JP6473991B2 - Capacitor - Google Patents

Description

  The present invention relates to a capacitor such as a film capacitor and a method for manufacturing the same, and more particularly to a technology of a capacitor having a structure capable of being fastened to an installation object such as a vehicle.

  Conventionally, a capacitor having a structure that can be fastened to an installation object, such as an on-vehicle capacitor, includes a capacitor element and a resin case that houses the capacitor element. A fastening part was provided to enable fastening. The fastening portion is provided with, for example, a screw hole used for screwing to the installation object.

  On the other hand, in such a capacitor, the capacitor element is sealed in an epoxy resin in order to prevent contact between the capacitor element and moisture in the atmosphere. Specifically, the capacitor element is placed in a resin case, and then the epoxy resin is poured into the case and cured, whereby the entire element body of the capacitor element is sealed in the epoxy resin. For this reason, the proportion of the epoxy resin in the capacitor is large, and the weight of the capacitor has to be increased.

  Therefore, it has been proposed to seal the element body of the capacitor element in a bag formed of a resin film in order to reduce the weight of the capacitor (see, for example, Patent Document 1). In such a capacitor, the fastening portion is provided on a bus bar that is an electrode terminal of the capacitor element.

JP 2013-197267 A

  A conventional capacitor in which a capacitor element is housed in a resin case and sealed in an epoxy resin, when it is fastened to an installation target such as a vehicle via a fastening portion, vibration of the installation target etc. However, the impact is received by the fastening portion and the case. Therefore, the capacitor element itself is not easily shocked and the capacitor element is not easily damaged. However, as described above, this conventional capacitor has a problem of increasing weight.

  On the other hand, a capacitor in which a capacitor element is sealed in a bag formed of a resin film is lightweight, but when subjected to an external impact caused by vibration of an installation object, the impact is transferred to a fastening portion or a bus bar. It cannot be received by the shock, and the impact is transmitted to the element body. For this reason, this capacitor has a problem that a portion where stress is easily concentrated (for example, a connection portion between a bus bar and an element body) is easily damaged.

  Under such circumstances, the following capacitor has been proposed (Japanese Patent Application No. 2014-146222). That is, this capacitor includes a capacitor element, a resin molded body, and an exterior member, and is manufactured by assembling them. Specifically, the capacitor element has an element body and a bus bar drawn from the element body. The resin molding covers a part of the outer peripheral surface of the element body. The exterior member is a member different from the resin molded body, and covers at least a region different from the region covered with the resin molded body on the outer peripheral surface of the element body. The periphery of the element body is sealed with the resin molded body and the exterior member with a part of the bus bar exposed to the outside. Moreover, the fastening part which makes the fastening to an installation target object possible is provided in the resin molding. According to this capacitor, weight reduction and high strength against external impact are realized.

  Here, in the proposed capacitor, a slit-shaped through-hole through which the bus bar passes is provided in the resin molded body so that a part of the bus bar is exposed to the outside. In order to prevent moisture from entering from the through hole, the through hole is formed in a shape and dimensions that allow the bus bar to pass through with almost no gap.

  However, if the bus bar and the through hole have been misaligned due to errors that occur during the production of the capacitor element and the resin molded body, it is difficult to pass the bus bar through the slit-like through hole when assembling the capacitor, Even if the bus bar is allowed to pass through the through-hole, a situation may occur in which assembly is hindered at other locations. For this reason, the proposed capacitor requires high accuracy with respect to the shape, size, and position of the bus bar and the through hole, and thus complicates the manufacturing.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a capacitor that is lightweight and has high strength against external impact, and that is easy to manufacture, and a method for manufacturing the same.

The capacitor according to the present invention is a capacitor that can be fastened to an installation target, and includes a capacitor element, a resin molded body, and an exterior member. The capacitor element has an element body and electrode terminals drawn from the element body. The resin molding covers a part of the outer peripheral surface of the element body. The exterior member is a member different from the resin molded body, and covers at least a region different from the region covered with the resin molded body on the outer peripheral surface of the element body. The resin molded body is provided with a through-hole through which the electrode terminal is passed and a fastening portion that enables fastening to the installation object. The through hole has a width larger than the width of the electrode terminal passed through the through hole in at least one direction perpendicular to the through direction, and a gap between the through hole and the electrode terminal is filled with a filling member. Further, the periphery of the element body is sealed with the resin molded body and the exterior member in a state where a part of the electrode terminal and the fastening portion are exposed to the outside.
The outer peripheral surface of the element body includes a first end surface, a second end surface located on the opposite side of the first end surface, and a side surface extending from the first end surface to the second end surface. The resin molded body has a first facing portion having a facing surface facing the first end surface of the element body, and a through hole and a fastening portion are provided in the first facing portion. The exterior member is a bag-like film or a bottomed cylindrical case that covers the second end surface and side surface of the element body, and the opening of the exterior member includes a part of the electrode terminal protruding from the through hole and the fastening portion. In the state exposed to the outside, the periphery of the element body is sealed by being fixed to the first facing portion of the resin molding.

According to capacitor according to the present invention, in the condenser, and light weight, with high strength against impact from the outside is realized, it becomes easy to manufacture a capacitor.

