Capacitor

Abstract

To provide a capacitor capable of preferably removing bubble contained in a liquid-phase state filling resin from an inside of a case.SOLUTION: In a film capacitor 1, a capacitor element 100 is arranged in a case 20 so that a peripheral surface 130 is opposite to an inner surface 22a of a bottom surface part 22. A first bus bar 200 and a second bus bar 300 include a first overlapping part 230 and a second overlapping part 330 that are overlapped each other, respectively. The first bus bar 200 includes: a first electrode terminal part 210 to be connected to a first electrode 110; and a first relay part 220 extended along the peripheral surface 130 and connecting the first electrode terminal part 210 with the first overlapping part 230. An insulation member 400 includes: a first part 410 interposed between the first overlapping part 230 and the second overlapping part 330; and a second part 420 interposed between the first relay part 220 and the peripheral surface 130. A surface directed to the peripheral surface 130 side of the second part 420 includes a first inclination surface 421 inclined with respect to the inner surface 22a of the bottom surface part 22.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a capacitor.

Background Art

[0002] A capacitor including a capacitor element having a first end face electrode and a second end face electrode, a first bus bar and a second bus bar connected to the first end face electrode and the second end face electrode of the capacitor element respectively, a first overlapping portion and a second overlapping portion each included in the first bus bar and the second bus bar and overlapping with each other, an insulating plate for insulating between the first overlapping portion and the second overlapping portion, a case for housing the capacitor element, and a filling resin filled in the case is described in Patent Document 1.

[0003] In this capacitor, the capacitor element is disposed in the case such that its outer peripheral surface faces the inner bottom surface of the case. The front bus bar as the first bus bar includes a front electrode terminal portion covering the front end face electrode as the first end face electrode, a front relay portion extending rearward along the outer peripheral surface of the capacitor element from the upper end portion of the front electrode terminal portion, and a front overlapping portion as the first overlapping portion extending upward from the rear end portion of the front relay portion. The rear bus bar as the second bus bar includes a rear electrode terminal portion covering the rear end face electrode as the second end face electrode, a rear relay portion extending forward along the outer peripheral surface of the capacitor element from the upper end portion of the rear electrode terminal portion, and a rear overlapping portion as the second overlapping portion extending upward from the front end portion of the rear relay portion.

[0004] At the lower end portion of the insulating plate, a front support plate for supporting the front relay portion of the front bus bar from below is formed to extend forward, and a rear support plate for supporting the rear relay portion of the rear bus bar from below is formed to extend rearward. The front support plate is interposed between the front relay portion and the outer peripheral surface of the capacitor element, and the rear support plate is interposed between the rear relay portion and the outer peripheral surface of the capacitor element.

[0005] The thermosetting resin is made of a thermosetting resin, injected into the case in a molten state (liquid phase state), and cured by heating the case.

[0006] In this capacitor, the first overlapping portion and the second overlapping portion overlap with each other via an insulating plate, so that a reduction in ESL (equivalent series inductance) is expected.

Prior Art Documents

Patent Documents

[0007]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0008] In the capacitor of the above Patent Document 1, when the molten filling resin is injected into the case, air may be entrained, so that a large number of air bubbles may be generated in the molten filling resin in the case. Therefore, before the filling resin is heated, the inside of the case is depressurized to perform defoaming.

[0009] However, in the capacitor of the above Patent Document 1, there is a concern that air bubbles may remain under the front support plate and the rear support plate extending substantially parallel to the inner bottom surface of the case, and the air bubbles may not be removed well from the inside of the case.

[0010] In Patent Document 1, the capacitor has a configuration in which a part of an insulating member extending substantially parallel to the inner bottom surface of the case exists between the bus bar and the peripheral surface of the capacitor element. However, in a capacitor having a configuration in which a part of the insulating member exists between the bus bar and the electrode of the capacitor element, the same problems as described above may occur.

[0011] Therefore, an object of the present invention is to provide a capacitor in which air bubbles contained in the filling resin in the liquid phase state can be removed well from the inside of the case.

Means for Solving the Problems

[0012] A first aspect of the present invention relates to a capacitor. The capacitor according to this aspect includes a capacitor element including a first electrode formed on one end face, a second electrode formed on the other end face, and a peripheral surface connecting the first electrode and the second electrode, an opening, and a bottom face portion facing the opening, and a case in which the capacitor element is accommodated, a first bus bar and a second bus bar respectively connected to the first electrode and the second electrode, an insulating member that insulates between the first bus bar and the second bus bar, and a filling resin filled in the case. Here, the capacitor element is disposed in the case such that the peripheral surface faces the inner surface of the bottom face portion. The first bus bar and the second bus bar are each located on the side opposite to the bottom face portion with respect to the capacitor element and extend in a direction perpendicular to the inner surface of the bottom face portion, and include a first overlapping portion and a second overlapping portion that overlap each other. The first bus bar includes a first electrode terminal portion connected to the first electrode, and a first relay portion that extends along the peripheral surface and connects the first electrode terminal portion and the first overlapping portion. The insulating member includes a first portion interposed between the first overlapping portion and the second overlapping portion, and a second portion interposed between the first relay portion and the peripheral surface, and a surface of the second portion facing the peripheral surface side includes a first inclined surface inclined with respect to the inner surface of the bottom face portion.

[0013] The second aspect of the present invention relates to a capacitor. The capacitor according to this aspect includes a capacitor element including a first electrode formed on one end face, a second electrode formed on the other end face, and a peripheral surface connecting the first electrode and the second electrode, an opening, a bottom surface portion facing the opening, and a case in which the capacitor element is accommodated, a first bus bar and a second bus bar respectively connected to the first electrode and the second electrode, an insulating member insulating between the first bus bar and the second bus bar, and a filling resin filled in the case. Here, the capacitor element is disposed in the case such that the second electrode faces the inner surface of the bottom surface portion. The first bus bar and the second bus bar are respectively located on the opposite side of the bottom surface portion with respect to the capacitor element and extend in a direction perpendicular to the inner surface of the bottom surface portion, and include a first overlapping portion and a second overlapping portion that overlap each other. The first bus bar includes a first electrode terminal portion connected to the first electrode, and a first relay portion extending along the first electrode and connecting the first electrode terminal portion and the first overlapping portion. The insulating member includes a first portion interposed between the first overlapping portion and the second overlapping portion, and a second portion interposed between the first relay portion and the first electrode, and a surface of the second portion facing the first electrode side includes a first inclined surface inclined with respect to the inner surface of the bottom surface portion.

Advantages of the Invention

[0014] According to the present invention, it is possible to provide a capacitor in which bubbles contained in the filling resin in the liquid phase state can be satisfactorily removed from inside the case.

[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 merely examples when implementing the present invention, and the present invention is not limited to those described in the following embodiments at all.

Brief Description of the Drawings

[0016]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

[0017] Hereinafter, a film capacitor which is an embodiment of the capacitor of the present invention will be described with reference to the drawings. For convenience, an X-axis, a Y-axis, and a Z-axis orthogonal to each other are appended to each drawing. The Z-axis is the direction in which the opening and the bottom surface of the case are aligned.

[0018] <Embodiment 1> The film capacitor 1 according to Embodiment 1 will be described.

[0019] FIG. 1(a) is a perspective view of the film capacitor 1. FIG. 1(b) is a side view of the film capacitor 1 in which the case 20 is shown in cross section and the filling resin 30 is shown in a transparent state. FIG. 2(a) is a perspective view of the capacitor element unit 10 as seen from the first bus bar 200 side. FIG. 2(b) is a perspective view of the capacitor element unit 10 as seen from the second bus bar 300 side. FIG. 3(a) is a front view of the capacitor element unit 10 as seen from the first bus bar 200 side. FIG. 3(b) is a perspective view of the capacitor element 100.

[0020] The film capacitor 1 includes a capacitor element unit 10, a case 20, and a filling resin 30. The capacitor element unit 10 is housed in the case 20, and the case 20 is filled with the filling resin 30.

[0021] The case 20 is formed of a resin material, for example, a thermoplastic resin such as polyphenylene sulfide (PPS). The case 20 may be formed of a thermosetting resin such as an epoxy resin.

[0022] The case 20 has a substantially rectangular parallelepiped box shape, and includes a rectangular opening 21, a rectangular bottom surface portion 22 facing the opening 21, a rectangular first side surface portion 23 and a rectangular second side surface portion 24 that extend from both edge portions on the X-axis direction side of the bottom surface portion 22 toward the opening 21 side (positive Z-axis direction) and face each other, and a rectangular third side surface portion 25 and a rectangular fourth side surface portion 26 that extend from both edge portions on the Y-axis direction side of the bottom surface portion 22 toward the opening 21 side (positive Z-axis direction) and face each other.

