Capacitor

Abstract

The present invention provides a capacitor. The first bus bar includes a flat first overlapping portion, the second bus bar includes a flat second overlapping portion, and the first overlapping portion and the second overlapping portion overlap each other. The first overlapping portion and the second overlapping portion are insulated by an insulating member. The first bus bar includes bent portions that are bent at right angles to the first overlapping portion respectively from two opposite end portions in the first overlapping portion, and through holes that are formed in the first overlapping portion and are connected to the bent portions. The insulating member includes a clamping portion that clamps the bent portions. The clamping portion has a first contact portion that contacts the bent portion from the outside of the first bus bar, and a second contact portion that penetrates the through hole and contacts the bent portion from the inside of the first bus bar, and the bent portion is clamped by the first contact portion and the second contact portion.

Description

Technical Field

[0001] The present invention relates to a capacitor. Background Art

[0002] In Patent Document 1, there is described a case-molded capacitor as follows. Metal sputtered electrodes are formed on both end faces of a capacitor element formed by laminating or winding a metallized film. Bus bars are connected to the respective metal sputtered electrodes, and a part of a pair of bus bars is overlapped with an insulating plate interposed therebetween, so that the inductance component of the bus bar, i.e., ESL (equivalent series inductance), is reduced.

[0003] In the case-molded capacitor of Patent Document 1, by providing protrusions on two surfaces of the insulating plate facing a pair of bus bars and fitting the protrusions into hole portions provided in the overlapping portions of the bus bars, the relative positions of the external connection terminal portions of the pair of bus bars are fixed, and the positions of the pair of bus bars and the insulating plate are also fixed.

[0004] Prior Art Documents

[0005] Patent Document

[0006] Patent Document 1: Japanese Unexamined Patent Application Publication No. 2010-251400 Summary of the Invention

[0007] Problems to be Solved by the Invention

[0008] In the case-molded capacitor of the above Patent Document 1, the contact between the protrusions and the hole portions in the overlapping direction of the pair of bus bars, which is the direction orthogonal to the surface of the insulating plate, becomes the thickness amount of the flat bus bar. Therefore, in this overlapping direction, the bus bar is likely to move, and it is difficult to stably position the bus bar relative to the insulating plate.

[0009] Therefore, an object of the present invention is to provide a capacitor in which the bus bar can be stably positioned relative to the insulating member easily.

[0010] Technical Means for Solving the Problems

[0011] The main method of the present invention relates to a capacitor including a capacitor element, a first bus bar and a second bus bar connected to the capacitor element, and an insulating member disposed between the first bus bar and the second bus bar. The first bus bar includes a flat first overlapping portion, the second bus bar includes a flat second overlapping portion, and the first overlapping portion and the second overlapping portion overlap each other. The insulating member is disposed between the first overlapping portion and the second overlapping portion to insulate the first overlapping portion and the second overlapping portion. Here, at least one of the first bus bar and the second bus bar includes a bent portion in which two opposite end portions of the overlapping portion of at least one of the first overlapping portion and the second overlapping portion are bent at a right angle with respect to the overlapping portion, and a through hole formed in the overlapping portion and connected to the bent portion. The insulating member includes a clamping portion that clamps the bent portion. The clamping portion has a first contact portion that contacts the bent portion from the outside of at least one of the bus bars, and a second contact portion that passes through the through hole and contacts the bent portion from the inside of at least one of the bus bars, and clamps the bent portion through the first contact portion and the second contact portion.

[0012] In addition, in the technical solution, the term "right angle" includes the meaning of "substantially right angle".

[0013] Advantages of the Invention

[0014] According to the present invention, a capacitor that can easily and stably position a bus bar relative to an insulating member can be provided.

[0015] The effects or significance of the present invention will become clearer from the description of the embodiments shown below. However, the embodiments shown below are only an example when implementing the present invention, and the present invention is not limited to the content described in the following embodiments at all. Brief Description of the Drawings

[0016] Figure 1 is a perspective view of a thin film capacitor according to an embodiment.

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

[0018] Figure 3 (a) is a perspective view of the first bus bar according to an embodiment, Figure 3 and (b) is a perspective view of the second bus bar according to an embodiment.

[0019] Figure 4FIG. (a) is a perspective view of an insulating member as viewed from the front upper side according to the embodiment. Figure 4 FIG. (b) is a perspective view of the insulating member as viewed from the rear upper side according to the embodiment.

[0020] Figure 5 is a front view of the main part of the capacitor element unit according to the embodiment.

[0021] Figure 6 FIG. (a) is a rear view of the main part of the capacitor element unit according to the embodiment. Figure 6 FIG. (b) is Figure 6 a cross-sectional view taken along line A-A' of FIG. (a).

[0022] Figure 7 is a cross-sectional view of a mold for injection molding an insulating member according to the embodiment.

[0023] Figure 8 FIGS. (a) and (b) are respectively top views of a first member and a second member constituting the mold as viewed from their parting surface sides according to the embodiment.

