Capacitor

Abstract

The present invention provides a capacitor. The first bus bar includes a non-overlapping portion that is continuous with the first overlapping portion and does not overlap with the second overlapping portion of the second bus bar, and a connection terminal portion that protrudes from the non-overlapping portion and is connected to an external terminal. The insulating member includes a flat first portion interposed between the first overlapping portion and the second overlapping portion, a flat second portion continuous with the first portion and overlapping with the non-overlapping portion, and a first rib portion protruding from the second portion toward the side opposite to the non-overlapping portion. The first rib portion extends in the left-right direction in such a manner that, when viewed from the up-down direction, it exists in a repeating range (R) where the range of the non-overlapping portion and the range of the second overlapping portion in the left-right direction overlap.

Description

Technical Field

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

[0002] In Patent Document 1, there is described a thin film capacitor as follows. Metal sputtered electrodes are formed on both end faces of a capacitor element, and bus bars are connected to the respective metal sputtered electrodes. A holding member formed of an insulating resin is sandwiched therebetween, and a part of a pair of bus bars is overlapped so as to reduce mutual inductance (equivalent series inductance).

[0003] In the thin film capacitor of Patent Document 1, the first portions of a pair of bus bars overlap with each other with a flat portion of the holding member interposed therebetween. An external connection terminal portion is formed at one end of each of the first portions. One ends of the two first portions are connected via one end of the flat portion, and a creepage distance corresponding to the thickness of the flat portion is ensured between the two first portions.

[0004] Prior Art Documents

[0005] Patent Documents

[0006] Patent Document 1: WO 2016 / 027462 Summary of the Invention

[0007] Problems to be Solved by the Invention

[0008] In the above-described thin film capacitor, the positions of the ends where the external connection terminals are formed are the same for the two first portions. In contrast, a pair of bus bars can also be configured as follows: the first portion of one extends more outward than the first portion of the other on the end side where the external connection terminal portion is formed, and the ends of the two first portions do not have the same position. In this case, the portion extending outward becomes a non-overlapping portion that does not overlap with the first portion of the other.

[0009] In the case of such a configuration, if the flat portion is extended from one end of the first portion of the other toward the non-overlapping portion, the distance obtained by combining the thickness of the flat portion and the extended length becomes the creepage distance between the two first portions. Therefore, the creepage distance can be extended. As a result, even if the voltage applied to the thin film capacitor increases, it is easy to ensure the required creepage distance between the two first portions.

[0010] However, when the flat portion extends a long way toward the non-overlapping portion, when the thin film capacitor is provided in an external device, there is a concern that components related to the external device such as external terminals connected to the external connection terminal portion may easily interfere with the portion extending toward the non-overlapping portion.

[0011] Accordingly, an object of the present invention is to provide a capacitor that can suppress the amount of extension of the insulating member toward the non-overlapping portion side of the first bus bar and can ensure a long creepage distance between the first bus bar and the second bus bar.

[0012] Technical solution for solving the problem

[0013] The capacitor according to the main aspect of the present invention includes: a capacitor element; a first bus bar and a second bus bar, which are 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 first overlapping portion, the second bus bar includes a 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 between the first overlapping portion and the second overlapping portion. The first bus bar includes: a non-overlapping portion, which is continuous with the first overlapping portion and does not overlap with the second overlapping portion; and a connection terminal portion, which protrudes from the non-overlapping portion and is connected to an external terminal. The insulating member includes: a flat first portion, which is interposed between the first overlapping portion and the second overlapping portion; a flat second portion, which is continuous with the first portion and overlaps with the non-overlapping portion; and a protruding portion, which protrudes from the second portion toward the side opposite to the non-overlapping portion. The protruding portion extends in the second direction in such a manner that, when viewed in the first direction in which the first overlapping portion and the non-overlapping portion are arranged, it exists in the range where the ranges of the non-overlapping portion and the second overlapping portion overlap in the second direction perpendicular to the first direction.

[0014] Advantages of the invention

[0015] According to the present invention, it is possible to provide a capacitor that can suppress the amount of extension of the insulating member toward the non-overlapping portion side of the first bus bar and can ensure a long creepage distance between the first bus bar and the second bus bar.

[0016] 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 merely an example when implementing the present invention, and the present invention is not limited to the content described in the following embodiments at all. Description of the drawings

[0017] Figure 1 is a perspective view of a thin film capacitor according to an embodiment.

[0018] Figure 2 (a) is a perspective view of a capacitor element unit viewed from the front upper side according to an embodiment, Figure 2 (b) is a perspective view of the capacitor element unit viewed from the rear upper side according to an embodiment.

[0019] Figure 3 FIG. (a) is a perspective view of the first bus bar according to the embodiment. Figure 3 FIG. (b) is a perspective view of the second bus bar according to the embodiment.