[0023] The filling resin 30 is a thermosetting resin, for example, an epoxy resin. Most of the capacitor element unit 10 buried in the filling resin 30 is protected from moisture and impact by the case 20 and the filling resin 30.

[0024] The capacitor element unit 10 includes a capacitor element 100, a first bus bar 200, a second bus bar 300, and an insulating member 400.

[0025] The capacitor element 100 is formed into a shape close to a flat oblong cylinder by laminating two metallized films with aluminum vapor-deposited on a dielectric film, winding or laminating the laminated metallized films, and pressing them. On one end face of the capacitor element 100, a first electrode 110 is formed by spraying a metal such as zinc, and on the other end face, a second electrode 120 is formed by spraying the same metal such as zinc.

[0026] The capacitor element 100 has a peripheral surface 130 that connects the first electrode 110 and the second electrode 120. The peripheral surface 130 includes two first flat surfaces 131 arranged in the Z-axis direction, which is the short side direction of the capacitor element 100, two second flat surfaces 132 arranged in the Y-axis direction, which is the long side direction of the capacitor element 100, and four arc surfaces 133 existing between the first flat surface 131 and the second flat surface 132. The dimension of the first flat surface 131 in the Y-axis direction is larger than the dimension of the second flat surface 132 in the Z-axis direction.

[0027] The capacitor element 100 is disposed in the case 20 such that the peripheral surface 130 faces the inner surface 22a of the bottom portion 22.

[0028] Note that the capacitor element 100 of the present embodiment is formed of a metallized film obtained by vapor-depositing aluminum on a dielectric film. However, it may also be formed of a metallized film obtained by vapor-depositing other metals such as zinc and magnesium. Alternatively, the capacitor element 100 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.

[0029] The first bus bar 200 and the second bus bar 300 are arranged side by side in the Y-axis direction on the positive Z-axis side, which is one side in the short side direction of the capacitor element 100. The first bus bar 200 and the second bus bar 300 are located on the opening 21 side with respect to the capacitor element 100 within the case 20.

[0030] The first bus bar 200 is formed by appropriately cutting and bending a conductive material, for example, a copper plate, and has a configuration in which the first electrode terminal portion 210, the first relay portion 220, the first overlapping portion 230, and the first connection terminal portion 240 are integrated.

[0031] The first electrode terminal portion 210 has a substantially square plate shape and contacts the first electrode 110 of the capacitor element 100 from the positive X-axis direction side. A pair of electrode terminals 211 are formed on the edge of the first electrode terminal portion 210 in the negative Z-axis direction so as to extend in the negative Z-axis direction. The pair of electrode terminals 211 are joined to the first electrode 110 by a joining method such as soldering. Thereby, the first electrode terminal portion 210, that is, the first bus bar 200 is electrically connected to the first electrode 110.

[0032] The first relay portion 220 relays between the first electrode terminal portion 210 and the first overlapping portion 230. The first relay portion 220 has a substantially square plate shape and extends in the negative X-axis direction from the edge of the first electrode terminal portion 210 in the positive Z-axis direction along the peripheral surface 130 of the capacitor element 100 to near the center of the peripheral surface 130. Two first through holes 221 are formed in the first relay portion 220 so as to be arranged in the Y-axis direction. The first through hole 221 has an oval shape that is long in the X-axis direction.

[0033] The first overlapping portion 230 has a substantially square plate shape and extends in the positive Z-axis direction from the edge of the first relay portion 220 in the negative X-axis direction.

[0034] The first connection terminal portion 240 has a substantially square plate shape and extends in the positive Z-axis direction from the positive Y-axis side of the edge of the first overlapping portion 230 on the positive Z-axis side. A circular mounting hole 241 is formed at the tip of the first connection terminal portion 240.

[0035] The second bus bar 300 is formed by appropriately cutting and bending a conductive material, for example, a copper plate, and has a configuration in which the second electrode terminal portion 310, the second relay portion 320, the second overlapping portion 330, and the second connection terminal portion 340 are integrated.

[0036] The second electrode terminal portion 310 has a substantially square plate shape and contacts the second electrode 120 of the capacitor element 100 from the negative X-axis side. A pair of electrode terminals 311 are formed on the edge of the second electrode terminal portion 310 in the negative Z-axis direction so as to extend in the negative Z-axis direction. The pair of electrode terminals 311 are joined to the second electrode 120 by a joining method such as soldering. Thereby, the second electrode terminal portion 310, that is, the second bus bar 300 is electrically connected to the second electrode 120.

[0037] The second relay portion 320 relays between the second electrode terminal portion 310 and the second overlapping portion 330. The second relay portion 320 has a substantially square plate shape and extends in the positive X-axis direction from the edge of the second electrode terminal portion 310 in the positive Z-axis direction along the peripheral surface 130 of the capacitor element 100 to near the center of the peripheral surface 130. Two second through holes 321 are formed in the second relay portion 320 so as to be arranged in the Y-axis direction. The second through hole 321 has an oval shape that is long in the X-axis direction.

[0038] The second overlapping portion 330 has a substantially square plate shape and extends in the positive Z-axis direction from the edge of the second relay portion 320 in the positive X-axis direction.

[0039] The second connection terminal portion 340 has a substantially square plate shape and extends in the positive Z-axis direction from the negative Y-axis side of the edge on the positive Z-axis side in the second overlapping portion 330. A circular mounting hole 341 is formed at the tip of the second connection terminal portion 340.

[0040] The first overlapping portion 230 and the second overlapping portion 330 overlap each other in a state of approaching each other in the X-axis direction. Thereby, reduction of ESL (equivalent series inductance) in the capacitor element unit 10 is expected.

[0041] The first overlapping portion 230 and the second overlapping portion 330 are on the side opposite to the bottom surface portion 22 of the case 20 with respect to the capacitor element 100, are located at the central portion of the capacitor element 100 in the X-axis direction, extend in a direction (Z-axis direction) perpendicular to the inner surface 22a of the bottom surface portion 22, come out of the filling resin 30, and protrude outside the case 20. Outside the case 20, the first connection terminal portion 240 and the second connection terminal portion 340 are arranged side by side in the Y-axis direction with a predetermined distance in the X-axis direction and the Y-axis direction.

[0042] In the Y-axis direction, which is a direction perpendicular to the direction (X-axis direction) in which the first overlapping portion 230 and the second overlapping portion 330 overlap and the direction (Z-axis direction) in which the capacitor element 100, the first bus bar 200, and the second bus bar 300 are arranged, the dimension of the capacitor element 100 is larger than the dimensions of the first relay portion 220 and the second relay portion 320, and the arc surfaces 133 on both sides of the peripheral surface 130 of the capacitor element 100 protrude outside the first relay portion 220 and the second relay portion 320 (see Fig. 3(a)).

[0043] The insulating member 400 is formed of a material having electrical insulation properties such as polyphenylene sulfide (PPS), and is arranged between these bus bars to ensure the insulation between the first bus bar 200 and the second bus bar 300.

[0044] The insulating member 400 includes a first portion 410 interposed between the first overlapping portion 230 and the second overlapping portion 330, a second portion 420 interposed between the first relay portion 220 and the peripheral surface 130 of the capacitor element 100, and a third portion 430 interposed between the second relay portion 320 and the peripheral surface 130.

[0045] The first portion 410 has a substantially square plate shape. The first portion 410 protrudes outside the first overlapping portion 230 and the second overlapping portion 330 in the Y-axis direction and the positive Z-axis direction perpendicular to the X-axis direction in which the first overlapping portion 230 and the second overlapping portion 330 overlap.

[0046] The second part 420 has a substantially rectangular plate shape elongated in the Y-axis direction and extends from the edge of the first part 410 on the capacitor element 100 side in the positive X-axis direction, i.e., toward the first electrode 110. The second part 420 projects outward from the first relay part 220 and projects outward from the capacitor element 100 in the Y-axis direction perpendicular to the X-axis direction in which the first overlapping part 230 and the second overlapping part 330 overlap and the Z-axis direction in which the first relay part 220 and the peripheral surface 130 overlap (see Fig. 3(a)).

[0047] The surface of the second part 420 facing the first relay part 220 side is substantially parallel to the inner surface 22a of the bottom surface part 22 of the case 20. On the other hand, the surface of the second part 420 facing the peripheral surface 130 side is a first inclined surface 421 inclined with respect to the inner surface 22a of the bottom surface part 22. The first inclined surface 421 is inclined so as to be away from the peripheral surface 130 as it goes toward the tip side (positive X-axis direction) of the second part 420. Further, the first inclined surface 421 is formed as an arc surface, and the inclination becomes steeper as it goes toward the tip side of the second part 420.

