31 is fixed to the insulating member 4 via the fixing part 42, the second bus bar 35 may be fixed, or both may be fixed. For example, a fixing portion 42 for the second bus bar 35 may be provided. In this case, the first bus bar 31 and the second bus bar 35 can also be positioned relative to each other.

Although one hole 41a1 is provided for one capacitor element 2, one hole 41a1 may be provided for a plurality of capacitor elements 2. The shape can also be changed as appropriate as long as it can be connected to the second bus bar 35. Further, although the capacitor 1 shown in FIG. 5 is a so-called case-molded capacitor, it may be a case-less capacitor that is released after filling a mold with filler resin 6. The capacitor element 2 is not limited to a film capacitor, and various capacitor elements such as a ceramic capacitor can be used. Resin coating is not necessarily required either. As for the shape, various shapes such as cylindrical shape and prismatic shape can be adopted. Regardless of size or purpose. Capacitor elements of different shapes, sizes, uses, and types may be housed in the same case 5. The number can also be changed as appropriate, and may be one.

1 Capacitor 2 Capacitor element 2a One electrode surface 2b Other electrode surface 2c Axial outer peripheral surface 2c1 Flat portion 2c2 Curved surface portion 3 Bus bar 31 First bus bar 32 Base 32a Upper horizontal portion 32b Lower horizontal portion 32c Vertical portion 32d Slit 33 External connection part 34 Element connection part 35 Second bus bar 36 Base part 37 External connection part 38 Element connection part 4 Insulating member 41 Loading part 41a Bottom part 41a1 Hole 41b Edge 41c Partition wall 41d Projection part 42 Fixed part 5 Case 51 Bottom surface 52 Side surface 53 Opening 6 Filling resin 7 Spacer 71 Standing portion

Claims (5)

It includes a capacitor element, an insulating member, and a bus bar.
A capacitor characterized in that the insulating member includes capacitor element positioning means for positioning a capacitor element and bus bar positioning means for positioning a bus bar. The capacitor element positioning means is a loading part that can perform positioning by loading capacitor elements,
2. The capacitor according to claim 1, wherein the bus bar positioning means is a fixing part that can position and fix the bus bar by fixing it. 3. The capacitor according to claim 1, wherein the insulating member is entirely embedded in a filling resin that covers the capacitor element. A method for manufacturing a capacitor, in which a capacitor element is positioned by a capacitor element positioning means of an insulating member, a busbar is positioned by a busbar positioning means of an insulating member, and an element connection part of the busbar is connected to an electrode surface of the capacitor element. A method for manufacturing a capacitor, in which capacitor elements are loaded and positioned on a loading part of an insulating member, a bus bar is fixed and positioned on a fixed part of an insulating member, and the element connection part of the bus bar is connected to an electrode surface of the capacitor element. .

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