[0024] Figure 9 is a front view of a first bus bar and an insulating member according to a modification example.

[0025] Figure 10 is a rear view of the main part of the capacitor element unit according to a modification example. DETAILED DESCRIPTION

[0026] Hereinafter, a film capacitor 1 as an embodiment of the capacitor of the present invention will be described with reference to the drawings. For convenience, the directions of front and rear, left and right, and up and down are appropriately noted in each drawing. In addition, the directions shown in the drawings are merely relative directions of the film capacitor 1 and do not represent absolute directions. Further, for convenience of explanation, names conforming to the directions shown in the drawings, such as "front surface" and "rear surface", are sometimes marked on a part of the structure.

[0027] In the present embodiment, the film capacitor 1 corresponds to the "capacitor" described in the technical solution. In addition, the front-rear direction, the left-right direction, and the up-down direction respectively correspond to the "overlapping direction", the "clamping direction", and the "vertical direction" described in the technical solution.

[0028] However, the above description is merely for the purpose of establishing a correspondence between the structure of the technical solution and the structure of the embodiment, and the invention described in the technical solution is not completely limited to the structure of the embodiment by the above correspondence.

[0029] <Structure of Film Capacitor>

[0030] Figure 1is a perspective view of the thin film capacitor 1.

[0031] The thin film capacitor 1 includes a capacitor element unit 100, a housing 200 that houses the capacitor element unit 100, and a filling resin 300 filled into the housing 200. The portion of the capacitor element unit 100 buried in the filling resin 300, particularly the capacitor element 400, is protected by the housing 200 and the filling resin 300 from the effects of moisture and shock.

[0032] Figure 2 (a) is a perspective view of the capacitor element unit 100 observed from the front upper side, Figure 2 and (b) is a perspective view of the capacitor element unit 100 observed from the rear upper side.

[0033] The capacitor element unit 100 includes a capacitor element 400, a first bus bar 500, a second bus bar 600, and an insulating member 700.

[0034] The capacitor element 400 is formed by overlapping two metallized films obtained by vapor-depositing aluminum on a dielectric film, and winding or laminating the overlapping metallized films and pressing them into a flat shape. In the capacitor element 400, a first electrode 410 is formed by spraying a metal such as zinc on one end face, and a second electrode 420 is similarly formed by spraying a metal such as zinc on the other end face.

[0035] In addition, the capacitor element 400 of the present embodiment is formed of a metallized film obtained by vapor-depositing aluminum on a dielectric film, but in addition to this, it may also be formed of a metallized film obtained by vapor-depositing other metals such as zinc and magnesium. Alternatively, the capacitor element 400 may be formed of a metallized film obtained by vapor-depositing a plurality of these metals, or may be formed of a metallized film obtained by vapor-depositing an alloy of these metals with each other.

[0036] Figure 3 (a) is a perspective view of the first bus bar 500.

[0037] The first bus bar 500 is formed by appropriately cutting and performing bending and other processes on a metal plate, such as a copper plate, which is a conductive material having a given shape.

[0038] The first bus bar 500 has a main body portion 510 having a square flat plate shape. The main body portion 510 is divided in the vertical direction into a portion that becomes the first overlapping portion 511 and a portion that becomes a non-overlapping portion 512 continuous with the first overlapping portion 511. The non-overlapping portion 512 is located above the first overlapping portion 511. In Figure 3 (a), for convenience, the boundary between the first overlapping portion 511 and the non-overlapping portion 512 is shown by a double-dot chain line.

[0039] On the upper part of the main body portion 510 included in the non-overlapping portion 512, by cutting up a part of the main body portion 510, four connecting terminal portions 520 having a square shape are formed in a manner arranged in the left-right direction. In the part of the main body portion 510 where each connecting terminal portion 520 is cut up, an opening portion 513 having a square shape larger than the connecting terminal portion 520 is formed. Each opening portion 513 is adjacent to the corresponding connecting terminal portion 520 and is arranged in the left-right direction.

[0040] In the middle portion of the main body portion 510 included in the first overlapping portion 511, at the same positions in the left-right direction as the four opening portions 513, four opening portions 514 having a square shape are formed. The four opening portions 514 have the same size as the four opening portions 513. In addition, in the middle portion of the main body portion 510, at the left and right ends, through holes 515 having a rectangular shape elongated in the up-down direction are formed.

[0041] In the lower part of the main body portion 510 included in the first overlapping portion 511, a circular opening portion 516 is formed at the center.

[0042] Furthermore, the first bus bar 500 includes an electrode terminal portion 530 bent at a right angle with respect to the main body portion 510 from the lower end portion of the main body portion 510. The electrode terminal portion 530 has a rectangular plate shape elongated in the left-right direction.