[0048] The third part 430 has a substantially rectangular plate shape elongated in the Y-axis direction and extends from the edge of the first part 410 on the capacitor element 100 side in the negative X-axis direction, i.e., toward the second electrode 120. The third part 430 projects outward from the second relay part 320 and projects outward from the capacitor element 100 in the Y-axis direction perpendicular to the X-axis direction in which the first overlapping part 230 and the second overlapping part 330 overlap and the Z-axis direction in which the second relay part 320 and the peripheral surface 130 overlap (see Fig. 3(a)).

[0049] The surface of the third part 430 facing the second relay part 320 side is substantially parallel to the inner surface 22a of the bottom surface part 22 of the case 20. On the other hand, the surface of the third part 430 facing the peripheral surface 130 side is a second inclined surface 431 inclined with respect to the inner surface 22a of the bottom surface part 22. The second inclined surface 431 is inclined so as to be away from the peripheral surface 130 as it goes toward the tip side (negative X-axis direction) of the third part 430. Further, the second inclined surface 431 is formed as an arc surface, and the inclination becomes steeper as it goes toward the tip side of the third part 430.

[0050] The first part 410 increases the creepage distance between the first overlapping part 230 and the second overlapping part 330, ensuring insulation therebetween. The second part 420 and the third part 430 increase the creepage distance between the first relay part 220 and the second relay part 320, ensuring insulation therebetween.

[0051] When viewed in the direction in which the first relay part 220 and the second part 420 overlap (Z-axis direction), a part of each first through-hole 221 overlaps with the tip of the second part 420. Also, when viewed in the direction in which the second relay part 320 and the third part 430 overlap (Z-axis direction), a part of each second through-hole 321 overlaps with the tip of the third part 430.

[0052] The insulating member 400 may be in contact with the peripheral surface 130 of the capacitor element 100 or may be separated from the peripheral surface 130.

[0053] Note that fixing means are appropriately provided between the insulating member 400 and the first bus bar 200 and the second bus bar 300 so that the insulating member 400 does not come out in the Y-axis direction from between the first bus bar 200 and the second bus bar 300. For example, the fixing means can be realized by a pair of first protrusions that protrude from the surface of the first part 410 of the insulating member 400 on the side of the first overlapping part 230 and sandwich the first overlapping part 230 in the Y-axis direction, and a pair of second protrusions that protrude from the surface of the first part 410 on the side of the second overlapping part 330 and sandwich the second overlapping part 330 in the Y-axis direction.

[0054] When the film capacitor 1 is assembled, the capacitor element 100, the first bus bar 200, the second bus bar 300, and the insulating member 400 are held in an assembled state by a holding jig. In this state, the first bus bar 200 and the second bus bar 300 are joined to the first electrode 110 and the second electrode 120 of the capacitor element 100, respectively, and the above four components are integrated. Thereby, the capacitor element unit 10 is completed. Thereafter, the holding jig is removed from the capacitor element unit 10.

[0055] Next, the capacitor element unit 10 is accommodated in the case 20 through the opening 21. The capacitor element unit 10 is positioned at a predetermined position within the case 20 by a positioning jig. The case 20 has a posture in which the opening 21 faces upward and the inner surface 22a of the bottom surface portion 22 is horizontal.

[0056] Next, a liquid-phase filling resin 30 is injected into the case 20 through the opening 21 and filled up to a position close to the opening 21. At this time, since air is entrained, a large number of air bubbles may be generated in the molten filling resin 30 within the case 20. For this reason, a process for degassing from the case 20 is performed and the inside of the case 20 is depressurized.

[0057] In the present embodiment, the surfaces of the second portion 420 and the third portion 430 of the insulating member 400 facing the peripheral surface 130 side of the capacitor element 100, that is, the surfaces facing downward in the state where the filling resin 30 is injected, are the first inclined surface 421 and the second inclined surface 431. For this reason, as shown by the solid-line arrow in Fig. 1(b), the air bubbles present below the second portion 420 and the third portion 430 rise along the first inclined surface 421 and the second inclined surface 431 and escape to the outside of the tips of the second portion 420 and the third portion 430. Thereafter, the air bubbles further rise through the first through-hole 221 and the second through-hole 321 if it is a region covered by the first relay portion 220 and the second relay portion 320, and further rise through both sides thereof if it is a region on both sides of the first relay portion 220 and the second relay portion 320, and escape from the opening 21 to the outside of the case 20. Thus, in the present embodiment, since air bubbles are less likely to stay below the second portion 420 and the third portion 430, the air bubbles can be removed from the case 20 satisfactorily.

[0058] In particular, below the second part 420 and the third part 430, there are likely to be many air bubbles in the upper part directly above the arc surfaces 133 on both sides of the circumferential surface 130 of the capacitor element 100, and in the portions where the second part 420 and the third part 430 on both sides of the capacitor element 100 protrude. However, only a part of the upper part directly above the arc surfaces 133 on both sides is covered by the first relay part 220 and the second relay part 320, and the both side portions of the capacitor element 100 are not covered by the first relay part 220 and the second relay part 320 at all. Therefore, in these portions, the air bubbles that have passed through the second part 420 and the third part 430 can smoothly rise to the opening 21 without being blocked by the first relay part 220 and the second relay part 320. Thus, air bubbles can be removed better from inside the case 20.

[0059] Also, since the first inclined surface 421 inclines toward the tip side of the second part 420 and the second inclined surface 431 inclines toward the tip side of the third part 430, the air bubbles below the second part 420 escape from the second part 420 through only the first inclined surface 421, and the air bubbles below the third part 430 escape from the third part 430 through only the second inclined surface 431. Therefore, the distance that the air bubbles move to escape from the second part 420 and the third part 430 becomes shorter, so the air bubbles can easily escape from the second part 420 and the third part 430.

[0060] Furthermore, the first inclined surface 421 and the second inclined surface 431 are formed on the arc surface, and the inclination becomes steeper toward the tip sides of the second part 420 and the third part 430. For this reason, it is less likely that air bubbles will stay at the tip sides of the first inclined surface 421 and the second inclined surface 431, that is, the outlet sides. Thus, the air bubbles can easily escape from the second part 420 and the third part 430 successively along the first inclined surface 421 and the second inclined surface 431.

[0061] When the defoaming from inside the case 20 is completed, next, the inside of the case 20 is heated, and the filling resin 30 is heated. As a result, the filling resin 30 hardens inside the case 20. Thus, the film capacitor 1 is completed.

[0062] The film capacitor 1 is mounted on an external device or the like. A pair of external terminals (not shown) provided in the external device or the like corresponding to these connection terminal portions 240 and 340 are connected to the first connection terminal portion 240 and the second connection terminal portion 340 by screwing using the mounting holes 241 and 341.

[0063] <Effects of Embodiment 1> As described above, according to Embodiment 1, the following effects are achieved.

[0064] The film capacitor 1 includes a capacitor element 100 including a first electrode 110 formed on one end face, a second electrode 120 formed on the other end face, and a peripheral surface 130 connecting the first electrode 110 and the second electrode 120, an opening 21, and a bottom surface portion 22 facing the opening 21, and the capacitor element 100 is accommodated in a case 20, a first bus bar 200 and a second bus bar 300 respectively connected to the first electrode 110 and the second electrode 120, an insulating member 400 insulating between the first bus bar 200 and the second bus bar 300, and a filling resin 30 filled in the case 20. Here, the capacitor element 100 is disposed in the case 20 such that the peripheral surface 130 faces the inner surface 22a of the bottom surface portion 22. The first bus bar 200 and the second bus bar 300 are respectively located on the opposite side of the bottom surface portion 22 with respect to the capacitor element 100 and extend in a direction perpendicular to the inner surface 22a of the bottom surface portion 22, and include a first overlapping portion 230 and a second overlapping portion 330 overlapping each other. The first bus bar 200 includes a first electrode terminal portion 210 connected to the first electrode 110 and a first relay portion 220 extending along the peripheral surface 130 and connecting the first electrode terminal portion 210 and the first overlapping portion 230. The insulating member 400 includes a first portion 410 interposed between the first overlapping portion 230 and the second overlapping portion 330 and a second portion 420 interposed between the first relay portion 220 and the peripheral surface 130, and the surface of the second portion 420 facing the peripheral surface 130 side includes a first inclined surface 421 inclined with respect to the inner surface 22a of the bottom surface portion 22.

[0065] According to this configuration, when bubbles are generated in the filling resin 30 in a liquid phase state within the case 20, the bubbles existing below the second portion 420 of the insulating member 400 rise along the first inclined surface 421 and pass through the second portion 420. As a result, since it is difficult for bubbles to stay below the second portion 420, it becomes possible to satisfactorily remove the bubbles from within the case 20.

[0066] Furthermore, the first relay portion 220 has a first through hole 221.

[0067] According to this configuration, the bubbles that have passed through the second portion 420 in the region covered by the first relay portion 220 pass through the first through hole 221 and out of the first relay portion 220. As a result, since it is difficult for bubbles to stay below the first relay portion 220, it becomes possible to more satisfactorily remove the bubbles from within the case 20.

