capacitors

Abstract

The present invention provides a capacitor. A film capacitor comprises a capacitor element, a busbar connected to an electrode of the capacitor element, a housing having an opening and accommodating the capacitor element, and a filling resin filled within the housing. The housing includes a bottom portion opposing the opening and a side portion surrounding the bottom portion. Ribs extending in a first direction aligned with the opening and the bottom portion are formed on the inner wall of the side portion. The busbar includes an electrode terminal portion opposing the side portion, the electrode terminal portion including a protrusion that abuts the rib.

Description

Technical Field

[0001] The present invention relates to capacitors. Background Art

[0002] Patent document 1 describes a structure in which, in a metallized film capacitor in which a capacitor element is housed in a resin case filled with epoxy resin, tooth-like protrusions of a gasket are formed on the inner side of the side surface of the resin case in a manner extending in the direction of the case opening.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. 2007-227696 Summary of the Invention

[0006] Problems to be solved by the invention

[0007] After the filling resin filled in the housing in a liquid state is heated and solidified, it may shrink when cooled. At this time, the side portion of the housing may be pulled by the shrinking filling resin and warp toward the inside of the housing.

[0008] If, as in the capacitor disclosed in Patent Document 1, the side surfaces of the casing are formed with long protrusions, or ribs, extending along the wall surface, the strength of the side surfaces is increased, thereby suppressing some degree of warping. However, in situations where the side surfaces of the casing require high flatness, a structure that further suppresses warping is required.

[0009] For example, in a capacitor that generates significant heat due to high current flowing through the capacitor element, a cooler may be attached to the device at the intended location. In this case, a high degree of flatness in the side surface improves contact with the cooler, thereby enhancing cooling performance.

[0010] In view of such a problem, an object of the present invention is to provide a capacitor capable of sufficiently suppressing inward warping of a case.

[0011] Technical solutions to solve problems

[0012] A capacitor according to a first aspect of the present invention comprises: a capacitor element; a bus bar connected to an electrode of the capacitor element; a case having an opening and accommodating the capacitor element; and a potting resin filled within the case. The case includes a first surface portion opposing the opening and a second surface portion surrounding the first surface portion. Ribs are formed on the inner wall of the second surface portion, extending in a first direction in which the opening and the first surface portion are aligned. The bus bar includes a portion opposing the second surface portion, the portion including an abutting portion that abuts the ribs.

[0013] Effects of the Invention

[0014] According to the present invention, it is possible to provide a capacitor in which inward warping of the case can be sufficiently suppressed.

[0015] The effects and significance of the present invention will become more apparent through the description of the following embodiments. However, the following embodiments are merely examples of the present invention, and the present invention is not limited to the contents described in the following embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 (a) is a perspective view of a film capacitor according to an embodiment as viewed from the front and above. Figure 1 (b) is a perspective view of the film capacitor according to the embodiment as viewed from the front and below.

[0017] Figure 2 (a) is a perspective view of the capacitor element unit according to the embodiment as viewed from the front and above. Figure 2 (b) is a perspective view of the capacitor element unit according to the embodiment as viewed from the rear and above.

[0018] Figure 3 (a) is a perspective view of the first bus bar according to the embodiment as viewed from the front and below. Figure 3 (b) is a partial side cross-sectional view of the first bus bar showing the periphery of the first protrusion according to the embodiment.

[0019] Figure 4 (a) is a perspective view of the second bus bar according to the embodiment as viewed from the front and below. Figure 4 (b) is a partial side cross-sectional view of the second bus bar showing the periphery of the second protrusion according to the embodiment.

[0020] Figure 5 (a) is a perspective view of the housing according to the embodiment as viewed from the front and above. Figure 5 (b) is a perspective view of the housing according to the embodiment as viewed from the rear and above.

[0021] Figure 6 (a) is a perspective view of the right side portion of the housing according to the embodiment as viewed from the front and below, Figure 6 (b) is a partial front cross-sectional view of the housing showing the periphery of the first through hole and the second through hole according to the embodiment.

[0022] Figure 7 (a) and (b) are respectively a perspective view and a top view of a sealing member according to an embodiment. Figure 7 (c) is Figure 7 AA′ cross-sectional view of (b).

[0023] Figure 8 (a) is a side cross-sectional view of the film capacitor in a state before being filled with a filling resin according to an embodiment. Figure 8 (b) is a plan view of the central portion of the film capacitor before being filled with the filling resin according to the embodiment.

[0024] Figure 9 This is a cross-sectional view of a main portion of a film capacitor according to an embodiment, showing a state before the periphery of a first through hole is filled with a filling resin. DETAILED DESCRIPTION

[0025] A film capacitor 1, one embodiment of the present invention, is described below with reference to the accompanying drawings. For convenience, the front-back, left-right, and up-down directions are appropriately indicated in the various figures. The directions shown in the figures represent only relative orientations of film capacitor 1, not absolute orientations. Furthermore, for convenience, some components may be labeled with terms corresponding to the directions shown in the figures, such as "bottom portion" and "front side portion."

[0026] In this embodiment, the thin film capacitor 1 corresponds to the "capacitor" described in the scope of the patent claims. In addition, the bottom portion 201 corresponds to the "first portion" described in the scope of the patent claims. Furthermore, the front side portion 202 and the rear side portion 203 correspond to the "second portion" described in the scope of the patent claims. Furthermore, the first rib 220 and the second rib 230 correspond to the "rib" described in the scope of the patent claims. Furthermore, the upper end surfaces 222 and 232 correspond to the "end surface" described in the scope of the patent claims. Furthermore, the first electrode 510 and the second electrode 520 correspond to the "electrode" described in the scope of the patent claims. Furthermore, the first bus bar 600 and the second bus bar 700 correspond to the "bus bar" described in the scope of the patent claims. Furthermore, the first electrode terminal portion 610 and the second electrode terminal portion 710 correspond to the "opposing portion" described in the scope of the patent claims. Furthermore, the first protrusion 615 and the second protrusion 715 correspond to the “contact portion” and the “protrusion” described in the claims. Furthermore, the front ends 615a and 715a correspond to the “side surface” described in the claims.

