Metallized film, film capacitor, inverter, and vehicle

Abstract

This invention provides a metallized film suitable as a material for manufacturing film capacitors with low equivalent series resistance (ESR). [Solution] The metallized film 1 comprises a dielectric film 2 having a longitudinal direction Y and a width direction Z, and a metal film 3 provided on the dielectric film 2. The metal film 3 has a large electrode 4 extending in the longitudinal direction Y, two or more rows of small electrodes 5 arranged in the width direction Z relative to the large electrode 4, and a plurality of fuses 6. Each of the two or more rows of small electrodes 5 includes a plurality of small electrodes 7 arranged in the longitudinal direction Y. Each of the plurality of fuses 6 connects between adjacent large electrodes 4 and small electrodes 7, or between adjacent small electrodes 7. The number of fuses 6 connected to each of the plurality of small electrodes 7 is the same. Each of the plurality of small electrodes 7 included in the small electrode row 5 closest to the large electrode 4 in the width direction Z is connected to the large electrode 4 by two or more fuses 6.

Description

Technical Field

[0001] The present disclosure generally relates to metallized films, film capacitors, inverters, and vehicles, and more particularly to metallized films, film capacitors, inverters, and vehicles having a dielectric film and a metal film.

Background Art

[0002] Patent Document 1 discloses a metallized film. In this metallized film, metal is deposited so that an insulating margin is formed at one end in the width direction of the dielectric film.

[0003] The metallized film includes a divided electrode formed by dividing the deposited metal on the insulating margin side with a slit-shaped non-deposited portion, and a fuse connected to the divided electrode. A plurality of divided electrodes are arranged side by side in the width direction of the dielectric film.

[0004] Furthermore, the divided electrodes in the first row and the second row when viewed from the insulating margin side satisfy all of the following conditions [1] to [3]. [1] The area is 15 mm or more. [2] Four or more fuses are connected. [3] All adjacent divided electrodes are connected via one fuse each.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] In Patent Document 1, by adopting the above configuration, an attempt is made to suppress the excessive operation of the fuse.

[0007] However, Patent Document 1 does not contain any description regarding equivalent series resistance (ESR). The inventors of this invention have considered that in order to achieve low ESR in the metallized film of Patent Document 1, it is necessary to revise, for example, the positional relationship between the divided electrodes and the fuse.

[0008] The object of this disclosure is to provide a metallized film suitable as a material for manufacturing a film capacitor with low equivalent series resistance (ESR), a film capacitor with low equivalent series resistance (ESR), an inverter and a vehicle using such a film capacitor. [Means for solving the problem]

[0009] A metallized film according to one aspect of the present disclosure comprises a dielectric film having a longitudinal direction and a width direction, and a metal film provided on the dielectric film. The metal film has a large electrode extending in the longitudinal direction, two or more rows of small electrodes arranged in the width direction relative to the large electrode, and a plurality of fuses. Each of the two or more rows of small electrodes includes a plurality of small electrodes arranged in the longitudinal direction. Each of the plurality of fuses connects adjacent large electrodes and small electrodes, or adjacent small electrodes to each other. The number of fuses connected to each of the plurality of small electrodes is the same. Each of the plurality of small electrodes included in the row of small electrodes closest to the large electrode in the width direction is connected to the large electrode by two or more fuses.

[0010] A film capacitor according to one aspect of the present disclosure comprises the metallized film.

[0011] An inverter according to one aspect of the present disclosure includes the film capacitor.

[0012] A vehicle according to one aspect of this disclosure is equipped with the inverter. [Effects of the Invention]

[0013] According to this disclosure, metallized films are suitable as materials for manufacturing film capacitors with low equivalent series resistance (ESR). [Brief explanation of the drawing]

[0014] [Figure 1] Figure 1 is a schematic plan view showing a metallized film (variation 1) according to this embodiment. [Figure 2] Figure 2 is a schematic plan view showing the metallized film (variation 2) according to this embodiment. [Figure 3] Figure 3 is a schematic plan view showing the metallized film (variation 3) according to this embodiment. [Figure 4] Figure 4 is a schematic plan view showing a metallized film (variation 4) according to this embodiment. [Figure 5] Figure 5 is a schematic plan view showing a metallized film (variation 5) according to this embodiment. [Figure 6] Figure 6 is a schematic plan view showing a metallized film (variation 6) according to this embodiment. [Figure 7] Figure 7 is a schematic plan view showing the metallized film (variation 7) according to this embodiment. [Figure 8] Figure 8 is a schematic plan view showing a metallized film (variation 8) according to this embodiment. [Figure 9] Figure 9 is a schematic plan view showing a metallized film (variation 9) according to this embodiment. [Figure 10] Figure 10 is a schematic perspective view showing a film capacitor according to this embodiment. [Figure 11] Figure 11 is a schematic perspective view showing an example of the manufacturing process for the film capacitor mentioned above. [Figure 12] Figure 12 is a block diagram of the inverter according to this embodiment. [Figure 13] Figure 13 is a schematic diagram showing a vehicle according to this embodiment. [Modes for carrying out the invention]

[0015] 1. Summary In order to solve the problems of the metallized film of Patent Document 1, as a result of the inventors' intensive research, the following metallized film 1 has been developed.

[0016] That is, the metallized film 1 according to the present embodiment includes a dielectric film 2 having a longitudinal direction Y and a width direction Z, and a metal film 3 provided on the dielectric film 2 (see FIGS. 1 to 9). The metal film 3 includes a large electrode 4 extending in the longitudinal direction Y, two or more rows of small electrode rows 5 (outer row 51, intermediate row 53, inner row 52) arranged in the width direction Z with respect to the large electrode 4, and a plurality of fuses 6 (horizontal fuses 6z, vertical fuses 6y). Each of the two or more rows of small electrode rows 5 includes a plurality of small electrodes 7 arranged in the longitudinal direction Y. Each of the plurality of fuses 6 connects between adjacent large electrodes 4 and small electrodes 7, or between adjacent small electrodes 7.