[0068] Furthermore, when viewed in the direction (Z-axis direction) in which the first relay portion 220 and the second portion 420 overlap, a part of the first through hole 221 overlaps with the tip portion of the second portion 420.

[0069] According to this configuration, the bubbles that have escaped from the tip portion side of the second portion 420 are more likely to enter the first through hole 221 and more likely to pass through the first relay portion 220. Therefore, it becomes even more difficult for bubbles to stay below the first relay portion 220.

[0070] Furthermore, the second bus bar 300 includes a second electrode terminal portion 310 connected to the second electrode 120 of the capacitor element 100, and a second relay portion 320 extending along the peripheral surface 130 of the capacitor element 100 and connecting the second electrode terminal portion 310 and the second overlapping portion 330. The insulating member 400 further includes a third portion 430 interposed between the second relay portion 320 and the peripheral surface 130, and the surface facing the peripheral surface 130 side of the third portion 430 includes a second inclined surface 431 inclined with respect to the inner surface 22a of the bottom portion 22 of the case 20.

[0071] According to this configuration, the bubbles existing below the third portion 430 of the insulating member 400 rise along the second inclined surface 431 and pass through the third portion 430. As a result, it is difficult for bubbles to stay below the third portion 430, so that the bubbles can be removed from the case 20 well.

[0072] Furthermore, the second relay portion 320 has a second through hole 321.

[0073] According to this configuration, the bubbles that have passed through the third portion 430 in the region covered by the second relay portion 320 pass through the second through hole 321 and pass through the second relay portion 320. As a result, it is difficult for bubbles to stay below the second relay portion 320, so that the bubbles can be removed from the case 20 more favorably.

[0074] Furthermore, when viewed in the direction (Z-axis direction) in which the second relay portion 320 and the third portion 430 overlap, a part of the second through hole 321 overlaps with the tip of the third portion 430.

[0075] According to this configuration, the bubbles that have escaped from the tip side of the third portion 430 are likely to enter the second through hole 321 and are likely to pass through the second relay portion 320. Therefore, it becomes even more difficult for bubbles to stay below the second relay portion 320.

[0076] <Modification Example 1> FIG. 4(a) is a side view of the film capacitor 1 in which the case 20 is shown in cross section and the filling resin 30 is shown in a transparent state according to Modification Example 1. FIG. 4(b) is a perspective view of the capacitor element unit 10 viewed from the first bus bar 200 side according to Modification Example 1.

[0077] In the film capacitor 1 of this modification example, the configurations of the second bus bar 300 and the insulating member 400 are changed as follows.

[0078] That is, in the insulating member 400, the first inclined surface 421 of the second portion 420 is a flat surface. Also, the second inclined surface 431 of the third portion 430 is inclined so as to be away from the peripheral surface 130 of the capacitor element 100 as it goes from the tip side of the third portion 430 toward the second portion 420 side, and is a flat surface. That is, the surfaces facing the peripheral surface 130 side of the second portion 420 and the third portion 430 are, as a whole, an inclined surface 401 composed of the first inclined surface 421 and the second inclined surface 431. The inclined surface 401 is inclined so as to be away from the peripheral surface 130 as it goes from the tip side of the third portion 430 toward the tip side of the second portion 420, and is a flat surface. Further, in the second bus bar 300, no second through hole is formed in the second relay portion 320.

[0079] When bubbles are generated in the filling resin 30 when the filling resin 30 in a liquid phase state is injected into the case 20, as shown by the arrow in FIG. 4(a), the bubbles existing below the second portion 420 and the third portion 430 rise along the inclined surface 401 and escape to the outside of the tip of the second portion 420. Thereafter, the bubbles further rise through the first through hole 221 of the first relay portion 220 and both sides of the first relay portion 220, and escape from the opening 21 to the outside of the case 20. Therefore, since bubbles are less likely to stay below the second portion 420 and the third portion 430, the bubbles can be removed from the case 20 well.

[0080] In this modification example, since the bubbles existing below the third portion 430 need to move between the second inclined surface 431 and the first inclined surface 421, they are less likely to escape compared to the first embodiment. However, since bubbles do not flow into the region covered by the second relay portion 320, it is possible to eliminate the second through hole 321, and thus the second bus bar 300 can be made simpler in configuration.

[0081] Note that, in the configuration of this modification example, a second through hole 321 may be provided in the second relay portion 320.

[0082] <Modification Example 2> Figs. 5(a) and (b) are diagrams for explaining the film capacitor 1 according to Modification 2.

[0083] In the above Embodiment 1, in the insulating member 400, the first inclined surface 421 of the second portion 420 and the second inclined surface 431 of the third portion 430 are arc surfaces. However, in the above Embodiment 1, as shown in Fig. 5(a), the first inclined surface 421 and the second inclined surface 431 may be flat surfaces.

[0084] Furthermore, in the above Modification 1, in the insulating member 400, the first inclined surface 421 of the second portion 420 and the second inclined surface 431 of the third portion 430, that is, the inclined surface 401 is a flat surface. However, in the above Modification 1, as shown in Fig. 5(b), the inclined surface 401 (the first inclined surface 421, the second inclined surface 431) may be a flat surface.

[0085] <Embodiment 2> The film capacitor 2 according to Embodiment 2 will be described.

[0086] Fig. 6(a) is a perspective view of the film capacitor 2. Fig. 6(b) is a side view of the film capacitor 2 in which the case 20 is shown in cross section and the filling resin 30 is shown in a transparent state. Fig. 7(a) is a perspective view of the capacitor element unit 10A as viewed from the first bus bar 200A side. Fig. 7(b) is a perspective view of the capacitor element unit 10A as viewed from the second bus bar 300A side.

[0087] In the present embodiment, the same components as those in the above Embodiment 1 are denoted by the same reference numerals.

[0088] The film capacitor 2 includes a capacitor element unit 10A, a case 20, and a filling resin 30. The capacitor element unit 10A includes a capacitor element 100, a first bus bar 200A, a second bus bar 300A, and an insulating member 400A.

[0089] The first bus bar 200A is formed by appropriately cutting and bending a conductive material, for example, a copper plate, and has a configuration in which a first electrode terminal portion 210A, a first relay portion 220A, a first overlapping portion 230A, and a first connection terminal portion 240A are integrated.

[0090] The configurations of the first electrode terminal portion 210A, the first overlapping portion 230A, and the first connection terminal portion 240A are the same as those of the first electrode terminal portion 210, the first overlapping portion 230, and the first connection terminal portion 240 in the first embodiment. Similar to the first electrode terminal portion 210, the first electrode terminal portion 210A has a pair of electrode terminals 211, and similar to the first connection terminal portion 240, the first connection terminal portion 240A has a mounting hole 241.

[0091] The first relay portion 220A is longer in the X-axis direction than the first relay portion 220 in the first embodiment, and extends from the edge of the first electrode terminal portion 210A in the positive Z-axis direction along the peripheral surface 130 of the capacitor element 100 to the vicinity of the second electrode 120 in the negative X-axis direction. Similar to the first relay portion 220, the first relay portion 220A has two first through holes 221.

[0092] The second bus bar 300A is formed by appropriately cutting and bending a conductive material, for example, a copper plate, and has a configuration in which a second electrode terminal portion 310A, a second overlapping portion 330A, and a second connection terminal portion 340A are integrated.

[0093] The configurations of the second electrode terminal portion 310A, the second overlapping portion 330A, and the second connection terminal portion 340A are the same as those of the second electrode terminal portion 310, the second overlapping portion 330, and the second connection terminal portion 340 in the first embodiment. Similar to the second electrode terminal portion 310, the second electrode terminal portion 310A has a pair of electrode terminals 311, and similar to the second connection terminal portion 340, the second connection terminal portion 340A has a mounting hole 341.

[0094] In the second bus bar 300A, a second relay portion is not provided, and the second overlapping portion 330A is directly connected to the edge of the second electrode terminal portion 310A in the positive Z-axis direction.

[0095] The first overlapping portion 230A and the second overlapping portion 330A are located on the side opposite to the bottom surface portion 22 of the case 20 with respect to the capacitor element 100, near the second electrode 120 of the capacitor element 100 in the X-axis direction, extend in a direction (Z-axis direction) perpendicular to the inner surface 22a of the bottom surface portion 22, and protrude out of the case 20 from the filling resin 30. Further, the first overlapping portion 230A and the second overlapping portion 330A overlap each other in a state of being close to each other in the X-axis direction.

[0096] Outside the case 20, the first connection terminal portion 240A and the second connection terminal portion 340A are arranged side by side in the Y-axis direction with a predetermined distance in the X-axis direction and the Y-axis direction.