[0027] However, the above description is ultimately intended only to establish a correspondence between the structure of the scope of the patent claims and the structure of the embodiment, and does not limit the invention described in the scope of the patent claims to the structure of the embodiment by establishing the correspondence.

[0028] Figure 1 (a) is a perspective view of the film capacitor 1 viewed from the front and above. Figure 1 (b) is a perspective view of the film capacitor 1 as viewed from the front and below.

[0029] like Figure 1 As shown in (a) and (b) of FIG, the film capacitor 1 includes a capacitor element unit 100 , a case 200 accommodating the capacitor element unit 100 , a filling resin 300 filled in the case 200 , and two sealing members 400 .

[0030] Filling resin 300 is a thermosetting resin such as epoxy resin and is injected into case 200 containing capacitor element unit 100 in a liquid state. It is then cured by heating the interior of case 200. The majority of capacitor element unit 100 buried in filling resin 300 is protected from moisture and impact.

[0031] The three first upper connecting terminal portions 630 and the three second upper connecting terminal portions 730 in the capacitor element unit 100 are led outward from the opening portion 200a on the upper surface of the housing 200. The first upper connecting terminal portion 630 and the second upper connecting terminal portion 730 are arranged adjacent to each other in the left-right direction. In addition, the first lower connecting terminal portion 650 and the second lower connecting terminal portion 750 are respectively inserted through the first through-hole 240 and the second through-hole 250 provided in the bottom portion 201 of the housing 200 and led outward. The sealing member 400 is respectively interposed between the outer surface of the first lower connecting terminal portion 650 and the inner wall surface of the first through-hole 240, and between the outer surface of the second lower connecting terminal portion 750 and the inner wall surface of the second through-hole 250.

[0032] Figure 2 (a) is a perspective view of the capacitor element unit 100 viewed from the front and above. Figure 2 (b) is a perspective view of the capacitor element unit 100 viewed from the rear and above. Figure 3 (a) is a perspective view of the first bus bar 600 viewed from the front and below. Figure 3 (b) is a partial side cross-sectional view of the first bus bar 600 showing the periphery of the first protrusion 615 . Figure 4 (a) is a perspective view of the second bus bar 700 viewed from the front and below. Figure 4 (b) is a partial side cross-sectional view of the second bus bar 700 showing the periphery of the second protrusion 715 .

[0033] Reference Figures 2 to 4 In (b), the capacitor element unit 100 includes three capacitor elements 500 , a first bus bar 600 , a second bus bar 700 , and an insulating plate 800 .

[0034] Capacitor element 500 is formed by overlapping two metallized films, each formed by vapor-depositing aluminum onto a dielectric film, and then winding or stacking the overlapped metallized films and pressing them into a flat shape. In capacitor element 500, a first electrode 510 is formed on one end face by spraying a metal such as zinc, and a second electrode 520 is formed on the other end face by similarly spraying a metal such as zinc. Three capacitor elements 500 are arranged so that their circumferential surfaces face each other. In this state, a first bus bar 600 and a second bus bar 700 are connected to these capacitor elements 500.

[0035] Furthermore, capacitor element 500 of this embodiment is formed by vapor-depositing aluminum onto a dielectric film. However, it may also be formed by vapor-depositing another metal such as zinc or magnesium. Alternatively, capacitor element 500 may be formed by vapor-depositing a plurality of these metals, or by vapor-depositing an alloy of these metals.

[0036] The first bus bar 600 is formed of a conductive material, such as a copper plate, and includes a first electrode terminal portion 610, a first upper relay portion 620, three first upper connecting terminal portions 630, a first lower relay portion 640, and a first lower connecting terminal portion 650. The first bus bar 600 is formed, for example, by appropriately cutting and bending a single copper plate, and the first electrode terminal portion 610, the first upper relay portion 620, the first upper connecting terminal portion 630, the first lower relay portion 640, and the first lower connecting terminal portion 650 are integrated.

[0037] The first electrode terminal portion 610 has a roughly rectangular plate shape and covers the first electrode 510 of each capacitor element 500. In the first electrode terminal portion 610, a notch portion 611 cut out into a roughly L-shape is formed at the left end, a roughly rectangular opening portion 612 is formed in the center, and a notch portion 613 cut out into a roughly U-shape is formed at the right end. A pair of electrode pins 614 are formed at the upper edges of the left and right notches 611 and 613 and the opening portion 612. Each pair of electrode pins 614 is joined to the first electrode 510 of the corresponding capacitor element 500 by a joining method such as welding. Thus, the first bus bar 600 is electrically connected to the capacitor element 500.

[0038] A plurality of first protrusions 615 are formed on the upper portion of the first electrode terminal portion 610 so as to protrude forward in a manner aligned in the left-right direction. In this embodiment, four first protrusions 615 are formed. Figure 3 As shown in FIG. 1( b ), each first protrusion 615 has a substantially flat truncated cone shape, with a front end 615 a formed as a circular flat surface and a peripheral surface 615 b having a taper. Furthermore, two circular holes 616 are formed in the lower portion of the first electrode terminal 610 .

[0039] The first upper relay portion 620 provides a relay between the first electrode terminal portion 610 and the three first upper connection terminal portions 630. The first upper relay portion 620 extends slightly rearward and then slightly upward from the upper edge of the first electrode terminal portion 610. Two oblong holes 621 are formed in the first upper relay portion 620, aligned in the left-right direction.

[0040] Three first upper connection terminals 630 are formed at predetermined intervals on the upper edge of the first upper intermediate portion 620. Each first upper connection terminal 630 extends upward from the upper edge of the first upper intermediate portion 620, with a widened base and a large rounded corner at the distal end. A circular mounting hole 631 is formed in each first upper connection terminal 630.