[0043] Furthermore, the first bus bar 500 includes bent portions 540 bent at a right angle with respect to the main body portion 510 from the left end portion and the right end portion of the main body portion 510, that is, the first overlapping portion 511 and the non-overlapping portion 512, respectively. Each bent portion 540 has a rectangular plate shape elongated in the up-down direction. Each through hole 515 is in contact with each bent portion 540.

[0044] Figure 3 (b) is a perspective view of the second bus bar 600.

[0045] The second bus bar 600 is formed by appropriately cutting up and performing bending and other processes on a metal plate such as a copper plate which is a conductive material having a given shape.

[0046] The second bus bar 600 includes a main body portion 610 having a rectangular flat plate shape. The main body portion 610 is divided in the up-down direction into a portion that becomes the second overlapping portion 611 and a portion that becomes a non-overlapping portion 612 continuous with the second overlapping portion 611. The non-overlapping portion 612 is located below the second overlapping portion 611. In Figure 3 (b), for convenience, the boundary between the second overlapping portion 611 and the non-overlapping portion 612 is shown by a double-dashed line.

[0047] Above the main body portion 610 included in the second overlapping portion 611, by cutting out a part of the main body portion 610, four connection terminal portions 620 having a square shape are formed in a manner arranged in the left - right direction. In the portion of the main body portion 610 where each connection terminal portion 620 is cut out, an opening portion 613 having a square shape larger than the connection terminal portion 620 is formed. Each opening portion 613 is adjacent to the corresponding connection terminal portion 620 and is arranged in the left - right direction. The four opening portions 613 have the same size as the four opening portions 514 of the first bus bar 500.

[0048] In the middle portion of the main body portion 610 included in the second overlapping portion 611, a circular opening portion 614 is formed at the central portion.

[0049] Furthermore, the second bus bar 600 includes an electrode terminal portion 630 bent at a right angle with respect to the main body portion 610 from the lower end portion of the main body portion 610. The electrode terminal portion 630 has a rectangular plate - like shape elongated in the left - right direction.

[0050] Figure 4 (a) of is a perspective view of the insulating member 700 observed from the front upper side, Figure 4 (b) of is a perspective view of the insulating member 700 observed from the rear upper side.

[0051] The insulating member 700 is formed of a resin such as polyphenylene sulfide (PPS) by injection molding described later.

[0052] The insulating member 700 includes a main body portion 710 having a substantially rectangular plate - like shape elongated in the left - right direction. The main body portion 710 is divided in the up - down direction into a first portion 711, a second portion 712 continuous with the first portion 711, and a third portion 713 continuous with the first portion 711. The second portion 712 is located above the first portion 711, and the third portion 713 is located below the first portion 711. In Figure 4 (a) and (b) of, for convenience, the boundaries between the first portion 711 and the second portion 712 and between the first portion 711 and the third portion 713 are shown by double - dot dash lines.

[0053] In the first part 711 of the main body 710, at the central part, a part of the front surface 710a of the main body 710 protrudes, and a part of the rear surface 710b of the main body 710 is recessed, thereby forming a substantially cylindrical protruding portion 714. The protruding portion 714 has a concave portion 714a on the back side. On the rear surface 710b of the main body 710, at the bottom surface of the concave portion 714a which is the surface recessed by the protruding portion 714, a substantially cylindrical gate mark 715 is formed. The gate mark 715 is formed by injection molding. The outer diameter of the protruding portion 714 is set to be smaller than the inner diameters of the opening 516 of the first bus bar 500 and the opening 614 of the second bus bar 600.

[0054] Furthermore, in the first part 711, four square-shaped openings 716 arranged in the left-right direction are formed at the upper part. The four openings 716 have the same size as the four openings 514 of the first bus bar 500.

[0055] In the second part 712 of the main body 710, two first rib portions 717 protruding rearward and extending along the left-right direction from the left end to the right end are formed on the rear surface 710b. The two first rib portions 717 are arranged at a given interval in the up-down direction. The given interval is set to be an interval of 1 mm or more which is regarded as the interval at which the two first rib portions 717 are separated according to the regulation related to the creepage distance.

[0056] The two first rib portions 717 are connected by second rib portions 718 at the left and right end positions. The height of each second rib portion 718 is set to be the same as the height of each first rib portion 717.

[0057] Furthermore, the insulating member 700 is provided with clamping portions 720 at the left end and the right end on the front surface 710a side of the main body 710, respectively. The clamping portion 720 includes a first contact portion 721 located outside in the insulating member 700 and a second contact portion 722 located inside. The first contact portion 721 has a rectangular plate shape elongated in the up-down direction. The second contact portion 722 has a rectangular parallelepiped shape elongated in the up-down direction. The dimension of the first contact portion 721 in the up-down direction is larger than the dimension of the second contact portion 722 in the up-down direction, and the dimension of the first contact portion 721 in the left-right direction is smaller than the dimension of the second contact portion 722 in the left-right direction. The dimensions of the first contact portion 721 and the second contact portion 722 in the front-rear direction are set to be equal to each other. In addition, the dimension of the bent portion 540 of the first bus bar 500 in the front-rear direction is set to be larger than the dimensions of the first contact portion 721 and the second contact portion 722 in the front-rear direction.