[0097] The insulating member 400A is formed of a material having electrical insulation properties, and includes a first portion 410A interposed between the first overlapping portion 230A and the second overlapping portion 330A, and a second portion 420A interposed between the first relay portion 220A and the peripheral surface 130 of the capacitor element 100. The insulating member 400A is not provided with a third portion.

[0098] The configuration of the first portion 410A is the same as that of the first portion 410 of the first embodiment. The second portion 420A is longer in the X-axis direction than the second portion 420 of the first embodiment. Further, in the second portion 420A, the first inclined surface 421A of the surface facing the peripheral surface 130 side of the capacitor element 100 is a flat surface.

[0099] The length of the second portion 420A in the X-axis direction may be the same as that of the second portion 420 of the first embodiment. Further, the first inclined surface 421A may be an arc surface, similar to the first inclined surface 421 of the first embodiment.

[0100] The first portion 410A increases the creepage distance between the first overlapping portion 230A and the second overlapping portion 330A, and ensures the insulation between them. The second portion 420A increases the creepage distance between the first relay portion 220A and the second electrode terminal portion 310A and the second electrode 120, and ensures the insulation between them.

[0101] When viewed in the direction (Z-axis direction) in which the first relay portion 220A and the second portion 420A overlap, a part of each first through hole 221 overlaps with the tip of the second portion 420A.

[0102] The film capacitor 2 is assembled by the same process (method) as the film capacitor 1 of the above-described Embodiment 1.

[0103] When bubbles are generated in the filling resin 30 when the liquid-phase filling resin 30 is injected into the case 20, as shown by the arrow in FIG. 6(b), the bubbles existing below the second portion 420A rise along the first inclined surface 421A and escape to the outside of the tip of the second portion 420A. Thereafter, the bubbles further rise through the first through holes 221 of the first relay portion 220A and both sides of the first relay portion 220A, and escape from the opening 21 to the outside of the case 20. Therefore, since bubbles are less likely to stay below the second portion 420A, the bubbles can be removed from the case 20 well.

[0104] <Effect of Embodiment 2> Also in the film capacitor 2 of the present embodiment, as in the above-described Embodiment 1, since bubbles are less likely to stay below the second portion 420A, it is possible to remove the bubbles from the case 20 well. Further, since bubbles are less likely to stay below the first relay portion 220A, it is possible to remove the bubbles from the case 20 even better.

[0105] <Embodiment 3> The film capacitor 3 according to Embodiment 3 will be described.

[0106] FIG. 8(a) is a perspective view of the film capacitor 3. FIG. 8(b) is a side view of the film capacitor 3 in which the case 50 is shown in cross section and the filling resin 60 is shown in a transparent state. FIG. 9(a) is a perspective view of the capacitor element unit 40 viewed from the first bus bar 600 side. FIG. 9(b) is a perspective view of the capacitor element unit 40 viewed from the second bus bar 700 side.

[0107] The film capacitor 3 includes a capacitor element unit 40, a case 50, and a filling resin 60. The capacitor element unit 40 is housed in the case 50, and the case 50 is filled with the filling resin 60.

[0108] The case 50 is formed of a resin material, for example, a thermoplastic resin such as polyphenylene sulfide (PPS). The case 50 may be formed of a thermosetting resin such as an epoxy resin.

[0109] The case 50 has a substantially rectangular parallelepiped box shape similar to the case 20 of the first embodiment, and includes an opening 51, a bottom surface portion 52, a first side surface portion 53, a second side surface portion 54, a third side surface portion 55, and a fourth side surface portion 56. The filling resin 60 is a thermosetting resin, for example, an epoxy resin. Most of the capacitor element unit 40 buried in the filling resin 60 is protected from moisture and impact by the case 50 and the filling resin 60.

[0110] The capacitor element unit 40 includes a capacitor element 500, a first bus bar 600, a second bus bar 700, and an insulating member 800.

[0111] The capacitor element 500 has the same configuration as the capacitor element 100 of the first embodiment, and has a first electrode 510, a second electrode 520, and a peripheral surface 530. The peripheral surface 530 includes two first flat surfaces 531, two second flat surfaces 532, and four arc surfaces 533. The ratio of the dimension in the direction in which the two first flat surfaces 531 are arranged (short side direction) to the dimension in the direction in which the two second flat surfaces 532 are arranged (long side direction) of the capacitor element 500 is larger than the same ratio of the capacitor element 100.

[0112] The capacitor element 500 is arranged in the case 50 such that the second electrode 520 faces the inner surface 52a of the bottom surface portion 52.

[0113] The first bus bar 600 is formed by appropriately cutting and bending a conductive material, for example, a copper plate, and has a configuration in which a first electrode terminal portion 610, a first relay portion 620, a first overlapping portion 630, and a first connection terminal portion 640 are integrated.

[0114] The first electrode terminal portion 610 has a substantially square plate shape and contacts the first electrode 510 of the capacitor element 500 from the positive Z-axis direction side. A pair of electrode terminals 611 are formed on the edge of the first electrode terminal portion 610 in the positive Z-axis direction so as to extend in the positive X-axis direction. The pair of electrode terminals 611 are joined to the first electrode 510 by a joining method such as soldering. Thereby, the first electrode terminal portion 610, that is, the first bus bar 600 is electrically connected to the first electrode 510.

[0115] The first relay portion 620 relays between the first electrode terminal portion 610 and the first overlapping portion 630. The first relay portion 620 has a substantially square plate shape bent in an L shape, extends in the positive Z-axis direction from the edge of the first electrode terminal portion 610 in the negative X-axis direction, and then extends in the negative X-axis direction along the first electrode 510 of the capacitor element 500. Two first through holes 621 are formed in the first relay portion 620 at the bent portion (corner portion) so as to be arranged in the Y-axis direction. The first through hole 621 has a square shape.

[0116] The first overlapping portion 630 has a substantially square plate shape and extends in the positive Z-axis direction from the edge of the first relay portion 620 in the negative X-axis direction.

[0117] The first connection terminal portion 640 has a substantially square plate shape and extends in the positive Z-axis direction from the positive Y-axis side of the edge on the positive Z-axis side in the first overlapping portion 630. A circular mounting hole 641 is formed at the tip of the first connection terminal portion 640.

[0118] The second bus bar 700 is formed by appropriately cutting and bending a conductive material, for example, a copper plate, and has a configuration in which a second electrode terminal portion 710, a second relay portion 720, a second overlapping portion 730, and a second connection terminal portion 740 are integrated.

[0119] The second electrode terminal portion 710 has a substantially square plate shape and contacts the second electrode 520 of the capacitor element 500 from the negative Z-axis side. On the edge of the second electrode terminal portion 710 in the positive Z-axis direction, a pair of electrode terminals 711 are formed so as to extend in the positive X-axis direction. The pair of electrode terminals 711 are joined to the second electrode 520 by a joining method such as soldering. Thereby, the second electrode terminal portion 710, that is, the second bus bar 700 is electrically connected to the second electrode 520.

[0120] The second relay portion 720 relays between the second electrode terminal portion 710 and the second overlapping portion 730. The second relay portion 720 has a substantially square plate shape bent in an L shape, and extends from the edge of the second electrode terminal portion 710 in the negative X-axis direction along the peripheral surface 530 of the capacitor element 500 to a position beyond the first electrode 510, and then extends in the positive X-axis direction along the first electrode 510. In this embodiment, a second through hole similar to the first through hole 621 may be provided in the second relay portion 720.

[0121] The second overlapping portion 730 has a substantially square plate shape and extends in the positive Z-axis direction from the edge of the second relay portion 720 in the positive X-axis direction.

[0122] The second connection terminal portion 740 has a substantially square plate shape and extends in the positive Z-axis direction from the negative Y-axis side of the edge on the positive Z-axis side in the second overlapping portion 730. A circular mounting hole 741 is formed at the tip of the second connection terminal portion 740.

[0123] The first overlapping portion 630 and the second overlapping portion 730 overlap each other in a state of being close to each other in the X-axis direction. Thereby, reduction of ESL (equivalent series inductance) in the capacitor element unit 40 is expected.

[0124] The first overlapping portion 630 and the second overlapping portion 730 are located on the side opposite to the bottom surface portion 52 of the case 50 with respect to the capacitor element 500, near the edge of the first electrode 510 in the negative X-axis direction, extend in a direction (Z-axis direction) perpendicular to the inner surface 52a of the bottom surface portion 52, and protrude out of the case 50 from the filling resin 60. Outside the case 50, the first connection terminal portion 640 and the second connection terminal portion 740 are arranged side by side in the Y-axis direction with a predetermined distance in the X-axis direction and the Y-axis direction.