[0041] The first lower relay portion 640 provides a relay between the first electrode terminal portion 610 and the first lower connecting terminal portion 650. The first lower relay portion 640 extends rearward from the lower edge of the first electrode terminal portion 610. The first lower relay portion 640 includes a connecting portion 641 at its right end, extending rearward with the same width as the first lower connecting terminal portion 650 and connected to the first lower connecting terminal portion 650.

[0042] The first lower connection terminal portion 650 extends downward from the front end of the connection portion 641 of the first lower intermediate portion 640 and has a substantially rectangular plate shape. A circular mounting hole 651 is formed in the first lower connection terminal portion 650 .

[0043] The second bus bar 700 is formed of a conductive material, such as a copper plate, and includes a second electrode terminal portion 710, a second upper relay portion 720, a second upper connecting terminal portion 730, a second lower relay portion 740, and a second lower connecting terminal portion 750. The second bus bar 700 is formed, for example, by appropriately cutting and bending a single copper plate. The second electrode terminal portion 710, the second upper relay portion 720, the three second upper connecting terminal portions 730, the second lower relay portion 740, and the second lower connecting terminal portion 750 are integrated.

[0044] The second electrode terminal portion 710 has a roughly rectangular plate shape and covers the second electrode 520 of each capacitor element 500. A notch 711, cut into a roughly U-shaped shape, is formed at the left end of the second electrode terminal portion 710, and two roughly rectangular openings 712 and 713 are formed in the center and right portions. A pair of electrode pins 714 are formed at the upper edges of the notch 711 and the two openings 712 and 713. Each pair of electrode pins 714 is bonded to the second electrode 520 of the corresponding capacitor element 500 by welding or other bonding methods. This electrically connects the second bus bar 700 to the capacitor element 500.

[0045] A plurality of second protrusions 715 are formed on the upper portion of the second electrode terminal portion 710 so as to protrude rearward in a manner arranged in the left-right direction. In this embodiment, four second protrusions 715 are formed. Figure 4As shown in (b), each second protrusion 715 has a substantially flat truncated cone shape, with a front end 715a formed as a circular flat surface and a peripheral surface 715b having a taper. In addition, two circular holes 716 are formed in the upper and lower parts of the second electrode terminal portion 710, respectively.

[0046] The second upper relay portion 720 provides a relay between the second electrode terminal portion 710 and the three second upper connection terminal portions 730. The second upper relay portion 720 extends forward from the upper edge of the second electrode terminal portion 710 and then slightly upward. The second upper relay portion 720 has two oblong holes 721 and four circular holes 722 formed in a horizontal arrangement. Furthermore, the second upper relay portion 720 has three oblong holes 723 formed in a horizontal arrangement, further forward than the six holes 721 and 722.

[0047] Three second upper connection terminal portions 730 are formed at predetermined intervals on the upper edge of the second upper intermediate portion 720. Each second upper connection terminal portion 730 extends upward from the upper edge of the second upper intermediate portion 720, with a widened base and a large rounded corner at the distal end. A circular mounting hole 731 is formed in each second upper connection terminal portion 730.

[0048] The second lower relay portion 740 provides a relay between the second electrode terminal portion 710 and the second lower connecting terminal portion 750. The second lower relay portion 740 extends forward from the lower edge of the second electrode terminal portion 710. The second lower relay portion 740 includes a connecting portion 741 at its right end, extending rearward with the same width as the second lower connecting terminal portion 750 and connected to the second lower connecting terminal portion 750.

[0049] The second lower connection terminal portion 750 extends downward from the front end of the connection portion 741 of the second lower intermediate portion 740 and has a substantially rectangular plate shape. A circular mounting hole 751 is formed in the second lower connection terminal portion 750 .

[0050] The insulating plate 800 is formed of a resin material such as polyphenylene sulfide (PPS) and is interposed between the first upper relay portion 620 and the three first upper connecting terminal portions 630 of the first bus bar 600 and the second upper relay portion 720 and the three second upper connecting terminal portions 730 of the second bus bar 700, which overlap in the front-to-back direction. The insulating plate 800 ensures insulation between the first bus bar 600 and the second bus bar 700.

[0051] In the capacitor element unit 100 , the first lower connection terminal portion 650 of the first bus bar 600 and the second lower connection terminal portion 750 of the second bus bar 700 are located at the lower portion of the right end.

[0052] Figure 5(a) is a perspective view of the housing 200 viewed from the front and above. Figure 5 (b) is a perspective view of the housing 200 viewed from the rear and above. Figure 6 (a) is a perspective view of the right side of the housing 200 as viewed from the front and below. Figure 6 (b) is a partial front cross-sectional view of the housing 200 showing the periphery of the first through-hole 240 and the second through-hole 250 .

[0053] Reference Figure 5 (a) to Figure 6 (b) The housing 200 is made of resin, such as polyphenylene sulfide (PPS), and has a substantially rectangular box shape that is long in the left-right direction and has an open top surface. The housing 200 includes a bottom portion 201 that is opposite to the opening 200a in the top surface, and a front side portion 202, a rear side portion 203, a left side portion 204, and a right side portion 205 that rise from the bottom portion 201 and surround the front, rear, left, and right sides of the bottom portion 201, respectively. The front side portion 202 and the rear side portion 203 are a pair of side portions along the longitudinal direction of the housing 200 and have a relatively large width (dimension in the left-right direction). The left side portion 204 and the right side portion 205 are a pair of side portions along the transverse direction of the housing 200 and have a relatively small width (dimension in the front-to-back direction).

[0054] Mounting tabs 210 are provided on the outer wall surfaces of the left side surface 204 and the right side surface 205. Each mounting tab 210 has insertion holes 211 formed on the top and bottom. Metal collars 212 are inserted into the insertion holes 211 to increase their strength. When film capacitor 1 is installed in an external device, these mounting tabs 210 are secured to the installation using screws or the like.