[0017] And the inventors have found a combination of the following two configurations as a configuration contributing to the reduction of ESR. That is, the first configuration is that the number of fuses 6 connected to each of the plurality of small electrodes 7 is the same. The second configuration is that each of the plurality of small electrodes 7 included in the small electrode row 5 (inner row 52) closest to the large electrode 4 in the width direction Z is connected to the large electrode 4 by two or more fuses 6.

[0018] Therefore, the metallized film 1 according to the present embodiment is suitable as a material for manufacturing a film capacitor 10A with a low equivalent series resistance (ESR).

[0019] 2. Details (1) Metallized Film Hereinafter, the metallized film 1 according to the present embodiment will be described with reference to FIGS. 1 to 9. Each figure is a schematic diagram, and the ratio of the size and thickness of each component in each figure does not necessarily reflect the actual dimensional ratio.

[0020] The arrows indicating directions in each figure are not intended to specify the direction in which to use the metallized film 1, but are merely there to make the explanation easier to understand and do not represent any actual direction.

[0021] In Figures 1 to 9, the X, Y, and Z directions of the Cartesian coordinate system are defined. The X direction is the thickness direction of the metallized film 1. The +X direction may be considered "down" and the -X direction "up". The Y direction is the longitudinal direction of the metallized film 1. The +Y direction may be considered "front" and the -Y direction "back". The Z direction is the width direction of the metallized film 1. The +Z direction may be considered "left" and the -Z direction "right".

[0022] Examples of the metallized film 1 according to this embodiment include variations 1 to 9 shown in Figures 1 to 9, but are not limited to these. Figures 1 to 9 show two metallized films 1 (first metallized film 11 and second metallized film 12) superimposed on each other. The second metallized film 12 is obtained by horizontally reversing the first metallized film 11. Therefore, the following description will focus on the first metallized film 11, and the description of the second metallized film 12 will be omitted. Unless otherwise specified, when simply referring to the metallized film 1, it means the first metallized film 11.

[0023] (1.1) Variation 1 First, let's explain Variation 1 with reference to Figure 1. The metallized film 1 comprises a dielectric film 2 and a metal film 3. In Figure 1, the metal film 3 is represented by a dot pattern. The same applies to Figures 2 to 9.

[0024] <Dielectric film> The dielectric film 2 has a longitudinal direction Y and a width direction Z. That is, the dielectric film 2 is elongated and has a constant width.

[0025] The material of the dielectric film 2 is not particularly limited, but examples include polypropylene (PP), polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyphenylene sulfide (PPS), polycarbonate (PC), and polystyrene (PS).

[0026] The thickness of the dielectric film 2 is not particularly limited, but for example, it is between 1 μm and 30 μm. A dielectric film thickness of 1 μm or more can suppress dielectric breakdown. On the other hand, a dielectric film thickness of 30 μm or less can increase the capacitance of the film capacitor 10A.

[0027] <Metal film> The metal film 3 is provided on the dielectric film 2. In this embodiment, the metal film 3 is provided on only one side of the dielectric film 2. The metal film 3 is formed, for example, by vapor deposition.

[0028] The material of the metal film 3 is not particularly limited, but examples include aluminum (Al), gold (Au), magnesium (Mg), zinc (Zn), tin (Sn), nickel (Ni), chromium (Cr), iron (Fe), copper (Cu), titanium (Ti), and alloys thereof.

[0029] The metal film 3 has a large electrode 4, two or more (three in variation 1) rows of small electrodes 5, and multiple fuses 6. The upper limit of the number of rows of small electrodes 5 is not particularly limited, as long as the effects of this embodiment are not impaired.

[0030] ≪Large electrode≫ The large electrode 4 extends in the longitudinal direction Y. That is, the large electrode 4 is elongated and has a certain width. The width of the large electrode 4 is approximately half the width of the dielectric film 2. In this embodiment, the large electrode 4 is located in approximately the right half of the dielectric film 2. That is, the large electrode 4 extends from the right end of the dielectric film 2 to approximately the center in the width direction Z. In the second metallized film 12, the large electrode 4 is located in approximately the left half of the dielectric film 2. That is, the large electrode 4 of the second metallized film 12 extends from the left end of the dielectric film 2 to approximately the center in the width direction Z.

[0031] ≪Small electrode array≫ The two or more rows of small electrodes 5 are arranged in the width direction Z relative to the large electrode 4. In this embodiment, the two or more rows of small electrodes 5 are arranged in approximately the left half of the dielectric film 2. However, a margin portion 20 exists at the left end of the metallized film 1. Therefore, the two or more rows of small electrodes 5 are located between the large electrode 4 and the margin portion 20 in the width direction Z. The metal film 3 does not exist in the margin portion 20. The margin portion 20 is the portion where the dielectric film 2 is exposed, and it is in the shape of a narrow strip with a certain width, extending in the longitudinal direction Y.

[0032] On the other hand, in the second metallized film 12, the two or more rows of small electrodes 5 are arranged in approximately the right half of the dielectric film 2. However, since a margin portion 20 exists at the right end of the second metallized film 12, the two or more rows of small electrodes 5 are located between the large electrode 4 and the margin portion 20 in the width direction Z. The margin portion 20 of the second metallized film 12 is also the part where the dielectric film 2 is exposed, and it is in the shape of a narrow strip with a certain width, extending in the longitudinal direction Y.

[0033] Each of the two or more rows of small electrodes 5 extends in the longitudinal direction Y. Each of the two or more rows of small electrodes 5 contains multiple small electrodes 7. That is, in each row of small electrodes 5, the multiple small electrodes 7 are arranged in the longitudinal direction Y.

[0034] The two or more rows of small electrodes 5 include an outer row 51, an inner row 52, ​​and an intermediate row 53.

[0035] The outermost row 51 is the small electrode row 5 furthest from the large electrode 4 in the width direction Z. In other words, the outermost row 51 is the small electrode row 5 closest to the margin portion 20 in the width direction Z. That is, the outermost row 51 is the small electrode row 5 adjacent to the margin portion 20. Thus, the metal film 3 contains only one outermost row 51.

[0036] The inner row 52 is the small electrode row 5 closest to the large electrode 4 in the width direction Z. In other words, the inner row 52 is the small electrode row 5 adjacent to the large electrode 4. Thus, the metal film 3 also contains only one inner row 52.