[0058] The first contact portion 721 includes two first rib portions 721a. The two first rib portions 721a are respectively formed at positions on the side of the first contact portion 721 facing the second contact portion 722 and above and below the second contact portion 722, and extend in the front-rear direction. The second contact portion 722 includes one second rib portion 722a. The second rib portion 722a is located at a position on the side of the second contact portion 722 facing the first contact portion 721 and between the two first rib portions 721a, and extends in the front-rear direction. The gap between the first rib portion 721a and the second rib portion 722a is set to be slightly smaller than the thickness (dimension in the left-right direction) of the bent portion 540 of the first bus bar 500.

[0059] As Figure 2 As shown in (a) and (b) of, the first bus bar 500 is assembled on the front side of the insulating member 700. The main body portion 510 of the first bus bar 500 is in contact with the front surface 710a of the main body portion 710 of the insulating member 700. The protruding portion 714 of the insulating member 700 penetrates the opening portion 516 of the first bus bar 500. The bent portions 540 on the left and right sides of the first bus bar 500 are clamped by the clamping portions 720 of the insulating member 700. The four opening portions 514 of the first bus bar 500 overlap with the four opening portions 716 of the insulating member 700.

[0060] The second bus bar 600 is assembled on the rear side of the insulating member 700. The main body portion 610 of the second bus bar 600 is in contact with the rear surface 710b of the main body portion 710 of the insulating member 700. The concave portion 714a of the insulating member 700 overlaps with the opening portion 614 of the second bus bar 600, and the gate mark 715 overlaps with the opening portion 614. There may be a certain degree of deviation in the height of the gate mark 715. When the gate mark 715 becomes higher and protrudes rearward from the concave portion 714a, the front end portion of the protruding gate mark 715 is inserted into the opening portion 614, and does not interfere with the main body portion 610 of the second bus bar 600.

[0061] The four opening portions 613 of the second bus bar 600 overlap with the four opening portions 716 of the insulating member 700. Each connection terminal portion 620 of the second bus bar 600 is inserted through the three overlapping opening portions 514, 716, and 613 and protrudes forward of the first bus bar 500. The terminal rows of the four connection terminal portions 620 are located below the four connection terminal portions 520. The positions of the front ends of the four connection terminal portions 520 and the positions of the front ends of the four connection terminal portions 620 are aligned.

[0062] The first overlapping portion 511 of the first bus bar 500 and the second overlapping portion 611 of the second bus bar 600 overlap in the front-rear direction. The non-overlapping portion 512 of the first bus bar 500 does not overlap with the second overlapping portion 611, and the non-overlapping portion 612 of the second bus bar 600 does not overlap with the first overlapping portion 511. The first portion 711 of the insulating member 700 is interposed between the first overlapping portion 511 and the second overlapping portion 611. The second portion 712 of the insulating member 700 overlaps with the non-overlapping portion 512 of the first bus bar 500. The third portion 713 of the insulating member 700 is interposed between the non-overlapping portion 612 of the second bus bar 600 and the peripheral surface of the capacitor element 400.

[0063] The capacitor element 400 is disposed between the electrode terminal portion 530 of the first bus bar 500 and the electrode terminal portion 630 of the second bus bar 600. The electrode terminal portion 530 is joined to the first electrode 410 of the capacitor element 400 by a joining method such as welding. Thus, the first bus bar 500 is electrically connected to the first electrode 410. Similarly, the electrode terminal portion 630 is joined to the second electrode 420 of the capacitor element 400 by a joining method such as welding. Thus, the second bus bar 600 is electrically connected to the second electrode 420. Alternatively, pin-shaped terminals may be formed on the electrode terminal portions 530 and 630, and these terminals may be joined to the electrodes 410 and 420 by welding or the like.

[0064] Figure 5 It is a front view of the main part of the capacitor element unit 100.

[0065] As Figure 5 shown, in each clamping portion 720 of the insulating member 700, the first rib portion 721a of the first contact portion 721 contacts the bent portion 540 from the outside of the first bus bar 500, and the second rib portion 722a of the second contact portion 722 that penetrates the through hole 515 of the first bus bar 500 contacts the bent portion 540 from the inside of the first bus bar 500. The first rib portion 721a and the second rib portion 722a are so-called collision rib portions. When the bent portion 540 is inserted between the first contact portion 721 and the second contact portion 722, the front end portion thereof is cut off or deformed by the bent portion 540. The first contact portion 721 and the second contact portion 722 contact the bent portion 540 from both sides, thereby generating a force (a force for suppressing movement) for holding the first bus bar 500 in the insulating member 700 in the front-rear direction.

[0066] The first bus bar 500 is positioned relative to the insulating member 700 in the front-rear and left-right directions by a positioning structure based on the bent portion 540 and the clamping portion 720.