[0055] A plurality of first ribs 220 and a plurality of second ribs 230 are formed on the front side portion 202 and the rear side portion 203, respectively, so as to be arranged in the left-right direction and project from the inner wall toward the inner side of the housing 200. In this embodiment, there are six first ribs 220 and six second ribs 230. In other words, the plurality of first ribs 220 and the plurality of second ribs 230 are dispersedly arranged at predetermined intervals throughout the entirety of the front side portion 202 and the rear side portion 203 in order to reinforce these side portions.

[0056] Each first rib 220 and each second rib 230 extends from near the bottom surface 201 to near the opening 200a. Each first rib 220 and each second rib 230 has a generally rectangular parallelepiped shape that is elongated in the vertical direction and flat in the front-to-back direction. As a result, the front ends 221 and 231 of each first rib 220 and each second rib 230 form elongated, square, flat surfaces. The upper end surfaces (end surfaces facing the opening 200a) 222 and 232 of each first rib 220 and each second rib 230 are inclined so as to move away from the opening 200a as they move toward the interior of the housing 200.

[0057] Of the six first ribs 220, the positions of the four central first ribs 220 correspond to the positions of the four first protrusions 615 of the first bus bar 600. These four first ribs 220 have a horizontal dimension slightly smaller than the diameter of the front end 615a of the first protrusion 615 (the horizontal dimension), and a vertical dimension much larger than the diameter of the front end 615a of the first protrusion 615 (the vertical dimension).

[0058] Similarly, among the six second ribs 230, the positions of the four second ribs 230 in the central portion correspond to the positions of the four second protrusions 715 of the second bus bar 700. These four second ribs 230 have a horizontal dimension slightly smaller than the diameter of the front end 715a of the second protrusion 715, and a vertical dimension significantly larger than the diameter (vertical dimension) of the front end 715a of the second protrusion 715.

[0059] The bottom portion 201 has a shape in which the bottom is slightly deeper in the right end vicinity 201a than in the other portions. A substantially square protrusion 206 is formed in the right end vicinity 201a, and the wall thickness of the bottom portion 201 is greater than that of the other portions.

[0060] The protrusion 206 includes a first through-hole 240 and a second through-hole 250 arranged in the left-right direction. The first through-holes 240 and the second through-hole 250 include first holes 241, 251 and second holes 242, 252 continuous with the first holes 241, 251. The second holes 242, 252 are larger and longer (deeper) than the first holes 241, 251. The first holes 241, 251 are located inside the housing 200, while the second holes 242, 252 are located outside the housing 200.

[0061] First holes 241 and 251 have shapes corresponding to the horizontal cross-sections of first lower connecting terminal portion 650 and second lower connecting terminal portion 750, respectively, that is, elongated squares. The inner walls of first holes 241 and 251 have slopes 241a and 251a that widen toward the interior of housing 200. The diameters (front-to-back and left-to-right dimensions) of the smallest lower ends of first holes 241 and 251 are slightly larger than the diameters (thickness and width) of first lower connecting terminal portion 650 and second lower connecting terminal portion 750, respectively.

[0062] The second holes 242 and 252 have a shape corresponding to the planar shape of the sealing member 400, that is, an oval shape. The draft of the mold used to mold the case 200 is formed on the inner wall surface of the second holes 242 and 252.

[0063] Figure 7 (a) and (b) are respectively a perspective view and a top view of the sealing member 400. Figure 7 (c) is Figure 7 AA′ cross-sectional view of (b).

[0064] The two sealing members 400 are formed of an elastic material, for example, a rubber material such as silicone rubber, and have an oblong cylindrical shape.

[0065] In each sealing member 400, an elastically deformable annular fin portion 410 surrounding the outer peripheral surface is formed at the front end portion and the middle portion. Figure 7 As shown in (c), the fin portion 410 has a cross-section similar to a right triangle, with a surface 411 toward the front end direction (upward direction) slowly convexly curved and inclined, and a surface 412 toward the base end direction (downward direction) slowly concavely curved. In order to match the draft angle of the second holes 242 and 252 of the housing 200, the height of the fin portion 410 at the front end is slightly lower than the height of the fin portion 410 at the middle portion. In addition, a flange portion 420 is formed at the base end of each sealing member 400. Furthermore, two annular ribs 430 capable of elastic deformation are formed around the inner circumference of each sealing member 400. The cross-section of each rib 430 has a semicircular shape. In the longitudinal direction (up and down direction) of the sealing member 400, the rib 430 on the front end side is located between the two fin portions 410, and the rib 430 on the base end side is located between the fin portion 410 and the flange portion 420 in the middle portion. That is, in the longitudinal direction of the sealing member 400 , the positions of the two fin portions 410 and the positions of the two ribs 430 are different.

[0066] The outer diameter of the sealing member 400 including the fin portion 410 is larger than the diameters of the first through-hole 240 and the second holes 242 and 252 of the second through-hole 250. Furthermore, the inner diameter of the sealing member 400 including the rib 430 is smaller than the diameters (thickness, width) of the first lower connecting terminal portion 650 and the second lower connecting terminal portion 750.

[0067] Figure 8 (a) is a side cross-sectional view of the film capacitor 1 before the filling resin 300 is filled. Figure 8 (b) is a plan view of the central portion of the film capacitor 1 before being filled with the filling resin 300 . Figure 9 2 is a cross-sectional view of the main part of the film capacitor 1 showing a state before the filling resin 300 is filled around the first through hole 240. Figure 9 , for convenience, the sealing member 400 is shown in a state before the fin portion 410 and the rib 430 are deformed.

[0068] The capacitor element unit 100 is housed within the housing 200 through the opening 200a on the upper surface of the housing 200. At this point, the first lower connecting terminal portion 650 of the first bus bar 600 is inserted through the first through-hole 240 and led to the outside, while the second lower connecting terminal portion 750 of the second bus bar 700 is inserted through the second through-hole 250 and led to the outside. At this point, the first holes 241 and 251 of the first and second through-holes 240 and 250 expand toward the interior of the housing 200, making it easy to insert the first and second lower connecting terminal portions 650 and 750 into the first and second through-holes 240 and 250 within the housing 200. The first and second lower connecting terminal portions 650 and 750, inserted through the first and second through-holes 240 and 250, are positioned by the first holes 241 and 251.