[0037] The intermediate row 53 is a small electrode row 5 located between the outer row 51 and the inner row 52 in the width direction Z. Thus, in variation 1, the intermediate row 53 is included in the metal film 3, but as in variation 7 described later, the intermediate row 53 may not be included in the metal film 3 (see Figure 7).

[0038] [Small electrode] In this embodiment, the small electrode 7 is rectangular in shape. Two opposing sides of the small electrode 7 (left side and right side) are parallel to the longitudinal direction Y, and the remaining two sides (front side and back side) are parallel to the width direction Z.

[0039] Furthermore, in this embodiment, all small electrodes 7 included in two or more rows of small electrodes 5 are approximately the same shape and size.

[0040] Fuse Fuse 6 melts when an excessive current flows due to dielectric breakdown of the dielectric film 2 or the like. Each of the multiple fuses 6 connects either (a) "between adjacent large electrodes 4 and small electrodes 7" or (b) "between adjacent small electrodes 7".

[0041] Here, the phrase "between adjacent large electrodes 4 and small electrodes 7" in (a) above means the space between adjacent large electrodes 4 and each of the multiple small electrodes 7 included in the inner row 52, ​​in the width direction Z. In this embodiment, each of the multiple small electrodes 7 included in the inner row 52 is connected to the large electrode 4 by two or more (two in variation 1) fuses 6. A fuse 6 connected along the width direction Z in this way may be referred to as a "lateral fuse 6z" below.

[0042] Furthermore, the phrase "between adjacent small electrodes 7" in (b) above means both (b1) "between adjacent small electrodes 7 in the width direction Z" and (b2) "between adjacent small electrodes 7 in the longitudinal direction Y".

[0043] Regarding (b1) above, in this embodiment, the small electrodes 7 included in the outer row 51 and the small electrodes 7 included in the middle row 53 are connected by a fuse 6 (lateral fuse 6z). Furthermore, the small electrodes 7 included in the middle row 53 and the small electrodes 7 included in the inner row 52 are connected by a fuse 6 (lateral fuse 6z).

[0044] On the other hand, regarding (b2) above, in this embodiment, two small electrodes 7 that are adjacent in the longitudinal direction Y among the multiple small electrodes 7 included in the outer row 51 are connected by a fuse 6. A fuse 6 connected along the longitudinal direction Y in this way may be referred to as a "vertical fuse 6y" below.

[0045] Furthermore, in this embodiment, of the multiple small electrodes 7 included in the remaining small electrode rows 5 (intermediate row 53 and inner row 52 in variation 1) after removing the outer row 51 from two or more rows of small electrode rows 5, two small electrodes 7 adjacent to each other in the longitudinal direction Y are not connected by a fuse 6 (vertical fuse 6y).

[0046] Furthermore, the width of each of the multiple fuses 6 is preferably within the range of -80% to +80%, more preferably -50% to +50%, and even more preferably -20% to +20%, based on the average width of the multiple fuses 6. In particular, if the width of each of the multiple fuses 6 is within the range of -20% to +20%, based on the average width of the multiple fuses 6, then the widths of all the multiple fuses 6 are considered to be the same. In this embodiment, the widths of all the multiple fuses 6 are the same. That is, the width of the horizontal fuse 6z and the width of the vertical fuse 6y are the same. Note that the width of the fuse 6 refers to the length in the direction perpendicular to the direction in which the fuse 6 extends.

[0047] Furthermore, the length of each of the multiple fuses 6 is preferably within the range of -80% to +80%, more preferably -50% to +50%, and even more preferably -20% to +20%, based on the average length of the multiple fuses 6. In particular, if the length of each of the multiple fuses 6 falls within the range of -20% to +20%, based on the average length of the multiple fuses 6, then the lengths of all the multiple fuses 6 are considered to be the same. In this embodiment, the lengths of all the multiple fuses 6 are the same. That is, the length of the horizontal fuse 6z and the length of the vertical fuse 6y are the same. Note that the length of the fuse 6 refers to the length in the direction in which the fuse 6 extends.

[0048] In variation 1, each of the multiple small electrodes 7 is connected to four fuses 6. Specifically, each small electrode 7 in the outer row 51 is connected to two horizontal fuses 6z and two vertical fuses 6y. Each small electrode 7 in the middle row 53 is connected to four horizontal fuses 6z. Each small electrode 7 in the inner row 52 is connected to four horizontal fuses 6z. Thus, the number of fuses 6 connected to each of the multiple small electrodes 7 is the same.

[0049] Furthermore, in variation 1, the positions of adjacent small electrodes 7 in one small electrode row 5 and the positions of small electrodes 7 in another small electrode row 5 are not aligned in the width direction Z. The following explanation will apply specific examples to the above-mentioned "one small electrode row 5" and "another small electrode row 5".

[0050] In other words, when the "outer row 51" and "intermediate row 53" are applied to the "first small electrode row 5" and "other small electrode rows 5" respectively, the positions of the small electrodes 7 included in the outer row 51 and the positions of the small electrodes 7 included in the adjacent intermediate row 53 are not aligned in the width direction Z. This misalignment between the positions of the small electrodes 7 in the outer row 51 and the intermediate row 53 makes it easier for each small electrode 7 in the outer row 51 to be connected to multiple (two in variation 1) small electrodes 7 in the intermediate row 53 by fuse 6 (lateral fuse 6z). Similarly, each small electrode 7 in the intermediate row 53 is easily connected to multiple (two in variation 1) small electrodes 7 in the outer row 51 by fuse 6 (lateral fuse 6z).

[0051] Furthermore, when the "intermediate row 53" and "inner row 52" are applied to the "first small electrode row 5" and "other small electrode rows 5" respectively, the positions of the small electrodes 7 included in the intermediate row 53 and the positions of the small electrodes 7 included in the inner row 52 are not aligned in the width direction Z. In this way, the position of the small electrodes 7 in the intermediate row 53 and the position of the small electrodes 7 in the adjacent inner row 52 are misaligned, making it easier for each small electrode 7 in the intermediate row 53 to be connected to multiple (two in variation 1) small electrodes 7 in the inner row 52 by fuse 6 (lateral fuse 6z). Similarly, each small electrode 7 in the inner row 52 can be easily connected to multiple (two in variation 1) small electrodes 7 in the intermediate row 53 by fuse 6 (lateral fuse 6z).