[0020] Figure 4 FIG. (a) is a perspective view of the insulating member as viewed from above in the front according to the embodiment. Figure 4 FIG. (b) is a perspective view of the insulating member as viewed from above in the rear according to the embodiment.

[0021] Figure 5 is a front view of the main part of the capacitor element unit according to the embodiment.

[0022] 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 the line A - A' of FIG. (a).

[0023] Figure 7 is a cross-sectional view of the mold for injection molding the insulating member according to the embodiment.

[0024] Figure 8 FIGS. (a) and (b) are respectively top views of the first member and the second member constituting the mold as viewed from the side of their parting surface according to the embodiment.

[0025] Figure 9 FIG. (a) is a rear view of the insulating member according to the modification example. Figure 9 FIGS. (b) and (c) are side cross-sectional views of the insulating member according to the modification example. Detailed Embodiment

[0026] Hereinafter, a thin 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 - rear, left - right, and up - down are appropriately noted in each drawing. In addition, the directions shown in the drawings are ultimately only relative directions of the thin 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 thin film capacitor 1 corresponds to the "capacitor" described in the technical solution. In addition, the first rib portion 717 corresponds to the "protrusion" described in the technical solution. Further, the second rib portion 718 corresponds to the "connecting portion" described in the technical solution. Further, the up - down direction corresponds to the "first direction" described in the technical solution, and the left - right direction corresponds to the "second direction" described in the technical solution.

[0028] However, the above description is ultimately aimed at establishing a correspondence between the structure of the technical solution and the structure of the implementation manner. The invention described in the technical solution is not completely limited to the structure of the implementation manner through the above correspondence.

[0029] <Structure of the thin film capacitor>

[0030] Figure 1 is 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 (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 formed in the same manner 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 multiple metals among 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, which is a conductive material having a given shape, such as a copper plate.

[0038] The first bus bar 500 has a main body portion 510 with 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 the non-overlapping portion 512 that is continuous with the first overlapping portion 511. The non-overlapping portion 512 is located above the first overlapping portion 511. In Figure 3 In (a) of, for convenience, the boundary between the first overlapping portion 511 and the non-overlapping portion 512 is shown by a double-dashed line.

[0039] At 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] At the middle part of the main body portion 510 included in the first overlapping portion 511, at the same positions as the four opening portions 513 in the left-right direction, four square-shaped opening portions 514 are formed. The four opening portions 514 have the same size as the four opening portions 513. In addition, at the middle part of the main body portion 510, at the left and right ends, through holes 515 having a vertically long square shape are formed.

[0041] At 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 central part.

[0042] Furthermore, the first bus bar 500 has 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 square plate shape that is slender in the left-right direction.

[0043] Furthermore, the first bus bar 500 has 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 square plate shape that is slender in the vertical direction. Each through hole 515 is connected to each bent portion 540.

[0044] Figure 3 (b) of 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 that is a conductive material of a given shape.

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

[0047] At the upper part of the main body portion 610 included in the second overlapping portion 611, by cutting up 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 up, 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] At the middle part of the main body portion 610 included in the second overlapping portion 611, a circular opening portion 614 is formed at the center.

[0049] Furthermore, the second bus bar 600 includes an electrode terminal portion 630 that is 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 shape that is 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 and (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 shape that is long in the left-right direction. The main body portion 710 is divided in the vertical direction into a first portion 711, a second portion 712 that is continuous with the first portion 711, and a third portion 713 that is 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 In (a) and (b) thereof, for convenience, the boundary between the first portion 711 and the second portion 712 and the boundary between the first portion 711 and the third portion 713 are shown by double-dashed 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 protrusion 714. The protrusion 714 has a recess 714a on the back side. On the rear surface 710b of the main body 710, on the bottom surface of the recess 714a, which is the surface recessed by the protrusion 714, a substantially cylindrical gate mark 715 is formed. The gate mark 715 is formed by injection molding. The outer diameter of the protrusion 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 in 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 by 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 and a second contact portion 722 located inside the insulating member 700. 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 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 without interfering 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 has passed through 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 front-rear direction in the insulating member 700.

[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 size of the through hole 515 in the vertical direction is larger than the size 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. Through this positioning structure, the first bus bar 500 is positioned in the vertical direction with respect to the insulating member 700. Furthermore, positioning structures (not shown) are also provided between the second bus bar 600 and the insulating member 700. 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 (a) of is a rear view of the main part of the capacitor element unit 100, Figure 6 and (b) of is Figure 6 a cross-sectional view taken along line A-A' of (a) of .