[0069] When the capacitor element unit 100 is inserted into the housing 200, the first electrode terminal portion 610 of the first bus bar 600 faces the front side portion 202, and the four first protrusions 615 of the first electrode terminal portion 610 abut against the four first ribs 220 in the center of the front side portion 202 at the upper portion of the housing 200, that is, closer to the opening 200a than the bottom portion 201. Similarly, the second electrode terminal portion 710 of the second bus bar 700 faces the rear side portion 203, and the four second protrusions 715 of the second electrode terminal portion 710 abut against the four second ribs 230 in the center of the rear side portion 203 at the upper portion of the housing 200.

[0070] At this time, the flat surfaces of the front ends 221 and 615a of the first rib 220 and the first protrusion 615 abut against each other, and the flat surfaces of the front ends 231 and 715a of the second rib 230 and the second protrusion 715 abut against each other. Therefore, even if the positions of the first rib 220 and the first protrusion 615 or the positions of the second rib 230 and the second protrusion 715 are slightly offset in the left-right direction, they can still be reliably abutted. In addition, the diameter (dimension in the left-right direction) of the front ends 615a and 715a of the first protrusion 615 and the second protrusion 715 is larger than the width (dimension in the left-right direction) of the front ends 221 and 231 of the first rib 220 and the second rib 230. Therefore, while suppressing the increase in the amount of resin in the shell 200 caused by the widening of the width of the first rib 220 and the second rib 230, the first rib 220 and the first protrusion 615 can be more reliably abutted, and the second rib 230 and the second protrusion 715 can be more reliably abutted.

[0071] Furthermore, the upper end surfaces 222, 232 of the first and second ribs 220, 230, and the lower sides of the peripheral surfaces 615b, 715b of the first and second protrusions 615, 715, i.e., the bottom surface 201 side, are inclined so as to move away from the opening 200a as they move toward the interior of the housing 200. Consequently, when the capacitor element unit 100 is inserted into the housing 200 from above, the first and second protrusions 615, 715 are less likely to get caught on the upper end surfaces 222, 232 of the first and second ribs 220, 230. Consequently, the capacitor element unit 100 can be smoothly accommodated within the housing 200.

[0072] After the capacitor element unit 100 is housed in the housing 200, the sealing member 400 is inserted from the outside of the housing 200 into the first lower connecting terminal portion 650 and the second lower connecting terminal portion 750, and then into the second holes 242 and 252 of the first through-hole 240 and the second through-hole 250. When the sealing member 400 is pressed into the second holes 242 and 252 until its flange portion 420 abuts against the wall surface surrounding the second holes 242 and 252 in the protrusion 206 of the housing 200, the assembly of the sealing member 400 is complete. By confirming that the flange portion 420 abuts against the wall surface of the protrusion 206, it can be confirmed that the sealing member 400 is fully assembled.

[0073] like Figure 9As shown, the sealing member 400 is interposed between the outer surface of the first lower connecting terminal portion 650 and the inner wall surface of the second hole 242 of the first through-hole 240, thereby sealing the first lower connecting terminal portion 650 and the first through-hole 240. The two fin portions 410 on the outer peripheral surface of the sealing member 400 collapse downward, that is, collapse in a direction opposite to the insertion direction of the sealing member 400 into the first through-hole 240, and deform inwardly, thereby contacting the inner wall surface of the second hole 242 along the entire circumference. Each fin portion 410 is pressed against the inner wall surface of the second hole 242.

[0074] Furthermore, the two ribs 430 on the inner circumferential surface of the sealing member 400 deform inwardly, contracting to contact the outer surface of the first lower connecting terminal portion 650 along its entire circumference. Each rib 430 is pressed against the outer surface of the first lower connecting terminal portion 650. Portions of the inner circumferential surface of the sealing member 400 other than the ribs 430 do not contact the outer surface of the first lower connecting terminal portion 650. This makes it easier to insert the sealing member 400 into the first lower connecting terminal portion 650.

[0075] The length from the front end of the sealing member 400 to the front of the flange portion 420 is shorter than the length of the second hole 242. Therefore, a small gap is formed between the wall surface between the first hole 241 and the second hole 242 of the first through hole 240 and the front end surface of the sealing member 400.

[0076] Similarly, the sealing member 400 is interposed between the outer surface of the second lower connecting terminal portion 750 and the inner wall surface of the second hole 252 of the second through-hole 250, thereby sealing the second lower connecting terminal portion 750 and the second through-hole 250. The two fin portions 410 deform to abut against the inner wall surface of the second hole 252 over their entire circumference, and the two ribs 430 deform to abut against the outer surface of the second lower connecting terminal portion 750 over their entire circumference. A small gap is formed between the wall surface between the first hole 251 and the second hole 252 of the second through-hole 250 and the front end surface of the sealing member 400.

[0077] Furthermore, the fin portion 410 of the sealing member 400 has a surface 411 inclined toward the distal end, ie, the insertion direction.

[0078] Liquid-phase filling resin 300 is injected through opening 200a and stored in housing 200, which houses capacitor element unit 100. At this point, sealing member 400 seals the space between first lower connecting terminal 650 and first through-hole 240, and sealing member 400 seals the space between second lower connecting terminal 750 and second through-hole 250. This prevents liquid-phase filling resin 300 from leaking from first through-hole 240 and second through-hole 250 to the outside of housing 200.

[0079] In particular, regarding the sealing member 400, the fin portion 410 is in close contact with the inner wall surfaces of the first through-hole 240 and the second through-hole 242, 252 of the second through-hole 250 due to the pressing force (stress) generated by the deformation of the fin portion 410, thereby strongly blocking the gap between the sealing member 400 and the inner wall surfaces of the second holes 242, 252. This effectively prevents the filling resin 300 from leaking from between the sealing member 400 and the second holes 242, 252.