(A) The perspective view which showed the film capacitor which concerns on one Embodiment of this invention notionally, (b) The perspective view from which the exterior member with which the film capacitor is provided was omitted. (A) The top view of a film capacitor, (b) It is sectional drawing which follows the IIb-IIb line | wire shown by Fig.2 (a). It is an enlarged front view of a film capacitor. (A) The perspective view which showed the capacitor | condenser element with which a film capacitor is equipped notionally, (b) The perspective view which changed the direction which sees the capacitor | condenser element from Fig.4 (a). FIG. 5 is a perspective view showing the capacitor element with the top and bottom reversed from the state shown in FIG. (A) The perspective view which showed notionally the resin molding with which a film capacitor is provided, and (b) The perspective view which turned upside down and showed the resin molding from the state shown by Fig.6 (a). is there. It is the perspective view which changed the direction which sees a resin molding from Fig.6 (a), and was shown. It is a perspective view used for description of the manufacturing method of a film capacitor. About the film capacitor which concerns on a 1st modification, (a) The expansion front view which showed the example conceptually, (b) The expansion front view which showed the other example notionally. It is the enlarged front view which showed notionally an example of the film capacitor which concerns on a 2nd modification. It is the enlarged front view which showed notionally the other example of the film capacitor which concerns on a 2nd modification. It is the perspective view which showed notionally the film capacitor which concerns on a 3rd modification. (A) The perspective view which showed notionally the film capacitor which concerns on a 4th modification, (b) The perspective view which showed notionally the resin molding with which the film capacitor is provided. It is the (a) perspective view and (b) sectional view which showed notionally the resin fabrication object with which the film capacitor concerning the 5th modification is provided. It is sectional drawing which showed the positional relationship of a capacitor | condenser element and a resin molding about the film capacitor which concerns on a 5th modification. It is the perspective view which showed notionally the resin molding with which the film capacitor which concerns on a 6th modification is provided. (A) The perspective view which showed notionally the film capacitor which concerns on a 7th modification, (b) The perspective view from which the exterior member with which the film capacitor is provided was omitted. It is sectional drawing which showed notionally the film capacitor which concerns on an 8th modification. It is the perspective view which showed notionally the resin molding with which the film capacitor which concerns on a 9th modification is provided. It is sectional drawing which showed the positional relationship of a capacitor | condenser element and a resin molding about the film capacitor which concerns on a 9th modification.

First, the capacitor according to the present invention will be described.
The capacitor according to the present invention is a capacitor that can be fastened to an installation target, and includes a capacitor element, a resin molded body, and an exterior member. The capacitor element has an element body and electrode terminals drawn from the element body. Here, the configuration in which the electrode terminal is drawn out from the element body includes a configuration in which the electrode terminal is electrically connected to the outer peripheral surface of the element body. The resin molding covers a part of the outer peripheral surface of the element body. The exterior member is a member different from the resin molded body, and covers at least a region different from the region covered with the resin molded body on the outer peripheral surface of the element body. The resin molded body is provided with a through-hole through which the electrode terminal is passed and a fastening portion that enables fastening to the installation object. The through hole has a width larger than the width of the electrode terminal passed through the through hole in at least one direction perpendicular to the through direction, and a gap between the through hole and the electrode terminal is filled with a filling member. Further, the periphery of the element body is sealed with the resin molded body and the exterior member in a state where a part of the electrode terminal and the fastening portion are exposed to the outside.

  According to the capacitor, weight reduction and high strength against external impact are realized. That is, in the conventional capacitor in which the entire element body of the capacitor element is sealed in the epoxy resin, the weight increases, whereas in the above capacitor, the amount of resin used is small, and as a result, the capacitor Is lighter. In addition, the conventional capacitor in which the element body of the capacitor element is sealed with a bag-like resin film without using a molding resin is easily damaged by an external impact, whereas the above-described capacitor is resin-molded. Since the body is incorporated and a fastening portion is provided in the resin molded body, an impact from the outside is received by the resin molded body. Therefore, the capacitor element itself is not easily subjected to an impact, and thus a high strength against an external impact is realized.

  Furthermore, the capacitor is particularly preferable when the capacitor element, the resin molding, and the exterior member are assembled. In other words, even when the electrode terminal and the through hole are displaced due to errors that occur during the production of the capacitor element and the resin molded body, the electrode terminal is passed through the through hole and the resin molded body when the capacitor is assembled. Capacitor elements can be arranged at predetermined positions with respect to. This is because the through-hole has a width larger than the width of the electrode terminal passed through the through-hole in at least one direction perpendicular to the through-direction, so that the position generated in the electrode terminal or the through-hole in that direction. This is because deviation is allowed. On the other hand, such a through hole creates a gap between the electrode terminal even when the electrode terminal is passed therethrough. Therefore, in the capacitor, the gap is filled with a filling member in order to prevent moisture from entering from the through hole. Therefore, according to the capacitor, the electrode terminal and the through hole do not require high accuracy with respect to the shape, size, and position, and therefore the capacitor is easy to manufacture.

  A preferred specific configuration of the capacitor is as follows. The outer peripheral surface of the element body includes a first end surface, a second end surface located on the opposite side of the first end surface, and a side surface extending from the first end surface to the second end surface. The resin molded body has a first facing portion having a facing surface facing the first end surface of the element body, and a through hole and a fastening portion are provided in the first facing portion. The exterior member is a bag-like film or a bottomed cylindrical case that covers the second end surface and side surface of the element body, and the opening of the exterior member includes a part of the electrode terminal protruding from the through hole and the fastening portion. In the state exposed to the outside, the periphery of the element body is sealed by being fixed to the first facing portion of the resin molding.

  Another preferable specific configuration of the capacitor is as follows. The outer peripheral surface of the element body includes a first end surface, a second end surface located on the opposite side of the first end surface, and a side surface extending from the first end surface to the second end surface. The resin molded body includes a first facing portion having a facing surface facing the first end surface of the element body, and a second facing portion having a facing surface facing the second end surface of the element body. While the through hole is provided in the facing portion, the fastening portion is provided in both the first facing portion and the second facing portion. The exterior member is a cylindrical film or a cylindrical case that covers the side surface of the element body, and the two open end portions of the exterior member expose a part of the electrode terminal protruding from the through hole and the fastening portion to the outside. In this state, the periphery of the element body is sealed by being fixed to the first facing portion and the second facing portion of the resin molded body.