[0125] In the Y-axis direction, which is perpendicular to the direction (X-axis direction) in which the first overlapping portion 630 and the second overlapping portion 730 overlap and the direction (Z-axis direction) in which the first electrode 510 and the second electrode 520 of the capacitor element 500 are arranged, the dimension of the capacitor element 500 is larger than the dimensions of the first relay portion 620 and the second relay portion 720, and both ends including the arc surface 533 in the capacitor element 500 protrude outward beyond the first relay portion 620 and the second relay portion 720.

[0126] The insulating member 800 is formed of a material having electrical insulation properties such as polyphenylene sulfide (PPS), and is disposed between these bus bars to ensure insulation between the first bus bar 600 and the second bus bar 700.

[0127] The insulating member 800 includes a first portion 810 interposed between the first overlapping portion 630 and the second overlapping portion 730, a second portion 820 interposed between the first relay portion 620 and the first electrode 510 of the capacitor element 500, a third portion 830 interposed between the second relay portion 720 and the first electrode 510, and a fourth portion 840 interposed between the second relay portion 720 and the peripheral surface 530 of the capacitor element 500.

[0128] The first portion 810 has a substantially square plate shape. The first portion 810 protrudes outward beyond the first overlapping portion 630 and the second overlapping portion 730 in the Y-axis direction and the positive Z-axis direction perpendicular to the X-axis direction in which the first overlapping portion 630 and the second overlapping portion 730 overlap.

[0129] The second part 820 has a substantially rectangular plate shape elongated in the Y-axis direction and extends from the edge of the first part 810 on the side of the capacitor element 500 in the positive X-axis direction, i.e., toward the first electrode terminal part 610. A gap is provided between the tip of the second part 820 and the part of the first relay part 620 extending in the Z-axis direction.

[0130] The surface of the second part 820 facing the first relay part 620 side is substantially parallel to the inner surface 52a of the bottom face part 52 of the case 50. On the other hand, the surface of the second part 820 facing the first electrode 510 side is a first inclined surface 821 that is inclined with respect to the inner surface 52a of the bottom face part 52. The first inclined surface 821 is inclined so as to be separated from the first electrode 510 as it goes toward the tip side (positive X-axis direction) of the second part 820. Further, the first inclined surface 821 is formed as a flat surface.

[0131] The third part 830 has a substantially rectangular plate shape elongated in the Y-axis direction and extends from the edge of the first part 810 on the side of the capacitor element 500 in the negative X-axis direction, i.e., the side opposite to the first electrode terminal part 610. The surface of the third part 830 facing the second relay part 720 side is substantially parallel to the inner surface 52a of the bottom face part 52 of the case 50. On the other hand, the surface of the third part 830 facing the first electrode 510 side is a second inclined surface 831 that is inclined with respect to the inner surface 52a of the bottom face part 52. The second inclined surface 831 is formed as a flat surface and is inclined so as to be separated from the first electrode 510 as it goes from the tip side of the third part 830 toward the second part 820 side. That is, the surfaces of the second part 820 and the third part 830 facing the peripheral surface 130 side are, as a whole, an inclined surface 801 composed of the first inclined surface 821 and the second inclined surface 831. The inclined surface 801 is inclined so as to be separated from the first electrode 510 as it goes from the tip side of the third part 830 toward the tip side of the second part 820 and is a flat surface.

[0132] The fourth part 840 has a substantially rectangular plate shape and extends from the tip of the third part 830 in the negative Z-axis direction, i.e., toward the second electrode 520 side.

[0133] The second portion 820 extends outward beyond the first relay portion 620 in the Y-axis direction that is perpendicular to the X-axis direction in which the first overlapping portion 630 and the second overlapping portion 730 overlap and the Z-axis direction in which the first relay portion 620 and the first electrode 510 overlap. The third portion 830 and the fourth portion 840 extend outward beyond the second relay portion 720 in the Y-axis direction. Note that, in the Y-axis direction, the second portion 820, the third portion 830, and the fourth portion 840 do not extend outside the capacitor element 500, but they may extend outside the capacitor element 500.

[0134] The first portion 810 increases the creepage distance between the first overlapping portion 630 and the second overlapping portion 730, ensuring the insulation between them. The second portion 820 and the third portion 830 increase the creepage distance between the first relay portion 620 and the second relay portion 720, ensuring the insulation between them. The fourth portion 840 increases the creepage distance between the second relay portion 720 and the first electrode 510, ensuring the insulation between them.

[0135] When viewed in the direction (Z-axis direction) in which the first relay portion 620 and the second portion 820 overlap, a part of each first through hole 621 overlaps with the tip of the second portion 820.

[0136] The insulating member 800 may be in contact with the peripheral surface 530 of the capacitor element 500 or may be separated from the peripheral surface 530.

[0137] Note that fixing means are appropriately provided between the insulating member 800 and the first bus bar 600 and the second bus bar 700 so that the insulating member 800 does not come out in the Y-axis direction from between the first bus bar 600 and the second bus bar 700.

[0138] The film capacitor 3 is assembled by the same process (method) as the film capacitor 1 of the above-described Embodiment 1.

[0139] When bubbles are generated in the filling resin 60 in the liquid phase state within the case 50, as shown by the arrows in Fig. 8(b), the bubbles existing below the second portion 820 and the third portion 830 rise along the inclined surface 801 (the first inclined surface 821 and the second inclined surface 831) and escape to the outside of the tip of the second portion 820. Thereafter, the bubbles further rise through the first through hole 621 of the first relay portion 620 and both sides of the first relay portion 620, and escape from the opening 51 to the outside of the case 50. Therefore, since bubbles are less likely to stay below the second portion 820 and the third portion 830, the bubbles can be removed from the case 50 well.

[0140] In particular, below the third portion 830, many bubbles are likely to exist in the portion between the arc surfaces 533 on both sides of the peripheral surface 530 of the capacitor element 500 and the fourth portion 840. However, the bubbles generated in this portion and moving along the inclined surface 801 and escaping from the tip side of the second portion 820 are likely to rise to the opening 51 without being blocked by the first relay portion 620. Therefore, the bubbles can be removed from the case 50 even better.

[0141] Furthermore, when the defoaming process is performed, the air contained inside the capacitor element 500 is released as bubbles from the surface of the first electrode 510. These bubbles also easily escape to the opening 51 side without being blocked by the second portion 820 and the third portion 830. Therefore, it is less likely for air to remain inside the capacitor element 500.

[0142] <Effects of Embodiment 3> As described above, according to Embodiment 3, the following effects are achieved.

[0143] In the film capacitor 3, the capacitor element 500 is disposed in the case 50 such that the second electrode 520 faces the inner surface 52a of the bottom portion 52. The first bus bar 600 and the second bus bar 700 are each located on the opposite side of the capacitor element 500 from the bottom portion 52 and extend in a direction perpendicular to the inner surface 52a of the bottom portion 52, and include a first overlapping portion 630 and a second overlapping portion 730 that overlap each other. The first bus bar 600 includes a first electrode terminal portion 610 connected to the first electrode 510 of the capacitor element 500, and a first relay portion 620 that extends along the first electrode 510 and connects the first electrode terminal portion 610 and the first overlapping portion 630. The insulating member 800 includes a first portion 810 interposed between the first overlapping portion 630 and the second overlapping portion 730, and a second portion 820 interposed between the first relay portion 620 and the first electrode 510. The surface of the second portion 820 facing the first electrode 510 side includes a first inclined surface 821 inclined with respect to the inner surface 52a of the bottom portion 52.

[0144] According to this configuration, when bubbles are generated in the filling resin 60 in a liquid phase state in the case 50, the bubbles existing below the second portion 820 of the insulating member 800 rise along the first inclined surface 821 and pass through the second portion 820. As a result, since bubbles are less likely to remain below the second portion 820, it becomes possible to satisfactorily remove the bubbles from the case 50.

[0145] Furthermore, the first relay portion 620 has a first through hole 621.

[0146] According to this configuration, the bubbles that have passed through the second portion 820 in the region covered by the first relay portion 620 pass through the first through hole 621 and out of the first relay portion 620. As a result, since bubbles are less likely to remain below the first relay portion 620, it becomes possible to more satisfactorily remove the bubbles from the case 50.

[0147] Furthermore, when viewed in the direction (Z-axis direction) in which the first relay portion 620 and the second portion 820 overlap, a part of the first through hole 621 overlaps with the tip of the second portion 820.

[0148] According to this configuration, the bubbles that have escaped from the tip side of the second portion 820 are more likely to enter the first through hole 621 and more likely to pass through the first relay portion 620. Therefore, it becomes less likely for bubbles to stay below the first relay portion 620.

[0149] Furthermore, the second bus bar 700 includes a second electrode terminal portion 710 connected to the second electrode 120, and a second relay portion 720 that extends along the peripheral surface 530 of the capacitor element 500 and then extends along the first electrode 510 to connect the second electrode terminal portion 710 and the second overlapping portion 730. The insulating member 800 further includes a third portion 830 interposed between the second relay portion 720 and the first electrode 510, and the surface of the third portion 830 facing the first electrode 510 side includes a second inclined surface 831 inclined with respect to the inner surface 52a of the bottom surface portion 52.