[0080] Furthermore, regarding the sealing member 400, the ribs 430 are in close contact with the outer surfaces of the first lower connecting terminal portion 650 and the second lower connecting terminal portion 750 due to the pressing force (stress) generated by the deformation of the ribs 430, thereby strongly blocking the gap between the sealing member 400 and the outer surfaces of the first lower connecting terminal portion 650 and the second lower connecting terminal portion 750. This effectively prevents the filling resin 300 from leaking from between the sealing member 400 and the first lower connecting terminal portion 650 and the second lower connecting terminal portion 750.

[0081] Furthermore, the second holes 242 and 252 are blocked from the outside of the housing 200 by the flange portion 420 of the sealing member 400 , thereby further preventing the filling resin 300 from leaking from the first through-hole 240 and the second through-hole 250 to the outside of the housing 200 .

[0082] Part of the filling resin 300 injected into the housing 200 flows between the front side portion 202 and the first electrode terminal portion 610 and between the rear side portion 203 and the second electrode terminal portion 710 .

[0083] The vertical dimension of the first protrusion 615 (the direction in which the opening 200a and the bottom surface 201 are aligned) is smaller than the vertical dimension of the first rib 220. At the four central first ribs 220, a gap is formed between the first electrode terminal 610 and the first rib 220, except for the portion where the first rib 220 and the first protrusion 615 contact each other. Similarly, the vertical dimension of the second protrusion 715 is smaller than the vertical dimension of the second rib 230. At the four central second ribs 230, a gap is formed between the second electrode terminal 710 and the second rib 230, except for the portion where the second rib 230 and the second protrusion 715 contact each other. Therefore, the filling resin 300 can smoothly move back and forth in the left-right direction at the positions of the first ribs 220 and the second ribs 230 and can be well distributed between the front side portion 202 and the first electrode terminal portion 610 and between the rear side portion 203 and the second electrode terminal portion 710 .

[0084] In addition, in the case of a structure in which the first electrode terminal portion 610 and the second electrode terminal portion 710 are not provided with the first protrusion portion 615 and the second protrusion portion 715, and the front ends 221 and 231 of the first rib 220 and the second rib 230 are substantially entirely in contact with the flat outer surfaces of the first electrode terminal portion 610 and the second electrode terminal portion 710, there is almost no gap between the first electrode terminal portion 610 and the first rib 220 and between the second electrode terminal portion 710 and the second rib 230, so that the filling resin 300 cannot move smoothly in the left-right direction and is not easy to spread between the front side portion 202 and the first electrode terminal portion 610 and between the rear side portion 203 and the second electrode terminal portion 710.

[0085] Furthermore, the filling resin 300 that flows into the shell 200 flows through the holes 616, 621 provided in the first bus bar 600 and the holes 716, 721, 722, and 723 provided in the second bus bar 700, thereby also being well distributed to the inner side of the capacitor element unit 100, that is, between the first bus bar 600 and the second bus bar 700 and the three capacitor elements 500.

[0086] Once the filling resin 300 has been injected into the housing 200, the housing 200 is heated, thereby solidifying the filling resin 300 within the housing 200. The solidified filling resin 300 then cools, but this may cause the filling resin 300 to shrink. This creates stress on the front side 202, rear side 203, left side 204, and right side 205 of the housing 200, causing the shrinking filling resin 300 to pull the filling resin 300 toward the interior of the housing 200.

[0087] The front side portion 202 and the rear side portion 203 are reinforced by six first ribs 220 and six second ribs 230, respectively. Furthermore, the four first ribs 220 and four second ribs 230 in the central portion abut against the first protrusion 615 and the second protrusion 715, respectively. As a result, the front side portion 202 and the rear side portion 203 are supported from the inside of the housing 200 by the first protrusion 615 and the second protrusion 715. This effectively prevents the front side portion 202 and the rear side portion 203 from warping toward the inside of the housing 200. In particular, the upper portions of the front side portion 202 and the rear side portion 203 near the opening 200a are susceptible to warping. However, the first protrusion 615 and the second protrusion 715 are located at the upper portions, effectively preventing warping of the front side portion 202 and the rear side portion 203.

[0088] On the other hand, the left side surface 204 and the right side surface 205 are not only small in the front-to-back direction, but are also reinforced by the mounting joint 210 formed on the outer wall. Thus, even if the left side surface 204 and the right side surface 205 do not have a structure based on the first rib 220 and the second rib 230 and the first protrusion 615 and the second protrusion 715, warping toward the interior of the housing 200 can be prevented.

[0089] In this way, Figure 1 As shown in (a) and (b), the film capacitor 1 is completed.

[0090] The film capacitor 1 is mounted on various external devices, such as inverters, included in electric vehicles. A pair of external terminals (not shown) corresponding to these connection terminals 630 and 730, provided on the external device, are connected to the first upper connection terminal portion 630 and the second upper connection terminal portion 730. Furthermore, a pair of external terminals (not shown) corresponding to these connection terminals 650 and 750, provided on the external device, are connected to the first lower connection terminal portion 650 and the second lower connection terminal portion 750.

[0091] In addition, the front, back, left, and right directions of the film capacitor 1 when mounted on an external device are not necessarily the same as those shown in this embodiment, that is, the direction in which the opening 200a of the housing 200 is in the upward direction and the bottom portion 201 is in the downward direction is not necessarily the same. For example, the film capacitor 1 can be set in an external device in such a way that the rear side portion 203 is in the downward direction. Moreover, in the case where the film capacitor 1 requires strong cooling, a cooler (not shown) is mounted on the outer surface of the rear side portion 203. In this case, since the flatness of the rear side portion 203 of the film capacitor 1 becomes higher, the adhesion of the cooler becomes better, and good cooling performance can be obtained.

[0092] <Effects of Implementation>

[0093] As described above, according to this embodiment, the following effects can be achieved.