In a more specific configuration, the electrode terminal includes a first electrode terminal and a second electrode terminal drawn out to the first end face side of the element body, and the through hole provided in the first facing portion of the resin molded body includes: A first through hole through which the first electrode terminal is passed and a second through hole different from the first through hole through which the second electrode terminal is passed are included. At least one of the first through hole and the second through hole has a width larger than the width of the electrode terminal passed through the through hole in at least one direction perpendicular to the through direction. In such a configuration, the through hole provided in the first facing portion of the resin molded body may be one in which the first through hole and the second through hole communicate with each other. As an example,
The through hole provided in the first facing portion of the resin molded body may be one through hole formed by communicating the first through hole and the second through hole with each other. In this case, it is understood that the first through hole and the second through hole constitute one through hole and constitute different parts of the through hole.

  The manufacturing method according to the present invention is a method for manufacturing the capacitor, and includes steps (i) to (iii). In the step (i), the electrode terminal of the capacitor element is passed through the through hole provided in the resin molded body, and the capacitor element is disposed at a predetermined position with respect to the resin molded body. After step (i), steps (ii) and (iii) are performed. In step (ii), the gap between the through hole and the electrode terminal is filled with a filling member in a state where the capacitor element is arranged at a predetermined position. In the step (iii), the periphery of the element body is sealed with the resin molded body and the exterior member in a state where a part of the electrode terminal and the fastening portion are exposed to the outside. According to this manufacturing method, the electrode terminal and the through hole do not require high accuracy with respect to the shape, size, and position, and thus the capacitor can be easily manufactured.

Next, an embodiment in which the present invention is applied to a film capacitor will be specifically described with reference to the drawings.
[1] Configuration of Film Capacitor FIGS. 1 (a) and (b) are perspective views conceptually showing a film capacitor according to an embodiment of the present invention, and FIG. 2 (a) and FIG. It is the top view and enlarged front view of the film capacitor. Moreover, FIG.2 (b) is sectional drawing which follows the IIb-IIb line | wire shown by Fig.2 (a). As shown in these drawings, the film capacitor includes a capacitor element 1, a resin molded body 2, and an exterior member 3. In addition, illustration of the exterior member 3 is abbreviate | omitted in FIG.1 (b).

[1-1] Capacitor Element FIG. 4A is a perspective view conceptually showing the capacitor element 1. FIG. 4B is a perspective view showing the capacitor element 1 in a different direction from that shown in FIG. FIG. 5 is a perspective view showing the capacitor element 1 upside down from the state shown in FIG. As shown in these drawings, the capacitor element 1 includes an element body 11 and an electrode terminal 12 drawn from the element body 11.

  In the present embodiment, the capacitor element 1 is a wound type element, and the element body 11 is formed with a plastic film having a metal layer serving as a first electrode layer formed on the surface and a metal layer serving as a second electrode layer. The plastic film thus obtained is rolled up in an overlapping manner. Accordingly, on the outer peripheral surface of the element body 11, there are two end surfaces 11a and 11b, which are two winding end surfaces formed by winding, and a side surface 11c extending from the first end surface 11a to the second end surface 11b. include. The capacitor element 1 may be a multilayer element, and this case will be described later.

  One of the first electrode layer and the second electrode layer functions as a positive electrode layer, and the other functions as a negative electrode layer. Specifically, when the film capacitor is connected to an external device, of the first electrode layer and the second electrode layer, the electrode layer connected to the positive electrode side of the external device functions as a positive electrode layer, and the negative electrode of the external device The electrode layer connected to the side functions as a negative electrode layer. In the capacitor element 1, the plastic film forms a dielectric layer interposed between the first electrode layer and the second electrode layer (that is, between the positive electrode layer and the negative electrode layer). As a constituent material of the plastic film, for example, a resin such as polyethylene terephthalate (PET), polypropylene (PP), polyphenylene sulfide (PPS), polyethylene naphthalate (PEN) is used.

  More specifically, in the element body 11, the first electrode layer and the second electrode layer are arranged in a predetermined region on the surface of the plastic film so that the first electrode layer and the second electrode layer are displaced from each other along the winding axis. Each of the layers and the second electrode layer is formed, or these positions are adjusted by being relatively shifted when the plastic film is overlaid. Therefore, in the element body 11, the first electrode layer is exposed at one of the first end surface 11a and the second end surface 11b, and the second electrode layer is exposed at the other end surface. In other words, either one of the first end surface 11 a and the second end surface 11 b functions as a positive electrode portion of the element body 11, and the other end surface functions as a negative electrode portion of the element body 11.

  In the present embodiment, the electrode terminal 12 includes two bus bars 121 and 122 formed in a plate shape. The bus bars 121 and 122 are electrically connected to the first end surface 11a and the second end surface 11b, respectively. Here, when the first electrode layer is exposed at the first end face 11a and the second electrode layer is exposed at the second end face 11b, the bus bar 121 functions as a terminal having the same polarity as the first electrode layer, The bus bar 122 functions as a terminal having the same polarity as the second electrode layer. On the other hand, when the second electrode layer is exposed at the first end face 11a and the first electrode layer is exposed at the second end face 11b, the bus bar 121 functions as a terminal having the same polarity as the second electrode layer. 122 functions as a terminal having the same polarity as the first electrode layer. That is, one of the bus bars 121 and 122 functions as a positive terminal, and the other functions as a negative terminal.

  In the present embodiment, the bus bar 121 connected to the first end surface 11a extends to the opposite side of the second end surface 11b, while the bus bar 122 connected to the second end surface 11b is on the outer peripheral surface of the element body 11. Extends along the side surface 11c of the element body 11 and protrudes toward the first end surface 11a. The two bus bars 121 and 122 are arranged such that a portion of the bus bar 122 protruding toward the first end face 11 a faces the bus bar 121.