[0052] In this embodiment, the determination of whether adjacent small electrodes 7 are aligned in the width direction Z can be made by checking whether either the front or rear edge of one small electrode 7 lies on the same straight line (a straight line parallel to the width direction Z) as either the front or rear edge of the other small electrode 7. That is, if either the front or rear edge of one small electrode 7 lies on the same straight line as either the front or rear edge of the other small electrode 7, it is determined that the positions of the two small electrodes 7 are aligned. Conversely, if either the front or rear edge of one small electrode 7 lies on the same straight line as either the front or rear edge of the other small electrode 7, it is determined that the positions of the two small electrodes 7 are not aligned.

[0053] (1.2) Variation 2 Next, Variation 2 will be explained with reference to Figure 2. Variation 2 differs from Variation 1 in that it has one more intermediate column 53. The other configurations are the same as Variation 1.

[0054] (1.3) Variation 3 Next, we will explain variation 3 with reference to Figure 3. For variation 3, we will focus on the differences from variations 1 and 2, and may omit explanations of the similarities with variations 1 and 2.

[0055] In variation 3, for each of the multiple small electrodes 7 included in the inner row 52, ​​the number of fuses 6 connected to the large electrode 4 is greater than the number of fuses 6 connected to other small electrodes 7 (small electrodes 7 included in the intermediate row 53 adjacent to the inner row 52). That is, each small electrode 7 in the inner row 52 is connected to a small electrode 7 in the intermediate row 53 by one fuse 6 (lateral fuse 6z) and to the large electrode 4 by three fuses 6 (lateral fuse 6z).

[0056] Furthermore, in variation 3, not all of the small electrodes 7 included in the two or more rows of small electrodes 5 are the same shape and size. That is, the small electrodes 7 in the outer row 51 and the small electrodes 7 in the middle row 53 are almost the same shape and size, but the small electrodes 7 in the inner row 52 are smaller than the small electrodes 7 in the middle row 53. Specifically, the lengths of the front and back sides of the small electrodes 7 in the inner row 52 are almost the same as the lengths of the front and back sides of the small electrodes 7 in the middle row 53, but the lengths of the left and right sides of the small electrodes 7 in the inner row 52 are almost half the lengths of the left and right sides of the small electrodes 7 in the middle row 53. Thus, the size of the small electrodes 7 in the inner row 52 is approximately half the size of the small electrodes 7 in the middle row 53.

[0057] (1.4) Variation 4 Next, variation 4 will be explained with reference to Figure 4. Variation 4 differs from variation 3 in that it has one more intermediate column 53. The other configurations are the same as variation 3.

[0058] (1.5) Variation 5 Next, we will explain variation 5 with reference to Figure 5. For variation 5, we will focus on the differences from variations 1-4, and may omit explanations of the similarities.

[0059] In variation 5, the positions of adjacent small electrodes 7 in one small electrode row 5 and the positions of small electrodes 7 in another small electrode row 5 are aligned in the width direction Z. The following explanation will use specific examples to illustrate the above-mentioned "one small electrode row 5" and "another small electrode row 5".

[0060] In other words, when the "outer row 51" and "intermediate row 53" are applied to the "first small electrode row 5" and "other small electrode rows 5" respectively, the positions of the small electrodes 7 included in the outer row 51 and the positions of the small electrodes 7 included in the intermediate row 53 are aligned in the width direction Z.

[0061] Furthermore, when the "intermediate row 53" and "inner row 52" are applied to the "first small electrode row 5" and "other small electrode rows 5" respectively, the positions of the small electrodes 7 included in the intermediate row 53 and the positions of the small electrodes 7 included in the inner row 52 are aligned in the width direction Z.

[0062] Thus, in variation 5, the front edges of the small electrodes 7 in the outer row 51, the front edges of the small electrodes 7 in the middle row 53, and the front edges of the small electrodes 7 in the inner row 52 lie on the same straight line (a straight line parallel to the width direction Z). Similarly, the rear edges of the small electrodes 7 in the outer row 51, the rear edges of the small electrodes 7 in the middle row 53, and the rear edges of the small electrodes 7 in the inner row 52 lie on the same straight line.

[0063] (1.6) Variation 6 Next, we will explain variation 6 with reference to Figure 6. For variation 6, we will focus on the differences from variations 1-5, and may omit explanations of the similarities.

[0064] In variation 6, not all of the small electrodes 7 included in two or more rows of small electrodes 5 are the same shape and size. That is, the small electrodes 7 in the middle row 53 and the small electrodes 7 in the inner row 52 are almost the same shape and size, but the small electrodes 7 in the outer row 51 are larger than the small electrodes 7 in the middle row 53. Specifically, the lengths of the front and back sides of the small electrodes 7 in the outer row 51 are almost the same as the lengths of the front and back sides of the small electrodes 7 in the middle row 53, but the lengths of the left and right sides of the small electrodes 7 in the outer row 51 are almost twice the lengths of the left and right sides of the small electrodes 7 in the middle row 53. Thus, the size of the small electrodes 7 in the outer row 51 is almost twice the size of the small electrodes 7 in the middle row 53.

[0065] In variation 6, the positions of the small electrodes 7 included in one small electrode row 5 and the positions of the small electrodes 7 included in another small electrode row 5 are aligned in the width direction Z. In particular, when the "outer row 51" and "intermediate row 53" are applied to the "one small electrode row 5" and "other small electrode rows 5" respectively, the positions of the small electrodes 7 included in the outer row 51 and the positions of the small electrodes 7 included in the intermediate row 53 are aligned in the width direction Z. To further explain this point, although the sizes of the small electrodes 7 in the outer row 51 and the intermediate row 53 are different, either the front or back edge of the small electrodes 7 in the outer row 51 is on the same line as either the front or back edge of the small electrodes 7 in the intermediate row 53, so the positions of the small electrodes 7 in the outer row 51 and the intermediate row 53 are aligned.