[0150] According to this configuration, the bubbles existing below the third portion 830 of the insulating member 800 rise along the second inclined surface 831 and pass through the third portion 830. As a result, it is difficult for bubbles to stay below the third portion 830, so that it is possible to satisfactorily remove the bubbles from the inside of the case 50.

[0151] <Embodiment 4> The film capacitor 4 according to Embodiment 4 will be described.

[0152] FIG. 10(a) is a perspective view of the film capacitor 4. FIG. 10(b) is a side view of the film capacitor 4 in a state where the case 50 is shown in cross section and the filling resin 60 is transparent. FIG. 11(a) is a perspective view of the capacitor element unit 40A as viewed from the first bus bar 600A side. FIG. 11(b) is a perspective view of the capacitor element unit 40A as viewed from the second bus bar 700A side.

[0153] In the present embodiment, the same components as those in the above-described Embodiment 3 are denoted by the same reference numerals.

[0154] The film capacitor 4 includes a capacitor element unit 40A, a case 50, and a filling resin 60. The capacitor element unit 40A includes a capacitor element 500, a first bus bar 600A, a second bus bar 700A, and an insulating member 800A.

[0155] The first bus bar 600A is formed by appropriately cutting and bending a conductive material, for example, a copper plate, and has a configuration in which a first electrode terminal portion 610A, a first relay portion 620A, a first overlapping portion 630A, and a first connection terminal portion 640A are integrated.

[0156] The first electrode terminal portion 610A is longer in the X-axis direction than the first electrode terminal portion 610 of the third embodiment. The first electrode terminal portion 610A has a pair of electrode terminals 611, similar to the first electrode terminal portion 610. The first relay portion 620A is longer in the X-axis direction than the first relay portion 620 of the third embodiment. The first relay portion 620A has two first through holes 621, similar to the first relay portion 620. The configurations of the first overlapping portion 630A and the first connection terminal portion 640A are the same as the configurations of the first overlapping portion 630 and the first connection terminal portion 640 of the third embodiment. The first connection terminal portion 640A has a mounting hole 641, similar to the first connection terminal portion 640.

[0157] The second bus bar 700A is formed by appropriately cutting and bending a conductive material, for example, a copper plate, and has a configuration in which a second electrode terminal portion 710A, a second relay portion 720A, a second overlapping portion 730A, and a second connection terminal portion 740A are integrated.

[0158] The configurations of the second electrode terminal portion 710A, the second overlapping portion 730A, and the second connection terminal portion 740A are the same as the configurations of the second electrode terminal portion 710, the second overlapping portion 730, and the second connection terminal portion 740 of the third embodiment. The second electrode terminal portion 710A has a pair of electrode terminals 711, similar to the second electrode terminal portion 710, and the second connection terminal portion 740A has a mounting hole 741, similar to the second connection terminal portion 740.

[0159] The second relay part 720A is not bent toward the first electrode 510 side like the second relay part 720 of the third embodiment, extends in the positive Z-axis direction along the peripheral surface 530 of the capacitor element 500, and then is connected to the second overlapping part 730A.

[0160] The first overlapping part 630A and the second overlapping part 730A are on the side opposite to the bottom surface part 52 of the case 50 with respect to the capacitor element 500, are located at the end of the first electrode 510 in the negative X-axis direction, extend in a direction (Z-axis direction) perpendicular to the inner surface 52a of the bottom surface part 52, come out of the filling resin 60, and protrude outside the case 50. Further, the first overlapping part 630A and the second overlapping part 730A overlap each other in a state of approaching each other in the X-axis direction.

[0161] Outside the case 50, the first connection terminal part 640A and the second connection terminal part 740A are arranged side by side in the Y-axis direction with a predetermined distance in the X-axis direction and the Y-axis direction.

[0162] The insulating member 800A is formed of a material having electrical insulation properties, and includes a first part 810A interposed between the first overlapping part 630A and the second overlapping part 730A, a second part 820A interposed between the first relay part 620A and the first electrode 510 of the capacitor element 500, and a fourth part 840A interposed between the second relay part 720A and the peripheral surface 530 of the capacitor element 500. The insulating member 800A is not provided with a third part.

[0163] The configuration of the first part 810A is the same as that of the first part 810 of the third embodiment. The second part 820A is longer in the X-axis direction than the second part 820 of the third embodiment. The length of the second part 820A in the X-axis direction may be the same as that of the second part 820. The fourth part 840A is provided at the edge of the first part 810A on the capacitor element 500 side. The configuration of the fourth part 840A is the same as that of the fourth part 840 of the third embodiment.

[0164] The first part 810A increases the creepage distance between the first overlapping part 630A and the second overlapping part 730A, ensuring insulation between them. The second part 820A increases the creepage distance between the first relay part 620A and the second relay part 720A, ensuring insulation between them. The fourth part 840A increases the creepage distance between the second relay part 720A and the first electrode 510, ensuring insulation between them.

[0165] When viewed in the direction (Z-axis direction) in which the first relay part 620A and the second part 820A overlap, a part of each first through-hole 621 overlaps with the tip of the second part 820A.

[0166] The film capacitor 4 is assembled by the same process (method) as the film capacitor 1 of the above Embodiment 1.

[0167] When bubbles are generated in the filling resin 60 when the liquid-phase filling resin 60 is injected into the case 50, as shown by the arrow in Fig. 10(b), the bubbles existing below the second part 820A rise along the first inclined surface 821A and escape to the outside of the tip of the second part 820A. Then, the bubbles further rise through the first through-hole 621 of the first relay part 620A and both sides of the first relay part 620A, and escape from the opening 51 to the outside of the case 50. Therefore, since bubbles are less likely to stay below the second part 820A, the bubbles can be removed from the case 50 well.

[0168] Furthermore, the bubbles released from the surface of the first electrode 510 of the capacitor element 500 are also likely to escape to the opening 51 side without being blocked by the second part 820A. Therefore, it is less likely that air remains inside the capacitor element 500.

[0169] <Effects of Embodiment 4> Also in the film capacitor 4 of the present embodiment, similar to the third embodiment, since air bubbles are less likely to remain below the second portion 820A, it is possible to satisfactorily remove the air bubbles from the inside of the case 50. Further, since air bubbles are less likely to remain below the first relay portion 620A, it is possible to more satisfactorily remove the air bubbles from the inside of the case 50.

[0170] <Modified Example 3> FIGS. 12(a) and (b) are diagrams for explaining the film capacitor 3 according to Modified Example 3.

[0171] In the third embodiment described above, in the insulating member 800, the first inclined surface 821 of the second portion 820 and the second inclined surface 831 of the third portion 830, that is, the inclined surface 801, are flat surfaces. However, in the third embodiment, as shown in FIG. 12(a), the inclined surface 801 (the first inclined surface 821, the second inclined surface 831) may be formed as an arc surface.

[0172] Furthermore, in the third embodiment described above, in the second bus bar 700, the second electrode terminal portion 710 extends to the negative X-axis side from the fourth portion 840 of the insulating member 800, so that the second relay portion 720 extends linearly in the Z-axis direction from the edge of the second electrode terminal portion 710 in the negative X-axis direction to a position beyond the first electrode 510. However, in the third embodiment, as shown in FIG. 12(b), the second electrode terminal portion 710 is not extended to the negative X-axis side from the fourth portion 840 of the insulating member 800, and the second relay portion 720 extends in the positive Z-axis direction from the edge of the second electrode terminal portion 710 in the negative X-axis direction to the vicinity of the fourth portion 840, and then bends to the negative X-axis side and extends to a position beyond the first electrode 510 in the positive Z-axis direction. In this configuration, although the configuration of the second relay portion 720, that is, the configuration of the second bus bar 700 becomes more complicated compared to the third embodiment, the portion 720a up to the vicinity of the fourth portion 840 in the second relay portion 720 approaches the peripheral surface 530 of the capacitor element 500, so that the ESL (equivalent series inductance) is likely to be reduced.

[0173] Note that, similar to the film capacitor 3, the film capacitor 4 of the above-described Embodiment 4 may also be applied with changes as shown in FIGS. 12(a) and (b).

[0174] <Other modification examples> As shown in FIG. 13(a), in the above-described Embodiment 1, when viewed in the direction (Z-axis direction) in which the first relay portion 220 of the first bus bar 200 and the second portion 420 overlap, instead of a part of the first through hole 221 overlapping with the tip of the second portion 420, the first through hole 221 may be in contact with the tip of the second portion 420. Similarly, in the above-described Embodiment 2, the first through hole 221 may be in contact with the tip of the second portion 420A.