[0067] The dimension of the through hole 515 in the vertical direction is larger than the dimension of the second contact portion 722 in the vertical direction, and relatively large gaps are generated above and below between the second contact portion 722 and the through hole 515. Therefore, in the present embodiment, other positioning structures (not shown) are provided between the first bus bar 500 and the insulating member 700, and through this positioning structure, the first bus bar 500 is positioned in the vertical direction with respect to the insulating member 700. Further, positioning structures (not shown) are also provided between the second bus bar 600 and the insulating member 700, and through this positioning structure, the second bus bar 600 is positioned in the vertical, front-rear, and left-right directions with respect to the insulating member 700.

[0068] Figure 6 FIG. (a) is a rear view of the main part of the capacitor element unit 100. Figure 6 FIG. (b) is Figure 6 a cross-sectional view taken along the line A-A' of FIG. (a).

[0069] As Figure 6 shown in FIGS. (a) and (b), the four connection terminal portions 520 of the first bus bar 500 project from the non-overlapping portion 512 toward the side opposite to the second portion 712 of the insulating member 700 (front side). The upper end of the second portion 712 has the same height position as the lower ends of the four opening portions 513 of the first bus bar 500, and the second portion 712 does not overlap with the four opening portions 513 and the four connection terminal portions 520 in the front-rear direction. In addition, the second portion 712 may slightly overlap with the lower end portions of the four opening portions 513.

[0070] In the second portion 712 of the insulating member 700, two first rib portions 717 project toward the side opposite to the non-overlapping portion 512 of the first bus bar 500 (rear side), and have a dimension slightly longer than the overlapping range R in the left-right direction in such a manner that they exist in the overlapping range R where the non-overlapping portion 512 and the second overlapping portion 611 of the second bus bar 600 overlap when viewed from the vertical direction. In addition, two second rib portions 718 connect the two first rib portions 717 outside the overlapping range R in the left-right direction.

[0071] As Figure 6 shown by the thick line in FIG. (b), in the vertical direction, between the non-overlapping portion 512 of the first bus bar 500 and the second overlapping portion 611 of the second bus bar 600, the creepage distance D is ensured by the second portion 712 of the insulating member 700 and the two first rib portions 717. The rear surface side of the second portion 712 becomes a concavo-convex shape due to the two first rib portions 717. Therefore, the creepage distance D becomes longer compared with the case where the rear surface side of the second portion 712 is planar.

[0072] Refer to Figure 1, the housing 200 is made of resin, for example, formed of polyphenylene sulfide (PPS) which is a thermoplastic resin. The housing 200 is formed in a substantially rectangular parallelepiped box shape and has an opening 201 on its upper surface.

[0073] In the housing 200, mounting joints 210 are provided on the left and right outer side surfaces and the outer bottom surface. In each mounting joint 210, an insertion through-hole 211 penetrating in the front-rear direction is formed. In order to improve the strength of the hole, a metal collar 212 is inserted into the insertion through-hole 211. When the thin film capacitor 1 is disposed in a setting portion such as an external device, these mounting joints 210 are fixed to the setting portion by screws or the like.

[0074] The potting resin 300 is a thermosetting resin such as an epoxy resin.

[0075] In the housing 200, the capacitor element unit 100 is accommodated through the opening 201. In the housing 200 in which the capacitor element unit 100 is accommodated, the liquid-phase potting resin 300 is injected through the opening 201. The potting resin 300 fills the inside of the housing 200 up to the vicinity of the opening 201. When the injection of the potting resin 300 is completed, the housing 200 is heated. As a result, the potting resin 300 inside the housing 200 is cured. Thus, the thin film capacitor 1 is completed.

[0076] The thin film capacitor 1 is mounted on an external device or the like. In an external device or the like, for example, four external terminals 2a on the positive electrode side and four external terminals 2b on the negative electrode side in the form of bus bars are provided. For example, when the first bus bar 500 is a bus bar on the positive electrode side and the second bus bar 600 is a bus bar on the negative electrode side, as Figure 1 shown, the four external terminals 2a come into contact with the four connection terminal portions 520 of the first bus bar 500 from the rear through the opening 513 and are connected to these connection terminal portions 520 by a joining method such as welding. Further, the four external terminals 2b come into contact with the four connection terminal portions 620 of the second bus bar 600 from the rear through three openings 613, 716, 514 that overlap in the front-rear direction and are connected to these connection terminal portions 620 by a joining method such as welding.

[0077] <Manufacturing method of insulating member>

[0078] Next, a manufacturing method of the insulating member 700 will be described.

[0079] Figure 7 is a cross-sectional view of a mold 800 for injection molding the insulating member 700. Figure 8 (a) and (b) of are respectively top views of the first member 801 and the second member 802 constituting the mold 800 as viewed from their parting surface sides. In addition, in Figure 8In (a) for convenience, the outer shape of the first molding surface 811 is shown by a dashed line. In Figure 8 In (b) for convenience, the gate 820 is shown by a dashed line.