[0094] The film capacitor 1 includes a capacitor element 500, a first bus bar 600 (second bus bar 700) connected to the first electrode 510 (second electrode 520) of the capacitor element 500, a case 200 having an opening 200a and accommodating the capacitor element 500, and a potting resin 300 filled within the case 200. The case 200 includes a bottom portion 201 facing the opening 200a and a front side portion 202 (rear side portion 203) surrounding the bottom portion 201. First ribs 220 (second ribs 230) extending in the direction in which the opening 200a and the bottom portion 201 are aligned are formed on the inner wall surface of the front side portion 202 (rear side portion 203). The first bus bar 600 (second bus bar 700) includes a first electrode terminal portion 610 (second electrode terminal portion 710) facing the front side portion 202 (rear side portion 203). The first electrode terminal portion 610 (second electrode terminal portion 710) includes a first protrusion 615 (second protrusion 715) that contacts the first rib 220 (second rib 230). The first protrusion 615 (second protrusion 715) protrudes toward the first electrode terminal portion 610 (second electrode terminal portion 710) and is shorter in the direction in which the opening 200a and the bottom portion 201 are aligned than the first rib 220 (second rib 230) in that direction.

[0095] According to this structure, the strength of the front side portion 202 (rear side portion 203) can be increased by the first rib 220 (second rib 230). In addition, the first protrusion 615 (second protrusion 715) abuts against the first rib 220 (second rib 230), so that the first protrusion 615 (second protrusion 715) can support the front side portion 202 (rear side portion 203) from the inside of the housing 200. As a result, it is possible to strongly suppress the front side portion 202 (rear side portion 203) from warping toward the inside of the housing 200.

[0096] Furthermore, the dimensions of the first protrusion 615 (second protrusion 715) in the direction (vertical direction) in which the opening 200a and the bottom surface 201 are aligned are smaller than the dimensions of the first rib 220 (second rib 230) in that direction. At the location of the first rib 220 (second rib 230), in the aforementioned alignment direction, a gap is created between the first electrode terminal 610 (second electrode terminal 710) and the first rib 220 (second rib 230), except for the portion where the first rib 220 (second rib 230) and the first protrusion 615 (second protrusion 715) contact each other. Consequently, when the liquid filling resin 300 is injected into the housing 200, the filling resin 300 can flow smoothly in a direction perpendicular to the aforementioned alignment direction (horizontal direction) at the location of the first rib 220 (second rib 230). Therefore, the poured filling resin 300 can be spread well between the front side portion 202 and the first electrode terminal portion 610 (between the rear side portion 203 and the second electrode terminal portion 710 ).

[0097] Furthermore, in the film capacitor 1 , the respective tips 221 ( 231 ) and 615 a ( 715 a ) of the first rib 220 (second rib 230 ) and the first protrusion 615 (second protrusion 715 ) are formed as flat surfaces.

[0098] According to this structure, the flat surfaces of the front ends 221 (231) and 615a (715a) of the first rib 220 (second rib 230) and the first protrusion 615 (second protrusion 715) abut against each other. Therefore, even if the positions of the first rib 220 (second rib 230) and the first protrusion 615 (second protrusion 715) are slightly offset in a direction perpendicular to the direction in which the opening 200a and the bottom surface 201 are arranged (in the left-right direction), they can still be reliably abutted.

[0099] Furthermore, in the film capacitor 1, the upper end surface 222 (232) of the first rib 220 (second rib 230) and the peripheral surface 615b (715b) on the bottom surface 201 side of the first protrusion 615 (second protrusion 715) are inclined so as to move away from the opening 200a as they move toward the interior of the housing 200.

[0100] According to this structure, when the capacitor element unit 100 is inserted into the shell 200 from the opening 200a, the first protrusion 615 (the second protrusion 715) is not easily hung on the upper end surface 222 (232) of the first rib 220 (the second rib 230), and the capacitor element unit 100 can be smoothly accommodated in the shell 200.

[0101] Furthermore, the film capacitor 1 is configured such that the first protrusion 615 (the second protrusion 715 ) is positioned closer to the opening 200 a than the bottom portion 201 .

[0102] According to this structure, although the front side portion 202 (rear side portion 203) is prone to warping on the side close to the opening portion 200a, the position of the first protrusion 615 (second protrusion 715) is closer to the opening portion 200a than the bottom portion 201, so the warping of the front side portion 202 (rear side portion 203) can be effectively suppressed.

[0103] As mentioned above, although embodiment of this invention was demonstrated, this invention is not limited to the said embodiment, Moreover, application example of this invention can also be variously changed besides the said embodiment.

[0104] For example, in the above embodiment, the first protrusions 615 and the second protrusions 715 are formed on the first electrode terminal portion 610 and the second electrode terminal portion 710 as contact portions with the first ribs 220 and the second ribs 230. However, a configuration may be employed in which the first protrusions 615 and the second protrusions 715 are not formed on the first electrode terminal portion 610 and the second electrode terminal portion 710, and the outer surfaces of the first electrode terminal portion 610 and the second electrode terminal portion 710 serve as contact portions with the first ribs 220 and the second ribs 230. However, in this case, it is difficult to obtain a gap between the first electrode terminal portion 610 and the first rib 220 and between the second electrode terminal portion 710 and the second rib 230. Therefore, accordingly, the liquid-phase filling resin 300 injected into the shell 200 may become difficult to spread between the front side portion 202 and the first electrode terminal portion 610 and between the rear side portion 203 and the second electrode terminal portion 710.

[0105] In the above embodiment, the first protrusions 615 and the second protrusions 715 are configured to abut against a portion (four) of the plurality (six) of first ribs 220 and second ribs 230. However, a configuration may be employed in which the first protrusions 615 and the second protrusions 715 abut against all of the plurality of first ribs 220 and second ribs 230. Furthermore, the number of first ribs 220 and second ribs 230 and the number of first protrusions 615 and second protrusions 715 are not limited to those in the above embodiment and can be modified as appropriate.