  More specifically, in the element main body 11, the plastic film is wound so that the cross section of the element main body 11 perpendicular to the winding axis has a flat shape. Therefore, the side surface 11c of the element body 11 includes two planes located on opposite sides of each other and two curved surfaces that connect these planes on both sides. And the bus-bar 122 is extended along the plane especially among the side surfaces 11c.

  The capacitor element 1 may be a multilayer element. In this case, the element body 11 includes a plurality of plastic films having a first electrode layer and a plurality of plastic films having a second electrode layer. It will be laminated. Here, when the plastic film is laminated, the first electrode layer and the second electrode layer are arranged so as to be shifted from each other in a predetermined direction perpendicular to the stacking direction. Each of the first electrode layer and the second electrode layer is formed, or these positions are adjusted by being relatively shifted when the plastic film is overlaid. Therefore, in the multilayer element body 11, any one of the predetermined direction (the direction in which the first electrode layer and the second electrode layer are shifted from each other) and the two end surfaces facing in opposite directions is provided. The first electrode layer is exposed at one end face, and the second electrode layer is exposed at the other end face. And these two end surfaces become the 1st end surface 11a and the 2nd end surface 11b, respectively, and the bus-bars 121 and 122 are electrically connected to the 1st end surface 11a and the 2nd end surface 11b, respectively.

[1-2] Resin Molded Body The resin molded body 2 is a molded body formed from a resin such as polypropylene (PP) or polyphenylene sulfide (PPS). The method is used.

  As shown in FIG. 1B and FIG. 2B, in this embodiment, the resin molded body 2 includes a first facing portion 21 having a facing surface 21a facing the first end surface 11a of the element body 11. And a second facing portion 22 having a facing surface 22a facing the second end surface 11b of the element body 11. And in both the 1st opposing part 21 and the 2nd opposing part 22, the fastening part 4 which enables the fastening to installation objects, such as a vehicle, is provided.

  6A is a perspective view conceptually showing a portion including the first facing portion 21 of the resin molded body 2, and FIG. 6B shows the portion shown in FIG. It is the perspective view shown upside down from the state shown by. FIG. 7 is a perspective view showing the part shown in FIG. 6A in a different direction from that shown in FIG. 6A. In the plan view shape (see FIG. 2A), the first facing portion 21 has a shape in which the surface opposite to the facing surface 21a is recessed in a square groove shape at the center portion. And the fastening part 4 is formed in each part of the both sides which comprise the hollow part among the 1st opposing parts 21. As shown in FIG. In the present embodiment, the fastening portion 4 is a screw hole used for screwing to the installation object.

  The first opposing portion 21 is formed with two through holes 211 and 212 that lead from the opposing surface 21a to the opposite surface. In the present embodiment, each of the through holes 211 and 212 communicates with a recessed portion on the surface opposite to the facing surface 21a. Here, the through-hole 211 exposes a part of the bus bar 121 to the outside by passing the bus bar 121 as shown in FIG. The through-hole 212 exposes a part of the bus bar 122 to the outside by passing the bus bar 122 as shown in FIG.

  Specifically, the through-hole 211 is a rectangle whose cross-sectional shape perpendicular to the penetration direction extends in the horizontal direction d1 and the vertical direction d2 as shown in FIG. 3, and the horizontal direction d1 and the vertical direction d2 (these (The direction of each of which is perpendicular to the penetration direction) has widths W1 and W2 larger than the width of the bus bar 121 passed through the through hole 211. That is, the through-hole 211 has a width W1 larger than the width of the bus bar 121 in the horizontal direction d1, and a width W2 larger than the vertical width (ie, thickness) of the bus bar 121 in the vertical direction d2. On the other hand, the through hole 212 has a slit shape, and the bus bar 122 is passed through the through hole 212 with almost no gap.

  According to such a through-hole 211, even if the bus bars 121 and 122 and the through-holes 211 and 212 are misaligned due to errors that occur during the production of the capacitor element 1 and the resin molded body 2, The deviation is allowed in the horizontal direction d1 and the vertical direction d2. Accordingly, the bus bar 122 can be passed through the through hole 212 with almost no gap, and the bus bar 121 can be passed through the through hole 211.

  By allowing the bus bar 122 to pass through the through-hole 212 with almost no gap, entry of moisture from the through-hole 212 is prevented. On the other hand, the through hole 211 is different from the through hole 212 in that a gap is formed between the through hole 211 and the bus bar 121 even when the bus bar 121 is passed. Therefore, in the film capacitor according to the present embodiment, the gap between the through hole 211 and the bus bar 121 is filled with the filling member 5 in order to prevent moisture from entering through the through hole 211. Here, for the filling member 5, for example, a resin such as an epoxy resin is used. The filling member 5 fills the gap between the through hole 211 and the bus bar 121 and does not fill the film capacitor through the through hole 211.

  The second facing portion 22 has a shape similar to that of the first facing portion 21. In other words, the second facing portion 22 has a shape in which the surface opposite to the facing surface 22a is recessed in a square groove shape at the center in the plan view shape (see FIG. 2A). And the fastening part 4 is formed in each part of the both sides which comprise the hollow part among the 2nd opposing parts 22. FIG. In the present embodiment, the fastening portion 4 is a screw hole used for screwing to the installation object. On the other hand, unlike the first facing portion 21, the second facing portion 22 is not provided with a through hole for passing the bus bar.

  In the present embodiment, the resin molded body 2 further includes a first side plate portion 23 and a second side plate portion 24 that respectively cover two planes located on opposite sides of the side surface 11c of the element body 11. The first opposing portion 21 and the first side plate portion 23 are integrally formed, and the second opposing portion 22 and the second side plate portion 24 are integrally formed, while the first opposing portion 21 and the second opposing portion are formed. The part 22 is configured separately. The first side plate portion 23 does not intervene between the element body 11 and the bus bar 122 but covers the bus bar 122 from the side opposite to the element body 11 (that is, from the outside).