[0066] (1.7) Variation 7 Next, we will explain variation 7 with reference to Figure 7. For variation 7, we will focus on the differences from variations 1-6, and may omit explanations of the similarities.

[0067] While the metallized film 1 of variations 1 to 6 includes an intermediate row 53, the metallized film 1 of variation 7 does not include an intermediate row 53. In other words, variation 7 is equivalent to variation 5 (see Figure 5) with the intermediate row 53 removed. Therefore, in variation 7, the outer row 51 and the inner row 52 are adjacent to each other.

[0068] Furthermore, in variations 1 to 6, four fuses 6 are connected to each small electrode 7, whereas in variation 7, three fuses 6 are connected to each small electrode 7.

[0069] (1.8) Variation 8 Next, we will explain variation 8 with reference to Figure 8. For variation 8, we will focus on the differences from variations 1-7, and may omit explanations of the similarities.

[0070] In particular, when comparing variation 3 (Figure 3) and variation 8, in variation 3, the positions of the small electrodes 7 in the outer row 51 and the positions of the small electrodes 7 in the middle row 53 are not aligned, whereas in variation 8, the positions of the small electrodes 7 in the outer row 51 and the positions of the small electrodes 7 in the middle row 53 are aligned.

[0071] Furthermore, in variation 3, four fuses 6 are connected to each small electrode 7, whereas in variation 8, three fuses 6 are connected to each small electrode 7.

[0072] (1.9) Variation 9 Next, we will explain variation 9 with reference to Figure 9. For variation 9, we will focus on the differences from variations 1-8, and may omit explanations of the similarities.

[0073] In particular, when comparing variation 5 (Figure 5) and variation 9, in variation 5, the positions of the small electrodes 7 in the outer row 51 and the positions of the small electrodes 7 in the middle row 53 are aligned, whereas in variation 9, the positions of the small electrodes 7 in the outer row 51 and the positions of the small electrodes 7 in the middle row 53 are not aligned.

[0074] Furthermore, in variation 5, each small electrode 7 in the outer row 51 is connected to both the front and rear small electrodes 7 by a vertical fuse 6y, whereas in variation 9, each small electrode 7 in the outer row 51 is connected to either the front or rear small electrode 7 by a vertical fuse 6y.

[0075] Furthermore, in variation 5, four fuses 6 are connected to each small electrode 7, whereas in variation 9, three fuses 6 are connected to each small electrode 7.

[0076] <Effects and Effects> The metallized film 1 according to this embodiment is suitable as a material for manufacturing a film capacitor 10A with a low equivalent series resistance (ESR).

[0077] In particular, the fact that the number of fuses 6 connected to each small electrode 7 is the same (four for variations 1-6, and three for variations 7-9), and that each of the multiple small electrodes 7 included in the inner row 52 is connected to the large electrode 4 by two or more fuses 6 (two for variations 1, 2, 5, 7-9, and three for variations 3, 4, and 6).

[0078] As described above, if the number of fuses 6 connected to each small electrode 7 is the same, it becomes easier to equalize the sensitivity of the fuses 6 for all small electrodes 7. If the number of fuses 6 connected to each of the multiple small electrodes 7 is different, it will result in variations in the sensitivity of the fuses 6, which is undesirable. This is because, even though the magnitude of the current flowing through each small electrode 7 is the same when a short circuit occurs, the likelihood of the fuses 6 blowing will vary depending on the location.

[0079] Furthermore, in this embodiment, since the widths of all the fuses 6 are the same, it becomes easier to equalize the sensitivity of all the fuses 6.

[0080] In this embodiment, two adjacent small electrodes 7 in the longitudinal direction Y of the multiple small electrodes 7 included in the outer row 51 are connected by a fuse 6 (vertical fuse 6y). This makes it easier to match the number of fuses 6 connected to the small electrodes 7 in the outer row 51 with the number of fuses 6 connected to the small electrodes 7 in the other small electrode rows 5 (intermediate row 53 and inner row 52). In other words, it makes it easier to make the number of fuses 6 connected to each small electrode 7 the same. In addition, if the fuses 6 around the small electrodes 7 in the intermediate row 53 or inner row 52 blow, it is possible to prevent the small electrodes 7 in the outer row 51 from becoming isolated and losing their function as electrodes. In other words, it is possible to suppress an excessive decrease in the capacitance of the film capacitor 10A.

[0081] By the way, when a film capacitor 10A (described later) is manufactured using the metallized film 1 according to this embodiment, and the film capacitor 10A is charged or discharged, the current in the metallized film 1 tends to flow more easily in the width direction Z than in the longitudinal direction Y. Thus, the current mainly flows in the width direction Z. In this case, the fuse 6 is more likely to contribute to lower ESR if it extends in the width direction Z than if it extends in the longitudinal direction Y. In other words, a horizontal fuse 6z is more likely to contribute to lower ESR than a vertical fuse 6y. Moreover, the position where the vertical fuse 6y is formed is preferable as far away from the large electrode 4 as possible.

[0082] Therefore, in this embodiment, the small electrodes 7 in the inner row 52 are not connected by vertical fuses 6y (see Variations 1 to 9). It is also preferable that the small electrodes 7 in the intermediate row 53 are not connected by vertical fuses 6y (see Variations 1 to 5, 7 to 9). This makes it possible to further reduce the equivalent series resistance (ESR).

[0083] Furthermore, comparing variation 5 (Figure 5) and variation 1 (Figure 1) of this embodiment, in variation 5, the positions of adjacent small electrodes 7 are aligned in the width direction Z, whereas in variation 1, the positions of adjacent small electrodes 7 are not aligned in the width direction Z. Focusing on the small electrodes 7 of the intermediate row 53, in variation 5, one small electrode 7 in the intermediate row 53 is connected to only two small electrodes 7 by a horizontal fuse 6z, whereas in variation 1, one small electrode 7 in the intermediate row 53 is connected to four small electrodes 7 by a horizontal fuse 6z. Having adjacent small electrodes 7 not aligned in the width direction Z, as in variation 1, allows for an increase in the number of small electrodes 7 in other small electrode rows 5 (e.g., outer row 51 and inner row 52) adjacent to a small electrode 7 in one small electrode row 5 (e.g., intermediate row 53). Therefore, if the fuse 6 around a certain small electrode 7 melts, it is possible to suppress the small electrodes 7 around that electrode becoming isolated and losing their function as electrodes. In other words, it is possible to suppress an excessive decrease in the capacitance of the 10A film capacitor.