[0069] As Figure 6 shown in (a) and (b) of Figure 6 , 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. Additionally, 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 the range existing in the non-overlapping portion 512 and the range of 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 (b) of Figure 6 , 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 to 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 the 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 filling 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 filling resin 300 is injected through the opening 201. The filling resin 300 fills the inside of the housing 200 up to the vicinity of the opening 201. When the injection of the filling resin 300 is completed, the housing 200 is heated. As a result, the filling resin 300 in 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 the 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 part 810 having the shape of the insulating member 700 is formed. The mold part 810 includes: a first molding surface 811 for forming the rear surface 710b of the main body part 710 of the insulating member 700; and a second molding surface 812 for forming the front surface 710a of the main body part 710 facing the rear surface 710b.

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

[0083] On the first molding surface 811, a gate 820 serving as an injection port for injecting resin into the mold part 810 is formed at the front end surface 813a of the protruding part 813. The gate 820 is circular and opens to the large interval part 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 part 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 part 815 of the mold part 810. Then, the resin flows radially from the large interval part 815 and spreads around. Thus, the resin fills the entire mold part 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 gap 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) 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: a non-overlapping portion 512 that is continuous with the first overlapping portion 511 and does not overlap with the second overlapping portion 611 of the second bus bar 600; and a connection terminal portion 520 that protrudes from the non-overlapping portion 512 and is connected to the external terminal 2a. The insulating member 700 includes: a flat first portion 711 that is interposed between the first overlapping portion 511 and the second overlapping portion 611; a flat second portion 712 that is continuous with the first portion 711 and overlaps with the non-overlapping portion 512; and a first rib portion 717 that protrudes from the second portion 712 toward the side opposite to the non-overlapping portion 512 and extends in the left-right direction in such a manner that it exists within the range of the non-overlapping portion 512 and the range of the second overlapping portion 611 overlaps when viewed from the up-down direction, that is, in the overlapping range R.

[0091] According to this structure, it is possible to both reduce the amount by which the second portion 712 of the insulating member 700 extends toward the non-overlapping portion 512 side of the first bus bar 500 (the dimension in the vertical direction of the second portion 712), and extend the creepage distance D between the non-overlapping portion 512 of the first bus bar 500 in the vertical direction and the second overlapping portion 611 of the second bus bar 600.

[0092] In addition, a plurality (two) of the first rib portions 717 are provided so as to be arranged at intervals in the vertical direction, and the insulating member 700 includes a second rib portion 718 that is provided outside the repetition range R in the left-right direction and connects the plurality of first rib portions 717.

[0093] According to this structure, by providing a plurality of the first rib portions 717, it is possible to both reduce the height (projection amount) of the first rib portions 717 and ensure the same creepage distance D. In addition, by connecting with the second rib portion 718, the plurality of first rib portions 717 can be strengthened. Furthermore, since the second rib portion 718 is provided outside the repetition range R in the left-right direction, a portion where the creepage distance D becomes short does not occur.

[0094] In addition, when the second rib portion 718 is provided inside the repetition range R in the left-right direction, in the portion where the second rib portion 718 exists, the plurality of first rib portions 717 are connected by the second rib portion 718, and thus the creepage distance D becomes short.

[0095] Furthermore, the 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, and a plurality (four) of them are provided so as to be arranged at intervals in the left-right direction. In the non-overlapping portion 512, a plurality of opening portions 513 that are adjacent to the connection terminal portions 520 and through which the external terminal 2a is inserted are formed so as to be arranged in the left-right direction. The second portion 712 of the insulating member 700 does not overlap with the plurality of connection terminal portions 520.

[0096] According to this structure, when performing the operation of connecting the external terminal 2a to the connection terminal portion 520 by inserting it through the opening portion 513, the second portion 712 of the insulating member 700 does not easily interfere with this connection operation.

[0097] In addition, even in the case where the second portion 712 is structured not to overlap with the connection terminal portions 520 like this, since it is not easy to increase the dimension in the vertical direction of the second portion 712 in order to extend the creepage distance D, the dimension in the vertical direction of the non-overlapping portion 512 is not easily increased, and the first bus bar 500 is not easily increased.

[0098] 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, application examples of the present invention can be variously modified.

[0099] For example, in the above-described embodiment, two first rib portions 717 and two second rib portions 718 connecting these first rib portions 717 are formed in the second portion 712 of the insulating member 700. However, as shown in (a) of Figure 9 , the two second rib portions 718 may not be formed in the second portion 712 of the insulating member 700.

[0100] In addition, in the above-described embodiment, two first rib portions 717 are formed in the second portion 712 of the insulating member 700. However, the number of the first rib portions 717 can be appropriately changed. For example, in order to ensure the same creepage distance D as in the above-described embodiment, as shown in (b) of Figure 9 , three first rib portions 717a that are arranged in the vertical direction, have a height (projection amount) lower than that of the two first rib portions 717, and have the same length may be formed in the second portion 712. The left and right ends of these three first rib portions 717a are connected by the second rib portion 718a. Alternatively, as shown in (c) of Figure 9 , one first rib portion 717b having a height higher than that of the two first rib portions 717 and having the same length may be formed in the second portion 712. Regarding the first rib portion, the more the number, the lower the height can be, so when the film capacitor 1 is provided in an external device, it is less likely to interfere with surrounding components. The fewer the number, the simpler the structure of the second portion 712, so it is easier to manufacture the insulating member 700.