[0080] The insulating member 700 is formed by injection molding using a mold 800 in the molding process.

[0081] The mold 800 is formed of steel and is constituted by the combination of a first member 801 as a core and a second member 802 as a cavity. Inside the mold 800, a mold portion 810 having the shape of the insulating member 700 is formed. The mold portion 810 includes: a first molding surface 811 for forming the rear surface 710b of the main body portion 710 of the insulating member 700; and a second molding surface 812 for forming the front surface 710a of the main body portion 710 facing the rear surface 710b.

[0082] The first molding surface 811 includes a substantially cylindrical protruding portion 813 protruding toward the second molding surface 812 at a position corresponding to the central portion of the main body portion 710. In addition, the second molding surface 812 includes a substantially cylindrical concave portion 814 for accommodating the protruding portion 813. A gap is formed between the protruding portion 813 and the concave portion 814. The interval between the front end surface 813a of the protruding portion 813 and the bottom surface 814a of the concave portion 814 is set to be larger than the intervals of the surrounding first molding surface 811 and second molding surface 812, and the portion between these front end surface 813a and bottom surface 814a becomes a large interval portion 815.

[0083] On the first molding surface 811, a gate 820 serving as an injection port for injecting resin into the mold portion 810 is formed at the front end surface 813a of the protruding portion 813. The gate 820 is circular and opens to the large interval portion 815. In the mold 800, a runner 830 connected to the gate 820 is formed in the first member 801.

[0084] In the molding process, the gate 820 is opened by a valve (not shown), and the molten resin is injected into the mold portion 810 from the gate 820 through the runner 830. As shown by the arrows in Figure 7 and Figure 8 , first, the resin flows into the large interval portion 815 of the mold portion 810. Then, the resin flows radially from the large interval portion 815 and spreads around. Thus, the resin fills the entire mold portion 810.

[0085] Here, the gate 820 is provided on the first molding surface 811 of the molding portion 810 on the surface (rear surface 710b) of the main body portion 710 constituting the insulating member 700. Therefore, resin can be injected from a portion near the center in the plate-shaped main body portion 710. As a result, the distance that the resin flows within the molding portion 810 can be shortened, and thus the resin can easily spread throughout the molding portion 810. Furthermore, the large interval portion 815 serves as a reservoir for the resin flowing into the molding portion 810 from the gate 820. Therefore, the fluidity of the resin within the molding portion 810 is improved, and the time for the resin to spread throughout the molding portion 810 is shortened.

[0086] The resin filled into the molding portion 810 cools to form the insulating member 700. When the filling of the resin into the molding portion 810 is completed, the gate 820 is closed by a valve. At this time, resin remains near the gate 820, and this resin cools to form the gate mark 715. Then, the mold 800 is separated, and the insulating member 700 is taken out from the inside.

[0087] In this way, Figure 4 the insulating member 700 shown in (a) and (b) of is completed. In the main body portion 710 of the insulating member 700, resin is filled between the protruding portion 813 and the recessed portion 814 of the molding portion 810, thereby forming the protruding portion 714. The front end portion of the protruding portion 714 has a thicker wall than other portions of the main body portion 710. On the recessed surface on the back side of the protruding portion 714, a gate mark 715 protruding rearward is formed.

[0088] <Effects of the Embodiment>

[0089] As described above, according to the present embodiment, the following effects can be achieved.

[0090] The first bus bar 500 includes bent portions 540 that are bent at right angles with respect to the first overlapping portion 511 from the opposite left and right end portions in the first overlapping portion 511, and through holes 515 that are formed in the first overlapping portion 511 and are connected to the respective bent portions 540. The insulating member 700 has a first contact portion 721 that contacts the bent portion 540 from the outside of the first bus bar 500, and a second contact portion 722 that penetrates the through hole 515 and contacts the bent portion 540 from the inside of the first bus bar 500. The clamping portion 720 that clamps the respective bent portions 540 is included by these first contact portion 721 and second contact portion 722.

[0091] According to this structure, in the front-rear direction where the first overlapping portion 511 overlaps with the insulating member 700, the range in which the first contact portion 721 and the second contact portion 722 contact the bent portion 540 from both sides can be extended. Therefore, the force generated in the insulating member 700 to hold the first bus bar 500 in the front-rear direction can be increased. As a result, the first bus bar 500 is not easily moved in the front-rear direction, and thus the first bus bar 500 can be stably positioned in the front-rear direction with respect to the insulating member 700.

[0092] In addition, in the first contact portion 721 and the second contact portion 722, first ribs 721a and second ribs 722a extending in the front-rear direction are formed on the surface facing the bent portion 540, and the first ribs 721a and the second ribs 722a contact the bent portion 540.