[0084] Furthermore, in variations 3, 4, and 6-9 of this embodiment (Figures 3, 4, 6-9), for each of the multiple small electrodes 7 included in the inner row 52, ​​the number of fuses 6 connected to the large electrode 4 is greater than the number of fuses 6 connected to the small electrode 7 in the intermediate row 53. By creating this difference in the number of fuses 6, the equivalent series resistance (ESR) can be further reduced.

[0085] In particular, among the metallized film 1 variations 1 to 9, variations 1 to 4 are preferred from the viewpoint of reducing ESR. Of the two or more rows of small electrodes 5, the inner row 52 is closest to the large electrode 4. The current is greatest at the point where each of the multiple small electrodes 7 included in this inner row 52 is connected to the large electrode 4 (i.e., the fuse 6). Therefore, increasing the number of fuses 6 (horizontal fuses 6z) in this part can greatly contribute to reducing ESR. Moreover, the orientation of the horizontal fuses 6z almost coincides with the direction in which the current flows, so this also contributes to reducing ESR.

[0086] (2) Film capacitor Next, the film capacitor 10A (capacitor element) according to this embodiment will be described with reference to Figures 10 and 11. Each figure is a schematic diagram, and the ratios of the size and thickness of each component in each figure do not necessarily reflect the actual dimensional ratios.

[0087] The arrows indicating directions in each diagram are not intended to specify the direction in which to use the 10A film capacitor, but are merely there to make the explanation easier to understand and do not represent any actual function.

[0088] In Figures 10 and 11, the Z, R, and θ directions of the cylindrical coordinate system are defined. The Z direction is the axial direction of the winding body 100. The +Z direction is the direction from the first end face 101 to the second end face 102. The -Z direction is the opposite direction of the +Z direction. The R direction is the radial direction of the winding body 100. The +R direction is the direction away from the winding core 200. The -R direction is the opposite direction of the +R direction. The θ direction is the winding direction of the metallized film 1.

[0089] The X direction corresponds to the R direction in the cylindrical coordinate system. The Y direction corresponds to the θ direction in the cylindrical coordinate system. The Z direction corresponds to the Z direction in the cylindrical coordinate system. Therefore, for the Z direction in both the cylindrical and Cartesian coordinate systems, the +Z direction is sometimes referred to as "one side of the axial direction," and the -Z direction as "the other side of the axial direction."

[0090] As shown in Figure 10, the film capacitor 10A comprises a wound body 100 and a pair of end face electrodes 30.

[0091] <Revolving body> The winding body 100 is the main body of the film capacitor 10A. The winding body 100 has a rounded rectangular column shape extending in the axial direction (Z direction). That is, when viewed along the axial direction, the winding body 100 has a rounded rectangle shape. A rounded rectangle is a shape in which, for example, semicircles with diameters equal to the short sides of a rectangle are attached to two short sides of the rectangle. The shape of the winding body 100 is not particularly limited, but examples include a cylindrical shape, an oval column shape, etc.

[0092] The wound body 100 has a first end face 101 and a second end face 102. The first end face 101 is the face facing the other side in the axial direction. The second end face 102 is the face opposite to the first end face 101. That is, the second end face 102 is the face facing one side in the axial direction.

[0093] As shown in Figure 11, the winding body 100 comprises a winding core 200 and a metallized film 1 (first metallized film 11 and second metallized film 12). Thus, the film capacitor 10A comprises the metallized film 1. Note that in Figure 11, the metal film 3 is shown in a simplified manner.

[0094] The core 200 is made of a film having electrical insulating properties wound around it. The material of the film is not particularly limited, but examples include polypropylene (PP) and polyethylene terephthalate (PET).

[0095] As shown in Figure 10, a pair of end-face electrodes 30 are provided on both end faces of the wound body 100. Specifically, the pair of end-face electrodes 30 are the first end-face electrode 31 and the second end-face electrode 32.

[0096] The first end electrode 31 is formed by thermal spraying metal onto the first end face 101 of the wound body 100. On the other hand, the second end electrode 32 is formed by thermal spraying metal onto the second end face 102 of the wound body 100. The metals constituting the first end electrode 31 and the second end electrode 32 are not particularly limited, but examples include zinc (Zn), tin (Sn), and alloys thereof.

[0097] The edge of the metal film 3 of the first metallized film 11 is exposed at the first end face 101 of the winding body 100 and is in contact with the first end face electrode 31. In this way, the first end face electrode 31 is electrically connected to the metal film 3 of the first metallized film 11.

[0098] On the other hand, the edge of the metal film 3 of the second metallized film 12 is exposed at the second end face 102 of the winding body 100 and is in contact with the second end face electrode 32. In this way, the second end face electrode 32 is electrically connected to the metal film 3 of the second metallized film 12.

[0099] The metal film 3 of the first metallized film 11 is separated from the second end electrode 32 via the margin portion 20. Thus, the metal film 3 of the first metallized film 11 is not in contact with the second end electrode 32.

[0100] On the other hand, the metal film 3 of the second metallized film 12 is separated from the first end electrode 31 via the margin portion 20. Thus, the metal film 3 of the second metallized film 12 is not in contact with the first end electrode 31.

[0101] <Manufacturing method> The film capacitor 10A is manufactured as follows. First, as shown in Figure 11, a metallized film 1 is wound around a winding core 200 to form a cylindrical winding body 100. At this time, the first metallized film 11 and the second metallized film 12 are overlapped and wound around the winding core 200 so that the metal film 3 and the dielectric film 2 overlap alternately.

[0102] Next, the cylindrical winding body 100 is flattened to obtain a rounded rectangular columnar winding body 100 (see Figure 10). Here, the flattening is performed by pressing the cylindrical winding body 100 in the radial direction (R direction).