  In this way, the resin molded body 2 covers the first end surface 11a and the second end surface 11b of the element body 11 and the two planes located on the opposite sides of the side surface 11c of the element body 11. That is, the resin molded body 2 covers a part of the outer peripheral surface of the element body 11. Therefore, compared with the conventional capacitor in which the entire element body of the capacitor element is sealed in the epoxy resin, the film capacitor of this embodiment requires a smaller amount of resin.

  In the configuration of the present embodiment, it is preferable that an electrical insulating member is interposed between the bus bar 122 and the edge portion formed by the first end surface 11a and the side surface 11c of the element body 11. As a result, the contact between the bus bar 122 and the electrode layer exposed on the first end face 11a (the first electrode layer or the second electrode layer having a polarity opposite to that of the bus bar 122) is prevented. Such contact is preferably prevented because it can cause an electrical short between the positive and negative electrodes.

[1-3] Exterior Member The exterior member 3 is a member different from the resin molded body 2. As shown in FIGS. 1A and 2B, in the present embodiment, the exterior member 3 is a cylindrical film that covers the side surface 11 c of the element body 11. As an example, this cylindrical film is formed from a laminate film in which a metal layer made of aluminum is interposed between a resin layer made of polypropylene (PP) and a resin layer made of nylon.

  The exterior member 3 covers the first side plate portion 23 and the second side plate portion 24 of the resin molded body 2 from the outside, and is different from the region covered with the resin molded body 2 on the outer peripheral surface of the element body 11. The region (that is, the region exposed from the resin molded body 2) is covered. Here, the exterior member 3 is configured such that a resin layer made of polypropylene (PP) is located on the inner side (element body 11 side) and a resin layer made of nylon is located on the outer side. In addition, the two opening end portions 31 and 32 of the exterior member 3 are respectively fixed to the first facing portion 21 and the second facing portion 22 of the resin molded body 2 with the fastening portion 4 exposed to the outside. Yes. Thus, the periphery of the element body 11 is sealed by the resin molded body 2 and the exterior member 3 in a state where a part of each of the bus bars 121 and 122 is exposed to the outside. The exterior member 3 may be a cylindrical case instead of the cylindrical film. As an example, this case is a cylindrical metal case.

  The film capacitor according to the present embodiment is manufactured as follows. That is, the capacitor element 1, the resin molded body 2, and the exterior member 3 are manufactured in advance and are assembled. Specifically, first, as shown in FIG. 8A, the bus bars 121 and 122 of the capacitor element 1 are passed through the through holes 211 and 212 provided in the first facing portion 21 of the resin molded body 2, respectively. Capacitor element 1 is arranged at a predetermined position with respect to resin molded body 2. Here, it is easy to execute this process in this embodiment. This is because, as described above, according to the through-hole 211, even if the bus bars 121 and 122 and the through-holes 211 and 212 are misaligned due to errors that occur when the capacitor element 1 and the resin molded body 2 are manufactured. This is because such positional deviation is allowed in the horizontal direction d1 and the vertical direction d2.

  Next, as illustrated in FIG. 8B, the gap between the through hole 211 and the bus bar 121 is filled with the filling member 5 in a state where the capacitor element 1 is disposed at a predetermined position. Specifically, first, the filling member 5 is filled into the gap in a softened state. At this time, when the filling member 5 is filled in the gap, the viscosity of the filling member 5 is adjusted to a viscosity that allows the filling member 5 to stay in the gap without flowing out of the gap and to fill the entire gap. . Then, after filling the gap with the filling member 5, the filling member 5 is cured.

  After that, as shown in FIG. 1, the periphery of the element body 11 is sealed with the resin molded body 2 and the exterior member 3 in a state where a part of each of the bus bars 121 and 122 and the fastening portion 4 are exposed to the outside. To do. In addition, this process may be performed before the process (refer FIG.8 (b)) which fills a clearance gap with the filling member 5. FIG. According to the manufacturing method of the present embodiment, the influence of heat on the capacitor element 1 that may occur during resin molding can be eliminated.

  According to the film capacitor according to the present embodiment, weight reduction and high strength against external impact are realized. That is, in the conventional capacitor in which the entire element body of the capacitor element is sealed in the epoxy resin, the weight is increased, whereas in the film capacitor of the present embodiment, the amount of resin used can be reduced. As a result, the weight reduction of the film capacitor is realized. In addition, the conventional capacitor in which the element body of the capacitor element is sealed with a bag-shaped resin film without using a molding resin is easily damaged by an external impact, whereas the film capacitor of this embodiment Then, since the resin molded body 2 is incorporated in the film capacitor and the fastening portion 4 is provided in the resin molded body 2, an impact from the outside is received by the resin molded body 2. Therefore, the capacitor element 1 itself is not easily subjected to an impact, and thus a high strength against an external impact is realized.

  Further, in the film capacitor according to the present embodiment, the first side plate portion 23 is interposed between the exterior member 3 and the element body 11. Specifically, as shown in FIG. 2B, the first side plate portion 23 is interposed between the exterior member 3 and the bus bar 122. Therefore, even when the exterior member 3 is a laminate film or a metal case having a metal layer, the first side plate portion 23 prevents contact between the exterior member 3 and the bus bar 121. Such contact is preferably prevented because it can cause an electrical short between the positive and negative electrodes.