[0175] Furthermore, as shown in FIG. 13(b), in the above-described Embodiment 3, when viewed in the direction (Z-axis direction) in which the first relay portion 620 of the first bus bar 600 and the second portion 820 overlap, instead of a part of the first through hole 621 overlapping with the tip of the second portion 820, the first through hole 621 may be in contact with the tip of the second portion 820. Similarly, in the above-described Embodiment 4, the first through hole 621 may be in contact with the tip of the second portion 820A.

[0176] Furthermore, in the above-described Embodiments 1 and 2, the first through hole 221 of the first relay portion 220 of the first bus bar 200 does not have to be oval, and may be other shapes such as a perfect circle, a square, a rectangle, etc. Similarly, in the above-described Embodiment 1, the second through hole 321 of the second relay portion 320 of the second bus bar 300 does not have to be oval, and may be other shapes. Furthermore, in the above-described Embodiments 3 and 4, the first through hole 621 of the first relay portion 620 of the first bus bar 600 does not have to be square, and may be other shapes such as a perfect circle, an oval, etc.

[0177] Furthermore, in the above-described Embodiment 1, the first relay portion 220 of the first bus bar 200 is provided with a first through hole 221, and the second relay portion 320 of the second bus bar 300 is provided with a second through hole 321. However, for example, when the amount of bubbles escaping from below the first relay portion 220 and the second relay portion 320 is small, or when bubbles easily escape from below the first relay portion 220 and the second relay portion 320 to both sides, the first through hole 221 may not be provided in the first relay portion 220, and the second through hole 321 may not be provided in the second relay portion 320. Further, in the above-described Embodiments 2 to 4, in the case of the same situation as above, the first through holes 221 and 621 may not be provided in the first relay portions 220A, 620, and 620A.

[0178] Furthermore, the shapes of the cases 20 and 50 are not limited to those in the above-described Embodiments 1 to 4, and may be different from those in the above-described Embodiments 1 to 4.

[0179] Furthermore, in the above-described Embodiments 1 to 4, the film capacitors 1 to 4 include one capacitor element 100 and 500. However, the film capacitors 1 to 4 may include a plurality of capacitor elements 100 and 500. For example, in the above-described Embodiments 1 to 4, a plurality of capacitor elements 100 and 500 may be arranged in the Y-axis direction. In this case, accordingly, the first bus bars 200, 200A, 600, 600A, the second bus bars 300, 300A, 700, 700A, the insulating members 400, 800, and the cases 20 and 50 are lengthened in the Y-axis direction. Also, a pair of electrode terminals 211, 611, 311, and 711 are provided in the first electrode terminal portions 210, 210A, 610, 610A and the second electrode terminal portions 310, 310A, 710, 710A in accordance with the number of the capacitor elements 100 and 500.

[0180] Furthermore, in the above-described Embodiments 1 to 4, the capacitor elements 100 and 500 are formed by stacking two metallized films obtained by vapor-depositing aluminum on a dielectric film and then winding or laminating the stacked metallized films. However, alternatively, the capacitor elements 100 and 500 may be formed by stacking a metallized film obtained by vapor-depositing aluminum on both sides of a dielectric film and an insulating film and then winding or laminating them.

[0181] Furthermore, in the above-described Embodiments 1 to 4, as an example of the capacitor of the present invention, film capacitors 1 to 4 were cited. However, the present invention can also be applied to capacitors other than film capacitors.

[0182] 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.

Industrial Applicability

[0183] The present invention is useful for capacitors used in various electronic devices, electrical devices, industrial devices, vehicle electrical equipment, etc.

Explanation of Reference Numerals

[0184] 1 to 4 Film capacitors (capacitors) 20, 50 Case 30, 60 Filling resin 100, 500 Capacitor elements 110, 510 First electrode 120, 520 Second electrode 130, 530 Peripheral surface 200, 200A, 600, 600A First bus bar 210, 210A, 610, 610A First electrode terminal portion 220, 220A, 620, 620A First relay portion 221, 621 First through hole 230, 230A, 630, 630A First overlapping portion 240, 240A, 640, 640A First connection terminal portion Second bus bars 300, 300A, 700, 700A Second electrode terminal portions 310, 310A, 710, 710A Second relay portions 320, 720, 720A Second through-hole 321 Second overlapping portions 330, 330A, 730, 730A Second connection terminal portions 340, 340A, 740, 740A Insulating members 400, 400A, 800, 800A First portions 410, 410A, 810, 810A Second portions 420, 420A, 820, 820A First inclined surfaces 421, 421A, 821, 821A Third portions 430, 830 Second inclined surfaces 431, 831

Claims

1. A capacitor element including a first electrode formed on one end face, a second electrode formed on the other end face, and a peripheral surface connecting the first electrode and the second electrode; A case including an opening and a bottom face facing the opening, the capacitor element being housed therein; A first bus bar and a second bus bar respectively connected to the first electrode and the second electrode; An insulating member for insulating between the first bus bar and the second bus bar; A filling resin filled in the case; and The capacitor element is disposed in the case such that the peripheral surface faces the inner surface of the bottom face; The first bus bar and the second bus bar are respectively located on the opposite side of the bottom face with respect to the capacitor element and extend in a direction perpendicular to the inner surface of the bottom face, and include a first overlapping portion and a second overlapping portion that overlap each other; The first bus bar Includes a first electrode terminal portion connected to the first electrode; And a first relay portion extending along the peripheral surface and connecting the first electrode terminal portion and the first overlapping portion; The insulating member Includes a first portion interposed between the first overlapping portion and the second overlapping portion; And a second portion interposed between the first relay portion and the peripheral surface; The surface of the second portion facing the peripheral surface side includes a first inclined surface inclined with respect to the inner surface of the bottom face; A capacitor characterized by the above.

2. In the capacitor according to Claim 1, The first relay portion has a first through hole; A capacitor characterized by the above.

3. In the capacitor according to Claim 2, When viewed in the direction in which the first relay portion and the second portion overlap, a part of the first through hole overlaps with the end portion of the second portion, or the first through hole is in contact with the end portion of the second portion; A capacitor characterized by the above.

4. In the capacitor according to any one of Claims 1 to 3, The second bus bar Includes a second electrode terminal portion connected to the second electrode; And a second relay portion extending along the peripheral surface and connecting the second electrode terminal portion and the second overlapping portion; The insulating member further includes a third portion interposed between the second relay portion and the peripheral surface; The surface of the third portion facing the peripheral surface side includes a second inclined surface inclined with respect to the inner surface of the bottom face; A capacitor characterized by the above.

5. In the capacitor according to Claim 4, The second relay portion has a second through hole; A capacitor characterized by the above.

6. In the capacitor according to claim 5, when viewed in the direction in which the second relay portion and the third portion overlap, a part of the second through hole overlaps with an end portion of the third portion, or the second through hole is in contact with the end portion of the third portion. A capacitor characterized by the above.

7. A capacitor element including a first electrode formed on one end face, a second electrode formed on the other end face, and a circumferential surface connecting the first electrode and the second electrode; A case including an opening and a bottom face opposed to the opening, the capacitor element being accommodated therein; A first bus bar and a second bus bar respectively connected to the first electrode and the second electrode; An insulating member for insulating between the first bus bar and the second bus bar; A filling resin filled in the case, and the capacitor element is disposed in the case such that the second electrode faces the inner surface of the bottom face, the first bus bar and the second bus bar are respectively located on the side opposite to the bottom face with respect to the capacitor element and extend in a direction perpendicular to the inner surface of the bottom face, and include a first overlapping portion and a second overlapping portion that overlap each other, the first bus bar includes a first electrode terminal portion connected to the first electrode; and a first relay portion extending along the first electrode and connecting the first electrode terminal portion and the first overlapping portion, the insulating member includes a first portion interposed between the first overlapping portion and the second overlapping portion; and a second portion interposed between the first relay portion and the first electrode, a surface of the second portion facing the first electrode side includes a first inclined surface inclined with respect to the inner surface of the bottom face. A capacitor characterized by the above.

8. In the capacitor according to claim 7, the first relay portion has a first through hole. A capacitor characterized by the above.

9. In the capacitor according to claim 8, when viewed in the direction in which the first relay portion and the second portion overlap, a part of the first through hole overlaps with an end portion of the second portion, or the first through hole is in contact with the end portion of the second portion. A capacitor characterized by the above.

10. In the capacitor according to any one of claims 7 to 9, the second bus bar includes a second electrode terminal portion connected to the second electrode; and a second relay portion that extends along the circumferential surface and then extends along the first electrode to connect the second electrode terminal portion and the second overlapping portion. The insulating member further includes a third portion interposed between the second relay portion and the first electrode, and a surface of the third portion facing the first electrode side includes a second inclined surface inclined with respect to the inner surface of the bottom portion. A capacitor characterized by the above.

Images