[0103] Then, a pair of end face electrodes 30 are formed by thermal spraying metal onto the first end face 101 and the second end face 102 of the flattened winding body 100. This yields the film capacitor 10A (capacitor element) shown in Figure 10. Although not shown, busbars may be connected to each of the pair of end face electrodes 30 as needed, or the film capacitor 10A may be housed in a case and sealed with resin.

[0104] <Effects and Effects> According to the film capacitor 10A of this embodiment, since the metallized film 1 described above is used, it becomes easier to achieve a low ESR.

[0105] (3) Inverter Next, the inverter 10B according to this embodiment will be described with reference to Figure 12. The inverter 10B comprises a film capacitor 10A, a converter circuit 81, and an inverter circuit 82.

[0106] The converter circuit 81 is a circuit that converts alternating current to direct current and is electrically connected to the film capacitor 10A.

[0107] The inverter circuit 82 is a circuit that changes the voltage and / or frequency of the AC when converting DC to AC, and is electrically connected to the film capacitor 10A.

[0108] The inverter 10B is used, for example, as follows: The converter circuit 81 of the inverter 10B is connected to the power supply 83, and the inverter circuit 82 of the inverter 10B is connected to the motor 84. The power supply 83 and the motor 84 are included in the external equipment.

[0109] First, the AC power from the power supply 83 is converted to DC by the converter circuit 81 of the inverter 10B, and the converted DC is then stabilized by the film capacitor 10A through repeated charging and discharging. Next, this DC is converted back to AC at the desired voltage and frequency by the inverter circuit 82 of the inverter 10B and output.

[0110] <Effects and Effects> According to the inverter 10B of this embodiment, since the aforementioned film capacitor 10A is used, the efficiency of the circuit is improved and power loss can be minimized.

[0111] (4) Vehicles Next, the vehicle 10C according to this embodiment will be described with reference to Figure 13. In particular, the drive system of the vehicle 10C will be described.

[0112] Vehicle 10C comprises an inverter 10B, an AC motor 91, a transmission 92, a battery 94, an electronic control unit 95, wheels 90 (front wheels 90a and rear wheels 90b), a front axle 93, and a rear axle (not shown). Vehicle 10C is an electric vehicle (EV) that runs using the AC motor 91 as its power source.

[0113] Vehicle 10C employs a front-wheel drive (FF) system. An AC motor 91, which serves as the drive source, and a transmission 92 are located at the front of the vehicle body. The transmission 92 changes the speed of the rotation of the AC motor 91 and transmits it to the front axle 93.

[0114] The front axle 93 is positioned horizontally in the vehicle width direction. Drive wheels, the front wheels 90a, are attached to the left and right ends of the front axle 93. At the rear of the vehicle body, the rear axle (not shown) is positioned parallel to the front axle 93 and along the vehicle width direction. Rear wheels 90b are attached to the left and right ends of the rear axle.

[0115] The battery 94 is a DC power source. The DC power supplied from the battery 94 is converted to AC power by the inverter 10B and supplied to the AC motor 91, which is then driven to rotate. The driving force (output) of the AC motor 91 is controlled via the inverter 10B, which operates according to a control signal output from the electronic control unit 95.

[0116] <Effects and Effects> According to the vehicle 10C of this embodiment, since the inverter 10B described above is used, the heat generation of the film capacitor 10A is suppressed, extending its lifespan and thus reducing the frequency of repair and replacement of the film capacitor 10A.

[0117] 3. Variant In this embodiment, the width of the large electrode 4 is approximately half the width of the dielectric film 2, but it is not limited to this. That is, the width of the large electrode 4 may be wider or narrower than half the width of the dielectric film 2. In particular, when the width of the large electrode 4 is narrower than half the width of the dielectric film 2, for example, the width of the large electrode 4 may be about the same as the width of the margin portion 20. In this case, two or more rows of small electrodes 5 will be arranged over almost the entire surface of the dielectric film 2.

[0118] In this embodiment, the large electrode 4 is continuous along the longitudinal direction Y, but the large electrode 4 may be divided.

[0119] In this embodiment, the number of intermediate columns 53 included in the metal film 3 is between 0 and 2, but the upper limit of the number of intermediate columns 53 is not particularly limited as long as the effects of this embodiment are not impaired.

[0120] In this embodiment, the small electrode 7 is rectangular in shape, but the small electrode 7 may have a shape other than rectangular (for example, a rhombus, a hexagon, etc.).

[0121] In this embodiment, the film capacitor 10A is of the wound type, but the film capacitor 10A may also be of the laminated type.

[0122] In this embodiment, vehicle 10C has been described as an electric vehicle (EV), but vehicle 10C may also be a hybrid electric vehicle (HEV) equipped with an engine and an AC motor as a drive source.

[0123] 4. Appearance As will be apparent from the above embodiments and modifications, this disclosure includes the following aspects. In the following, reference numerals are enclosed in parentheses solely to indicate their correspondence with the embodiments.

[0124] The first embodiment is a metallized film (1) comprising a dielectric film (2) having a longitudinal direction (Y) and a width direction (Z), and a metal film (3) provided on the dielectric film (2). The metal film (3) has a large electrode (4) extending in the longitudinal direction (Y), two or more rows of small electrodes (5) arranged in the width direction (Z) relative to the large electrode (4), and a plurality of fuses (6). Each of the two or more rows of small electrodes (5) includes a plurality of small electrodes (7) arranged in the longitudinal direction (Y). Each of the plurality of fuses (6) connects between adjacent large electrodes (4) and small electrodes (7), or between adjacent small electrodes (7). The number of fuses (6) connected to each of the plurality of small electrodes (7) is the same. Each of the plurality of small electrodes (7) included in the row of small electrodes (5) closest to the large electrode (4) in the width direction (Z) is connected to the large electrode (4) by two or more fuses (6).

[0125] According to this embodiment, the metallized film (1) is suitable as a material for manufacturing a film capacitor (10A) with a low equivalent series resistance (ESR).

[0126] Specific examples of the metallized film (1) based on the first embodiment include variations 1 to 9.