  Furthermore, according to the film capacitor according to the present embodiment, even if the bus bars 121 and 122 and the through holes 211 and 212 are misaligned due to errors that occur when the capacitor element 1 and the resin molded body 2 are produced, When the film capacitor is assembled, the bus bars 121 and 122 are passed through the through holes 211 and 212, respectively, and the capacitor element 1 can be disposed at a predetermined position with respect to the resin molded body 2. This is because the through-hole 211 has widths W1 and W2 larger than the width of the bus bar 121 passed through the through-hole 211 in two directions (lateral direction d1 and vertical direction d2) perpendicular to the through-direction. This is because misalignment occurring in the bus bars 121 and 122 and the through holes 211 and 212 is allowed in two directions (the horizontal direction d1 and the vertical direction d2). On the other hand, such a through hole 211 is different from the through hole 212 in that a gap is generated between the bus bar 121 and the bus bar 121 even when the bus bar 121 is passed. Therefore, in the film capacitor according to the present embodiment, the gap is filled with the filling member 5 in order to prevent moisture from entering from the through hole 211. Therefore, according to the film capacitor according to the present embodiment, the bus bars 121 and 122 and the through holes 211 and 212 do not require high accuracy regarding the shape, size, and position. Easy to manufacture.

[2] Modified Example Next, a modified example of the film capacitor will be specifically described with reference to the drawings.
[2-1] First Modification FIGS. 9A and 9B are enlarged front views conceptually showing a film capacitor according to a first modification. As shown in FIG. 9A, the through hole 211 has a width W1 in the horizontal direction d1 larger than the horizontal width of the bus bar 121, while a width W2 in the vertical direction d2 is a vertical width of the bus bar 121 (that is, It may be the same as or slightly larger (thickness so that no gap is generated between the through hole 211 and the bus bar 121 in the longitudinal direction d2). As shown in FIG. 9B, the through hole 211 has a width W2 in the vertical direction d2 larger than the vertical width (ie, thickness) of the bus bar 121, while the width W1 in the horizontal direction d1. However, the width may be the same as or slightly larger than the horizontal width of the bus bar 121 (so that no gap is generated between the through hole 211 and the bus bar 121 in the horizontal direction d1). In addition, the aspect of the 1st modification regarding the through-hole 211 is applicable also to the 3rd-9th modification mentioned later.

  The above-described two modes of the through hole 211 according to the first modification are selected according to the mode of misalignment occurring in the bus bars 121 and 122 and the through holes 211 and 212 (the direction of misalignment, the positional relationship of torsion, etc.). That is, when the positional deviation is likely to occur in the lateral direction d1, the mode shown in FIG. 9A is adopted. On the other hand, when the positional deviation is likely to occur in the vertical direction d2, the mode shown in FIG. 9B is adopted.

  According to the film capacitor according to the first modification, the gap generated between the through hole 211 and the bus bar 121 can be reduced, so that the filling amount of the filling member 5 into the gap can also be reduced. Therefore, it is easy to prevent moisture from entering through the through hole 211 by a simple method of filling the gap with the filling member 5.

[2-2] Second Modification FIG. 10 is an enlarged front view conceptually showing an example of a film capacitor according to a second modification. As shown in FIG. 10, the through hole 212 is a rectangle in which the cross-sectional shape perpendicular to the through direction extends in the horizontal direction d1 and the vertical direction d2, similarly to the through hole 211, and the horizontal direction d1 and the vertical direction d2 , The width W3 and W4 may be larger than the width of the bus bar 122 passed through the through hole 212. The through holes 211 and 212 may have the same shape and dimensions as shown in FIG. 10 or may have different shapes and dimensions. Further, the above-described two aspects of the through hole 211 according to the first modification can be applied to the through hole 212. Furthermore, the aspects of the through holes 211 and 212 according to the second modification can be applied to third, fourth, and sixth to eighth modifications described later.

  FIG. 11 is an enlarged front view conceptually showing another example of the film capacitor according to the second modification. As shown in FIG. 11, the first facing portion 21 of the resin molded body 2 may be formed with one through hole 214 in which the first through hole 211 and the second through hole 212 are communicated with each other. In this example, the first through-hole 211 and the second through-hole 212 constitute one through-hole 214 and are understood to constitute different parts of the through-hole 214. This aspect can also be applied to third, fourth, and sixth to eighth modifications described later.

According to the second modified example, the allowable range for the positional deviation generated in the bus bars 121 and 122 and the through holes 211 and 212 is expanded. Therefore, it becomes easy to dispose the capacitor element 1 at a predetermined position with respect to the resin molded body 2 when the film capacitor is assembled.
[2-3] Third Modification FIG. 12 is a perspective view conceptually showing a film capacitor according to a third modification. In addition, illustration of the exterior member 3 is abbreviate | omitted in FIG. As shown in FIG. 12, in the resin molded body 2, the first facing portion 21 is formed integrally with both the first side plate portion 23 and the second side plate portion 24, but separate from the second facing portion 22. It may be composed of a body.

  According to the film capacitor in accordance with the third modified example, the weight can be reduced and the film capacitor can be easily manufactured as in the above embodiment. Further, since the element body 11 of the capacitor element 1 is sandwiched between the first side plate portion 23 and the second side plate portion 24, higher strength against external impact is realized.

[2-4] Fourth Modified Example FIG. 13A is a perspective view conceptually showing a film capacitor according to a fourth modified example. Moreover, FIG.13 (b) is the perspective view which showed notionally the resin molding 2 with which the film capacitor is provided. In FIG. 13A, illustration of the exterior member 3 is omitted, and in FIG. 13B, only a portion including the first facing portion 21 of the resin molded body 2 is shown. As shown in FIGS. 13A and 13B, the resin molded body 2 replaces the first side plate portion 23 and the second side plate portion 24 with a cylindrical third side plate surrounding the side surface 11 c of the element body 11. The portion 25 may be included. In this case, it is preferable that the first facing part 21 and the third side plate part 25 are integrally formed, while the first facing part 21 and the second facing part 22 are configured separately. In addition, the 1st opposing part 21 and the 3rd side board part 25 may be comprised by the different body. Moreover, the 3rd side board part 25 may be divided | segmented into the some cylindrical member.

  According to the film capacitor in accordance with the fourth modified example, the weight can be reduced and the manufacture of the film capacitor is facilitated as in the above embodiment. In addition, since the element body 11 of the capacitor element 1 is held by the cylindrical third side plate portion 25, higher strength against external impact is realized.