[0101] Furthermore, in the above-described embodiment, the first bus bar 500 is configured such that four connection terminal portions 520 protrude from the non-overlapping portion 512 toward the side opposite to the second portion 712 (front side) of the insulating member 700. However, the number of the connection terminal portions 520 can be appropriately changed. When the number of the connection terminal portions 520 is changed, the number of the opening portions 513 is changed accordingly. In addition, the formation position and the protruding direction of the connection terminal portions 520 in the non-overlapping portion 512 can also be appropriately changed. For example, the connection terminal portions 520 may protrude from the non-overlapping portion 512 toward the second portion 712 side (rear side). In addition, the connection terminal portions 520 may protrude upward, leftward, or rightward from the upper end portion, left end portion, or right end portion of the non-overlapping portion 512.

[0102] Furthermore, in the above-described embodiment, the left-right widths of the first overlapping portion 511 and the non-overlapping portion 512 of the first bus bar 500 are set to be equal. However, the left-right widths of the first overlapping portion 511 and the non-overlapping portion 512 may be different.

[0103] Furthermore, the shapes of the first overlapping portion 511 and the non-overlapping portion 512 of the first bus bar 500 and the second overlapping portion 611 of the second bus bar 600 may not be set to a square shape as in the above-described embodiment, and may be set to an appropriate shape.

[0104] Furthermore, in the above-described embodiment, one capacitor element 400 is provided in the thin film capacitor 1. However, the number of capacitor elements 400 may also be two or more, and may be appropriately changed.

[0105] Furthermore, in the above-described embodiment, 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. However, in addition to this, the capacitor element 400 may also be formed by overlapping a metallized film obtained by vapor-depositing aluminum on both sides of a dielectric film and an insulating film and winding or laminating them.

[0106] Furthermore, in the above-described embodiment, as an example of the capacitor of the present invention, the thin film capacitor 1 is cited. However, the present invention can also be applied to capacitors other than the thin film capacitor 1.

[0107] In addition, the embodiments of the present invention can be appropriately modified within the scope of the technical idea shown in the claims.

[0108] In addition, in the description of the above-described embodiment, terms indicating directions such as "above" and "below" indicate relative directions that depend only on the relative positional relationship of the structural members, and do not indicate absolute directions such as the vertical direction and the horizontal direction.

[0109] Industrial Applicability

[0110] The present invention is useful for capacitors used in various electronic devices, electrical devices, industrial devices, electrical installations of vehicles, and the like.

[0111] Symbol Explanation

[0112] 1 Thin film capacitor (capacitor);

[0113] 400 Capacitor element;

[0114] 500 First bus bar;

[0115] 511 First overlapping portion;

[0116] 512 Non-overlapping portion;

[0117] 513 Opening;

[0118] 520 Connection terminal portion;

[0119] 600 Second bus bar;

[0120] 611 Second overlapping part;

[0121] 700 Insulating member;

[0122] 711 First part;

[0123] 712 Second part;

[0124] 717 First rib portion (protrusion);

[0125] 718 Second rib portion (connection 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 first overlapping portion, the second bus bar includes a 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, the first bus bar includes: a non-overlapping portion, continuous with the first overlapping portion and not overlapping with the second overlapping portion; and a connection terminal portion protruding from the non-overlapping portion and connected to an external terminal, the insulating member includes: a flat first portion disposed between the first overlapping portion and the second overlapping portion; a flat second portion continuous with the first portion and overlapping with the non-overlapping portion; and a protruding portion protruding from the second portion toward the side opposite to the non-overlapping portion, the protruding portion extends in the second direction in such a manner that, when viewed in a first direction in which the first overlapping portion and the non-overlapping portion are arranged, it exists in a range where a range of the non-overlapping portion and a range of the second overlapping portion overlap in a second direction perpendicular to the first direction.

2. The capacitor according to claim 1, wherein, The protruding portion is composed of a plurality of protruding portions arranged at intervals in the first direction. The insulating member includes a connecting portion that connects the plurality of protruding portions. The connecting portion is provided outside the range where the range of the non-overlapping portion and the range of the second overlapping portion overlap in the second direction.

3. The capacitor according to claim 1 or 2, wherein, The connection terminal portion is composed of a plurality of connection terminal portions that protrude from the non-overlapping portion to the side opposite to the second portion and are arranged at intervals in the second direction. In the non-overlapping portion, a plurality of openings adjacent to the connection terminal portion and through which the external terminal is inserted are formed in a row in the second direction. The second portion does not overlap with the plurality of connection terminal portions.

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