[0127] The second embodiment is a metallized film (1) based on the first embodiment. In the second embodiment, two adjacent small electrodes (7) in the longitudinal direction (Y) of the multiple small electrodes (7) included in the outer row (51), which is the small electrode row (5) furthest from the large electrode (4) in the width direction (Z), are connected by a fuse (6).

[0128] According to this embodiment, it becomes easier to match the number of fuses (6) connected to the small electrodes (7) of the outer row (51) with the number of fuses (6) connected to the small electrodes (7) of the small electrode rows (5) other than the outer row (51).

[0129] Specific examples of the metallized film (1) based on the second embodiment include variations 1 to 9.

[0130] A third embodiment is a metallized film (1) based on the first or second embodiment. In the third embodiment, of the multiple small electrodes (7) included in the remaining small electrode rows (5), excluding the outer row (51), which is the small electrode row (5) furthest from the large electrode (4) in the width direction (Z), two small electrodes (7) adjacent in the longitudinal direction (Y) are not connected by a fuse (6).

[0131] According to this embodiment, the equivalent series resistance (ESR) can be further reduced.

[0132] Specific examples of the metallized film (1) based on the third embodiment include variations 1-5 and 7-9.

[0133] The fourth embodiment is a metallized film (1) based on any one of the first to third embodiments. In the fourth embodiment, there are four fuses (6) connected to each of the multiple small electrodes (7).

[0134] According to this embodiment, it becomes easier to equalize the sensitivity of the fuse (6) for all the small electrodes (7).

[0135] Specific examples of the metallized film (1) based on the fourth embodiment include variations 1 to 6.

[0136] The fifth embodiment is a metallized film (1) based on any one of the first to fourth embodiments. In the fifth embodiment, the positions of adjacent small electrodes (7) in one small electrode row (5) and the positions of small electrodes (7) in other small electrode rows (5) are not aligned in the width direction (Z).

[0137] According to this embodiment, the number of small electrodes (7) in one small electrode array (5) adjacent to a small electrode (7) in another small electrode array (5) can be increased.

[0138] Specific examples of the metallized film (1) based on the fifth embodiment include variations 1 to 4 and 9.

[0139] The sixth embodiment is a metallized film (1) based on any one of the first to fifth embodiments. In the sixth embodiment, for each of the multiple small electrodes (7) included in the small electrode row (5) closest to the large electrode (4) in the width direction (Z), the number of fuses (6) connected to the large electrode (4) is greater than the number of fuses (6) connected to other small electrodes (7).

[0140] According to this embodiment, the equivalent series resistance (ESR) can be further reduced.

[0141] Specific examples of the metallized film (1) based on the sixth embodiment include variations 3, 4, and 6-9.

[0142] The seventh aspect is a metallized film (1) based on any one of the first to sixth aspects. In the seventh aspect, the width of each of the multiple fuses (6) is within the range of -80% to +80% based on the average width of the multiple fuses (6). The length of each of the multiple fuses (6) is within the range of -80% to +80% based on the average length of the multiple fuses (6).

[0143] According to this embodiment, the sensitivity of all fuses (6) becomes more uniform, which helps to suppress an excessive decrease in the capacitance of the film capacitor (10A).

[0144] Specific examples of the metallized film (1) based on the seventh embodiment include variations 1 to 9.

[0145] The eighth embodiment is a film capacitor (10A) comprising a metallized film (1) based on any one of the first to seventh embodiments.

[0146] This configuration makes it easier to achieve low ESR.

[0147] The ninth aspect is an inverter (10B) comprising a film capacitor (10A) based on the eighth aspect.

[0148] According to this embodiment, the efficiency of the circuit can be improved and power loss can be minimized.

[0149] The tenth embodiment is a vehicle (10C) comprising an inverter (10B) based on the ninth embodiment.

[0150] According to this embodiment, the heat generated by the film capacitor (10A) is suppressed, extending its lifespan and thus reducing the frequency of repairs and replacements of the film capacitor (10A). [Explanation of Symbols]

[0151] 1. Metallized film 2 Dielectric film 3 Metal film 4 large electrodes 5 small electrode array 6 fuses 7 small electrode 10A film capacitor 10B Inverter 10C Vehicle Y-direction (longitudinal direction) Z width direction

Claims

1. A metallized film comprising a dielectric film having a longitudinal direction and a width direction, and a metal film provided on the dielectric film, The metal film comprises a large electrode extending in the longitudinal direction, two or more rows of small electrodes arranged in the width direction relative to the large electrode, and a plurality of fuses. Each of the two or more rows of small electrodes includes a plurality of small electrodes arranged in the longitudinal direction. Each of the aforementioned multiple fuses connects adjacent large electrodes and small electrodes, or adjacent small electrodes to each other. The number of fuses connected to each of the aforementioned plurality of small electrodes is the same. Each of the multiple small electrodes included in the small electrode row closest to the large electrode in the width direction is connected to the large electrode by two or more fuses. Metallized film.

2. In the width direction, two adjacent small electrodes in the outer row, which is the small electrode row furthest from the large electrode, are connected by the fuse. The metallized film according to claim 1.

3. In the width direction, excluding the outer row which is the row of small electrodes furthest from the large electrode, two adjacent small electrodes in the longitudinal direction of the remaining small electrode rows are not connected by the fuse. The metallized film according to claim 1.

4. The number of fuses connected to each of the plurality of small electrodes is four. The metallized film according to claim 1.

5. In the aforementioned width direction, the positions of adjacent small electrodes in one small electrode array and the positions of small electrodes in another small electrode array are not aligned in the aforementioned width direction. The metallized film according to claim 1.

6. For each of the multiple small electrodes included in the small electrode row closest to the large electrode in the width direction, the number of fuses connected to the large electrode is greater than the number of fuses connected to other small electrodes. The metallized film according to claim 1.

7. The width of each of the aforementioned multiple fuses is within the range of -80% to +80% based on the average value of the widths of the aforementioned multiple fuses. The length of each of the aforementioned plurality of fuses is within the range of -80% to +80% of the average length of the aforementioned plurality of fuses. The metallized film according to claim 1.

8. A film capacitor comprising a metallized film according to any one of claims 1 to 7.

9. An inverter comprising the film capacitor described in claim 8.

10. A vehicle equipped with the inverter described in claim 9.

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