[2-5] Fifth Modification FIGS. 14A and 14B are respectively a perspective view and a cross-sectional view conceptually showing the resin molded body 2 included in the film capacitor according to the fifth modification. FIG. 15 is a cross-sectional view showing the positional relationship between the capacitor element 1 and the resin molded body 2. In FIGS. 14A and 14B and FIG. 15, only the portion including the first facing portion 21 of the resin molded body 2 is shown. As shown in these drawings, in the resin molded body 2, a through hole 231 may be provided in the first side plate portion 23, and a through hole 212 may be further provided in the first facing portion 21. Here, the through hole 231 is a through hole that penetrates the bus bar 122 along the side surface 11 c of the element body 11. From the end surface of the first side plate portion 23 on the side opposite to the first opposing portion 21, the first opposing portion is provided. 21 to the interface between the first side plate portion 23 and the first side plate portion 23. The through-hole 212 is a through-hole that exposes a part of the bus bar 122 to the outside by passing a portion of the bus bar 122 that has penetrated the through-hole 231.

  According to the film capacitor according to the fifth modified example, as in the above-described embodiment, weight reduction and high strength against external impact are realized, and manufacture of the film capacitor is facilitated. In addition, a part of the resin molded body 2 is interposed between the bus bar 122 and the element body 11, and a part of the resin molded body 2 is also interposed between the bus bar 122 and the exterior member 3. Therefore, the contact between the bus bar 122 and the electrode layer (the first electrode layer or the second electrode layer having a polarity opposite to that of the bus bar 122) exposed on the first end surface 11a is prevented. Further, the contact between the exterior member 3 and the bus bar 121 is prevented. These contacts are preferably prevented because they can cause an electrical short between the positive and negative electrodes.

[2-6] Sixth Modification FIG. 16 is a perspective view conceptually showing the resin molded body 2 provided in the film capacitor according to the sixth modification. In FIG. 16, only the first facing portion 21 of the resin molded body 2 is shown. As shown in FIG. 16, in the 1st opposing part 21, the fitting groove by which the edge part of the element main body 11 containing the 1st end surface 11a is inserted by the opposing surface 21a facing the 1st end surface 11a of the element main body 11 is inserted. 213 may be recessed.

  According to the film capacitor according to the sixth modified example, the weight can be reduced and the film capacitor can be easily manufactured as in the above embodiment. Further, the element body 11 of the capacitor element 1 is held by the resin molding 2 by being inserted into the fitting groove 213. Therefore, higher strength against external impact is realized.

[2-7] Seventh Modification FIGS. 17A and 17B are perspective views conceptually showing a film capacitor according to a seventh modification. In addition, illustration of the exterior member 3 is abbreviate | omitted in FIG.17 (b). As shown in FIGS. 17A and 17B, the resin molded body 2 does not have the second facing portion 22, and is configured by the first facing portion 21 and the first side plate portion 23 formed integrally therewith. It may be a thing. In this case, the exterior member 3 is a bag-like film or a bottomed cylindrical case that covers the second end surface 11 b and the side surface 11 c of the element body 11. As an example, this bag-like film is formed from a laminate film in which a metal layer made of aluminum is interposed between a resin layer made of polypropylene (PP) and a resin layer made of nylon. When such a laminated film is used as the exterior member 3, the exterior member 3 has a resin layer made of polypropylene (PP) located on the inner side (element body 11 side) and a resin layer made of nylon on the outer side. Preferably it is comprised. Moreover, as an example of a case, the bottomed cylindrical metal case (metal can) formed, for example with metals, such as aluminum, is mentioned. When such a metal case is used as the exterior member 3, for example, by applying a modified polypropylene to the element body 11, an insulation coating is performed on the element body 11. It is preferable to ensure electrical insulation.

  The opening 33 of the exterior member 3 is fixed to the first facing portion 21 of the resin molded body 2 with the fastening portion 4 exposed to the outside. Thus, the periphery of the element body 11 is sealed by the resin molded body 2 and the exterior member 3 in a state where a part of each of the bus bars 121 and 122 is exposed to the outside.

  The film capacitor is not limited to the resin molded body 2 having the second facing portion 22 in the above-described embodiment (FIGS. 17A and 17B), and the resin molded body in the first to sixth modifications. 2 may not have the second facing portion 22. In any case, a bag-like film or a bottomed cylindrical case is used as the exterior member 3.

  According to the film capacitor according to the seventh modification, the weight of the resin molded body 2 is reduced, so that further weight reduction is realized. In addition, as in the above-described embodiment, high strength against external impact is realized, and manufacture of the film capacitor is facilitated.

[2-8] Eighth Modification FIG. 18 is a cross-sectional view conceptually showing a film capacitor according to an eighth modification. As shown in FIG. 18, the resin molded body 2 (mainly the first side plate portion 23 and the second side plate portion 24) has a facing surface 26 a that faces the side surface 11 c of the element body 11, and the facing surface 26 a It is preferable that the shape along the side surface 11c of the main body 11 is exhibited.

  According to the film capacitor according to the eighth modification, the contact area between the element body 11 of the capacitor element 1 and the resin molded body 2 is increased. Therefore, the holding power of the resin molded body 2 with respect to the capacitor element 1 is increased, and as a result, higher strength against external impact is realized.

[2-9] Ninth Modification FIG. 19 is a perspective view conceptually showing the resin molded body 2 included in the film capacitor according to the ninth modification. FIG. 20 is a cross-sectional view showing the positional relationship between the capacitor element 1 and the resin molded body 2. 19 and 20, only the portion including the first facing portion 21 of the resin molded body 2 is shown. As shown in FIGS. 19 and 20, in the first facing portion 21, a raised portion 27 may be provided on the facing surface 21 a facing the first end surface 11 a of the element body 11. Here, as shown in FIG. 20, the raised portion 27 includes a bus bar 122 and an electrode layer (a first electrode layer or a second electrode layer having a polarity opposite to that of the bus bar 122) exposed on the first end surface 11a. In order to prevent contact with each other, it has a shape, size, and position that make it possible to separate them.