[0106] Furthermore, in the above embodiment, the tips 615a and 715a of the first protrusion 615 and the second protrusion 715 are flat surfaces. However, the tips 615a and 715a may be arcuate surfaces instead of flat surfaces. Similarly, the tips 221 and 231 of the first rib 220 and the second rib 230 may be arcuate surfaces instead of flat surfaces.

[0107] Furthermore, the shapes of the first protrusion 615 and the second protrusion 715 are not limited to the above embodiment. For example, the first protrusion 615 and the second protrusion 715 may be shaped other than circular, such as oval, square, or rectangular, when viewed from the main surface.

[0108] Furthermore, in the above-mentioned embodiment, both the upper end surfaces 222, 232 of the first rib 220 and the second rib 230 and the peripheral surfaces 615b, 715b on the bottom surface 201 side of the first protrusion 615 and the second protrusion 715 are inclined in a manner away from the opening portion 200a as they move toward the interior of the shell 200, but only one side may be inclined.

[0109] Furthermore, in the above embodiment, the first protrusion 615 and the second protrusion 715 are formed on the upper portions of the first electrode terminal portion 610 and the second electrode terminal portion 710 so as to be closer to the opening portion 200a than the bottom portion 201. However, the first protrusion 615 and the second protrusion 715 may be formed not only on the upper portion but also on the lower portion of the first electrode terminal portion 610 and the second electrode terminal portion 710. Furthermore, a structure may be adopted in which three or more first protrusions 615 and second protrusions 715 abut against one first rib 220 and one second rib 230 in the direction in which these ribs extend.

[0110] Furthermore, in the above embodiment, the first electrode terminal portion 610 of the first bus bar 600 faces the front side portion 202, and the second electrode terminal portion 710 of the second bus bar 700 faces the rear side portion 203. However, the portion of the first bus bar 600 other than the first electrode terminal portion 610 may face the front side portion 202, and the portion of the second bus bar 700 other than the second electrode terminal portion 710 may face the rear side portion 203. In this case, the first protrusion 615 is formed on the portion of the first bus bar 600 facing the front side portion 202, and the second protrusion 715 is formed on the portion of the second bus bar 700 facing the rear side portion 203.

[0111] Furthermore, in the above embodiment, three capacitor elements 500 are included in the capacitor element unit 100. However, the number of capacitor element 500 may be one, and can be changed as appropriate.

[0112] Furthermore, in the above-described embodiment, capacitor element 500 is formed by overlapping two metallized films in which aluminum is vapor-deposited on a dielectric film and then winding or laminating the overlapped metallized films. Alternatively, capacitor element 500 may be formed by overlapping metallized films in which aluminum is vapor-deposited on both sides of a dielectric film and an insulating film and then winding or laminating them.

[0113] Furthermore, in the above embodiment, the film capacitor 1 is cited as an example of the capacitor of the present invention. However, the present invention is also applicable to capacitors other than the film capacitor 1.

[0114] In addition, various modifications can be made to the embodiments of the present invention as appropriate within the scope of the technical concept shown in the claims.

[0115] In the description of the above embodiments, terms indicating directions such as “above” and “below” indicate relative directions that depend only on the relative positional relationship of structural members, and do not indicate absolute directions such as vertical directions and horizontal directions.

[0116] Industrial applicability

[0117] The present invention is useful in capacitors used in various electronic devices, electrical equipment, industrial equipment, electrical components of vehicles, and the like.

[0118] Explanation of symbols

[0119] 1 film capacitor (capacitor);

[0120] 200 shell;

[0121] 200a opening;

[0122] 201 bottom face (first face);

[0123] 202 frontal face (second face);

[0124] 203 posterior face (second face);

[0125] 220 1st rib (rib);

[0126] 221 front end;

[0127] 222 upper end face (end face);

[0128] 230 2nd rib (rib);

[0129] 231 front end;

[0130] 232 upper end face (end face);

[0131] 300 filling resin;

[0132] 500 capacitor elements;

[0133] 510 1st electrode (electrode);

[0134] 520 2nd electrode (electrode);

[0135] 600 Bus Bar No. 1 (Bus Bar);

[0136] 610 first electrode terminal portion (opposing portion);

[0137] 615 first protrusion (abutment portion, protrusion);

[0138] 615a front end;

[0139] 615b circumference (side);

[0140] 700 Bus Bar 2 (Bus Bar);

[0141] 710 second electrode terminal portion (opposing portion);

[0142] 715 second protrusion (contact portion, protrusion);

[0143] 715a front end;

[0144] 715b circumference (side).

Claims

1. A capacitor comprising: capacitor elements; a bus bar connected to the electrodes of the capacitor element; a housing having an opening portion for accommodating the capacitor element; and Filling resin, filling the shell, The housing includes a bottom portion facing the opening and a side portion surrounding the bottom portion. The side face includes a front side face and a rear side face facing each other, and a right side face and a left side face facing each other, wherein the front side face and the rear side face are wider than the right side face and the left side face. A rib is formed on at least one inner wall surface of the front side portion and the inner wall surface of the rear side portion, The bus bar has an opposing portion that faces the inner wall surface having the ribs. The facing portion includes a contact portion that contacts the rib.

2. The capacitor according to claim 1, wherein The rib extends in a first direction in which the opening and the bottom surface portion are aligned.

3. The capacitor according to claim 2, wherein The opposing portion has a flat plate shape, The abutment portion is a protrusion protruding toward the inner wall surface having the rib. A dimension of the contact portion in the first direction is shorter than a dimension of the rib in the first direction.

4. The capacitor according to claim 3, wherein The front ends of the ribs and the protrusions are each formed as a flat surface.

5. The capacitor according to claim 3 or 4, wherein: At least one of an end surface of the rib on the side of the opening and a side surface of the protrusion on the side of the bottom surface is inclined so as to move away from the opening toward the inside of the housing.

6. The capacitor according to claim 3 or 4, wherein: The protrusion is located closer to the opening than the bottom surface.

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