[0093] According to this structure, by pressing the bent portion 540 between the first rib 721a and the second rib 722a, the bent portion 540 can be easily inserted between the first contact portion 721 and the second contact portion 722, and the first contact portion 721 and the second contact portion 722 can be reliably brought into contact with the bent portion 540.

[0094] Furthermore, the first contact portion 721 and the second contact portion 722 have a shape that is long in the up-down direction.

[0095] According to this structure, the clamping range based on the clamping portion 720 can be extended in the up-down direction. Therefore, the bent portion 540 can be firmly clamped by the clamping portion 720. As a result, the first bus bar 500 can be stably positioned in the left-right direction with respect to the insulating member 700.

[0096] Furthermore, first contact portions 721 are respectively formed at opposite left and right end portions of the insulating member 700, and in the left-right direction, the size of the first contact portion 721 is set to be smaller than the size of the second contact portion 722.

[0097] The larger the left-right direction size of the first contact portion 721 and the second contact portion 722, the higher the strength of the clamping portion 720 as a whole. On the other hand, when the first contact portion 721 is formed at the left and right end portions of the insulating member 700, the larger the left-right direction size of the first contact portion 721, the larger the left-right direction size of the insulating member 700.

[0098] According to this structure, in the left-right direction, the size of the first contact portion 721 can be relatively reduced, and the size of the second contact portion 722 can be relatively increased. Therefore, while suppressing a decrease in the strength of the clamping portion 720 as a whole, an increase in the left-right direction size of the insulating member 700 can be suppressed.

[0099] As described above, the embodiments of the present invention have been described, but the present invention is not limited to the above embodiments. In addition, in addition to the above embodiments, various changes can be made to the application examples of the present invention.

[0100] For example, in the above embodiment, the first rib portion 721a and the second rib portion 722a are respectively formed on the first contact portion 721 and the second contact portion 722 of the clamping portion 720. However, as Figure 9 shown, the first rib portion 721a and the second rib portion 722a may not be respectively formed on the first contact portion 721 and the second contact portion 722. In this case, the gap between the first contact portion 721 and the second contact portion 722 is set to be equal to the thickness (dimension in the left - right direction) of the bent portion 540 of the first bus bar 500. However, in order to manufacture the first bus bar 500 and the insulating member 700 such that the gap between the first contact portion 721 and the second contact portion 722 is equal to the thickness of the bent portion 540 of the first bus bar 500, extremely high precision is required. Therefore, in order to easily manufacture the first bus bar 500 and the insulating member 700, it is preferable to form the first rib portion 721a and the second rib portion 722a on the first contact portion 721 and the second contact portion 722 respectively.

[0101] In addition, in the above embodiment, the positioning structure based on the bent portion 540 and the clamping portion 720 is only applied between the first bus bar 500 and the insulating member 700. However, as Figure 10 shown, it may also be that the positioning structure based on the bent portion 640 and the clamping portion 730 is further applied between the second bus bar 600 and the insulating member 700. In this case, on the second bus bar 600, bent portions 640 are provided which are bent at right angles with respect to the main body portion 610 from the left end portion and the right end portion of the second overlapping portion 611 of the main body portion 610 respectively. In addition, a through - hole 615 which is in contact with the bent portion 640 is formed in the second overlapping portion 611. In the insulating member 700, clamping portions 730 are respectively provided on the left end portion and the right end portion on the rear - surface 710b side of the main body portion 710.

[0102] The clamping portion 730 includes a first contact portion 731 having two first rib portions 731a and a second contact portion 732 having one second rib portion 732a. The left - and - right bent portions 640 are clamped by the left - and - right clamping portions 730. Thus, the second bus bar 600 is positioned with respect to the insulating member 700 in the front - to - back and left - to - right directions. Similar to the structure shown in Figure 9 the structure may also be set as follows, that is, the first rib portion 731a and the second rib portion 732a are not respectively formed on the first contact portion 731 and the second contact portion 732.

[0103] In addition, although a positioning structure based on the bent portion 640 and the clamping portion 730 is applied between the second bus bar 600 and the insulating member 700, a structure may also be adopted in which the positioning structure based on the bent portion 540 and the clamping portion 720 is not applied between the first bus bar 500 and the insulating member 700.

[0104] Furthermore, the number of the first rib portions 721a of the first contact portion 721 and the number of the second rib portions 722a of the second contact portion 722 are not limited to the numbers in the above-described embodiment, and may be appropriately changed.

[0105] Furthermore, in the above-described embodiment, the first bus bar 500 is positioned relative to the insulating member 700 in the front-back and left-right directions by the bent portion 540 and the clamping portion 720. However, the bent portion 540 and the clamping portion 720 may be configured such that the first bus bar 500 is positioned not only in the front-back and left-right directions but also in the up-down direction relative to the insulating member 700. For example, by forming rib portions that contact the upper edge and the lower edge of the through hole 515 at the upper end and the lower end of the second contact portion 722 of the clamping portion 720, positioning in the up-down direction can be performed. Similarly, in Figure 10 the modified example shown, the bent portion 640 and the clamping portion 730 may be configured such that the second bus bar 600 is positioned not only in the front-back and left-right directions but also in the up-down direction relative to the insulating member 700.