  According to the film capacitor according to the ninth modification, the contact between the bus bar 122 and the electrode layer exposed on the first end surface 11a (the first electrode layer or the second electrode layer having a polarity opposite to that of the bus bar 122) is present. Is prevented. These contacts are preferably prevented because they can cause an electrical short between the positive and negative electrodes.

  In addition, each part structure of this invention is not restricted to the said embodiment, A various deformation | transformation is possible within the technical scope as described in a claim. For example, the shape and size of each of the through holes 211 and 212 are not limited to the above-described modes, and various modifications may be made depending on the mode of misalignment occurring in the bus bar or the through hole (the direction of misalignment, the positional relationship of the twist, etc.) Is possible.

  In the capacitor element 1, various modifications can be made to the shape of the element body 11 and the shape and the drawing direction of the electrode terminal 12. Further, the resin molded body 2 can be variously deformed according to the shape of the element body 11 and the shape of the electrode terminal 12 and the drawing direction. Furthermore, the shape of the fastening portion 4 can be variously modified according to the shape of the installation object.

  Furthermore, the number of terminals included in the electrode terminal 12 of the capacitor element 1 is not limited to two, and may be three or more. Moreover, each part structure of the said embodiment is applicable not only to a film capacitor but to various capacitors, such as an electrolytic capacitor and a ceramic capacitor.

DESCRIPTION OF SYMBOLS 1 Capacitor element 11 Element main body 11a 1st end surface 11b 2nd end surface 11c Side surface 12 Electrode terminal 121, 122 Bus bar 2 Molded resin body 21 1st opposing part 21a Opposing surface 211, 212, 214 Through-hole 213 Fitting groove 22 2nd opposing Part 22a Opposing surface 23 First side plate part 231 Through hole 24 Second side plate part 25 Third side plate part 26a Opposing surface 27 Raised part 3 Exterior member 31, 32 Opening end part 33 Opening part 4 Fastening part 5 Filling member d1 Lateral direction d2 Vertical direction W1-W4 width

Claims (4)

A capacitor that can be fastened to an installation object,
A capacitor element having an element body and an electrode terminal drawn from the element body;
A resin molded body covering a part of the outer peripheral surface of the element body;
The resin molded body is a separate member, and includes an exterior member that covers at least a region different from the region covered with the resin molded body of the outer peripheral surface of the element body,
The resin molded body is provided with a through hole through which the electrode terminal is passed, and a fastening portion that enables fastening to the installation object,
The through hole has a width larger than the width of the electrode terminal passed through the through hole in at least one direction perpendicular to the through direction, and a gap between the through hole and the electrode terminal is formed by a filling member. Buried,
The periphery of the element body is sealed by the resin molded body and the exterior member in a state where a part of the electrode terminal and the fastening portion are exposed to the outside ,
The outer peripheral surface of the element body includes a first end surface, a second end surface located on the opposite side of the first end surface, and a side surface extending from the first end surface to the second end surface,
The resin molded body has a first facing portion having a facing surface facing the first end surface of the element body, and the through hole and the fastening portion are provided in the first facing portion,
The exterior member is a bag-like film or a bottomed cylindrical case that covers the second end surface and the side surface of the element body, and an opening of the exterior member of the electrode terminal protruding from the through hole A capacitor in which the periphery of the element body is sealed by being fixed to the first facing portion of the resin molded body with a part and the fastening portion exposed to the outside . A capacitor that can be fastened to an installation object,
A capacitor element having an element body and an electrode terminal drawn from the element body;
A resin molded body covering a part of the outer peripheral surface of the element body;
The resin molded body is a separate member, and includes an exterior member that covers at least a region different from the region covered with the resin molded body of the outer peripheral surface of the element body,
The resin molded body is provided with a through hole through which the electrode terminal is passed, and a fastening portion that enables fastening to the installation object,
The through hole has a width larger than the width of the electrode terminal passed through the through hole in at least one direction perpendicular to the through direction, and a gap between the through hole and the electrode terminal is formed by a filling member. Buried,
The periphery of the element body is sealed by the resin molded body and the exterior member in a state where a part of the electrode terminal and the fastening portion are exposed to the outside ,
The outer peripheral surface of the element body includes a first end surface, a second end surface located on the opposite side of the first end surface, and a side surface extending from the first end surface to the second end surface,
The resin molding includes a first facing portion having a facing surface facing the first end surface of the element body, and a second facing portion having a facing surface facing the second end surface of the element body. And the first opposed portion is provided with the through hole, while the fastening portion is provided in both the first opposed portion and the second opposed portion,
The exterior member is a cylindrical film or a cylindrical case that covers the side surface of the element body, and two opening end portions of the exterior member are part of the electrode terminal protruding from the through hole and the A capacitor in which the periphery of the element body is sealed by being fixed to the first facing portion and the second facing portion of the resin molded body with the fastening portion exposed to the outside . The electrode terminal includes a first electrode terminal and a second electrode terminal drawn to the first end face side of the element body,
The through hole provided in the first facing portion of the resin molded body includes a first through hole through which the first electrode terminal is passed, and a first through hole through which the second electrode terminal is passed. Includes different second through holes,
At least one of the first through hole and the second through hole has a width larger than a width of the electrode terminal passed through the through hole in at least one direction perpendicular to the through direction. Item 3. The capacitor according to Item 1 or 2 . The capacitor according to claim 3 , wherein the through-hole provided in the first facing portion of the resin molded body is formed by communicating the first through-hole and the second through-hole with each other.

Images