[0106] Furthermore, in the above-described embodiment, the dimension of the first contact portion 721 in the up-down direction is set to be larger than the dimension of the second contact portion 722 in the up-down direction, and the dimension of the first contact portion 721 in the left-right direction is set to be smaller than the dimension of the second contact portion 722 in the left-right direction. However, the first contact portion 721 and the second contact portion 722 may be set such that their dimensions in the up-down direction and their dimensions in the left-right direction are equal to each other.

[0107] Furthermore, in the above-described embodiment, the bent portion 540 extends in the up-down direction from the first overlapping portion 511 to the non-overlapping portion 512. However, the bent portion 540 may also be configured not to extend to the non-overlapping portion 512, and it may be bent relative to the first overlapping portion 511 as long as it has at least a length that is clamped by the clamping portion 720 in the up-down direction.

[0108] Furthermore, in the above-described embodiment, one capacitor element 400 is provided in the film capacitor 1. However, the number of the capacitor elements 400 may also be two or more, and may be appropriately changed.

[0109] Furthermore, in the above-described embodiment, the capacitor element 400 is formed by overlapping two metallized films having aluminum vapor-deposited thereon a dielectric film and winding or laminating the overlapped metallized films. However, alternatively, the capacitor element 400 may be formed by overlapping a metallized film having aluminum vapor-deposited on both sides of a dielectric film and an insulating film and winding or laminating them.

[0110] Furthermore, in the above-described embodiment, as an example of the capacitor of the present invention, the film capacitor 1 is exemplified. However, the present invention can also be applied to capacitors other than the film capacitor 1.

[0111] In addition, the embodiments of the present invention can be appropriately modified in various ways within the scope of the technical idea shown in the claims.

[0112] In addition, in the description of the above embodiment, terms indicating directions such as "above" and "below" represent relative directions that depend only on the relative positional relationship of the structural members, rather than absolute directions such as the vertical direction and the horizontal direction.

[0113] Industrial Applicability

[0114] The present invention is useful for capacitors used in various electronic devices, electrical devices, industrial devices, electrical installations of vehicles, and the like.

[0115] Reference Signs

[0116] 1 Film capacitor (capacitor);

[0117] 400 Capacitor element;

[0118] 500 First bus bar;

[0119] 511 First overlapping portion;

[0120] 515 Through hole;

[0121] 540 Bent portion;

[0122] 600 Second bus bar;

[0123] 611 Second overlapping portion;

[0124] 700 Insulating member;

[0125] 720 Clamping portion;

[0126] 721 First contact portion;

[0127] 721a First rib portion;

[0128] 722 Second contact portion;

[0129] 722a second rib portion.

Claims

1. A capacitor, comprising: a capacitor element; a first bus bar and a second bus bar, connected to the capacitor element; and an insulating member disposed between the first bus bar and the second bus bar, the first bus bar includes a flat first overlapping portion, the second bus bar includes a flat second overlapping portion, the first overlapping portion and the second overlapping portion overlap each other, the insulating member is disposed between the first overlapping portion and the second overlapping portion to insulate between the first overlapping portion and the second overlapping portion, at least one of the first bus bar and the second bus bar includes: a bent portion that is bent at a right angle with respect to the overlapping portion from two opposite end portions of the overlapping portion of at least one of the first overlapping portion and the second overlapping portion; and a through hole formed in the overlapping portion and communicating with the bent portion, the insulating member includes a clamping portion that clamps the bent portion, the clamping portion has a first contact portion that contacts the bent portion from the outside of at least one of the bus bars and a second contact portion that passes through the through hole and contacts the bent portion from the inside of at least one of the bus bars, and the bent portion is clamped by the first contact portion and the second contact portion.

2. The capacitor according to claim 1, wherein, on a surface of the first contact portion facing the bent portion, a first rib extending in an overlapping direction in which the first overlapping portion, the second overlapping portion, and the insulating member overlap is formed, on a surface of the second contact portion facing the bent portion, a second rib extending in the overlapping direction is formed, the first rib and the second rib contact the bent portion.

3. The capacitor according to claim 1 or 2, wherein, the first contact portion and the second contact portion each have a shape in which a dimension in a direction perpendicular to an overlapping direction in which the first overlapping portion, the second overlapping portion, and the insulating member overlap and a clamping direction in which the clamping portion clamps the bent portion is longer than a dimension in the overlapping direction and the clamping direction.

4. The capacitor according to any one of claims 1 to 3, wherein, the first contact portions are respectively formed at two opposite end portions of the insulating member, in a clamping direction in which the clamping portion clamps the bent portion, a dimension of the first contact portion is smaller than a dimension of the second contact portion.

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