Resin-sealed electrical components

Abstract

To provide a resin-encapsulated electrical part that is easy to manufacture and assemble and capable of suppressing resin leakage.SOLUTION: The resin-encapsulated electrical part includes an electronic part 4, a case 2 having an opening 23 at the top for housing the electronic part 4, a resin 8 that is filled in the case 2, a plate-shaped body 5 provided with an extension part 62, one end of which is embedded in the resin 8 and the other end of which extends out of the case 2 over a side wall 22 of the case 2, and an elastic member 3 for preventing the resin from leaking through the underside of the extension part 62 to the outside of the case 2. The elastic member 3 includes a contact part 32 that contacts the lower surface of the extension part 62 by housing the plate-shaped body 5 in the case 2 from above.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to a resin-sealed electrical component having an extension that extends across a side wall of a case to the outside of the case. [Background technology]

[0002] In resin-sealed electrical components that have an extension, such as an external connection terminal, that extends across the side wall of the case to the outside of the case, resin leakage along the extension can be a problem during manufacturing. Specifically, when the extension is disposed close to the inner surface of the case, the resin creeps up between the extension and the inner surface of the case due to capillary action, and the creeping resin leaks out of the case along the underside of the extension.

[0003] Patent Document 1 discloses that the part of the side wall of the case facing the external connection terminal is protruded higher than the other parts to prevent the resin from creeping up to between the upper surface of the protruding part and the lower surface of the external connection terminal. Patent Document 2 discloses that the inner side of the upper end of the case facing the external connection terminal is notched to widen the gap between the external connection terminal and the inner surface of the case to prevent the resin from creeping up. Patent Document 3 discloses that the upper end of the case is made into a double wall to form a resin pool that opens upward, and the resin that has crawled up is made to flow into the resin pool to prevent leakage to the outside of the case. Patent Document 4 discloses that when the external connection terminal is drawn out from a through hole provided under the resin surface, a ring-shaped seal member (sealing member) made of a rubber material is interposed between the through hole and the external connection terminal to close the gap between them. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2008-85273 A [Patent Document 2] JP 2003-100547 A [Patent Document 3] JP 2010-129573 A [Patent Document 4] JP 2016-058688 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, in Patent Document 1, the height of the protrusion may not be sufficient due to changes in conditions such as the surface tension of the resin and the wettability of the case and the external connection terminal, and if the resin creeps up to between the upper surface of the protrusion and the lower surface of the external connection terminal, it is not possible to prevent resin leakage. In Patent Document 2, the case must be manufactured with high precision so that a predetermined gap is formed between the external connection terminal and the inner surface of the case, which is time-consuming. In Patent Document 3, the case must be manufactured with high precision to provide a resin pool with a predetermined gap, which is also time-consuming. Patent Document 4 is effective when the external connection terminal is extended from below the resin surface, but when the external connection terminal is drawn out from an opening at the top of the case outside the resin surface, it is an excessive method and the assembly is also complicated, so it cannot be said to be an appropriate method.

[0006] An object of the present invention is to provide a resin-sealed electrical component which is easy to manufacture and assemble and which can prevent resin leakage. [Means for solving the problem]

[0007] The resin-sealed electrical component 1 of the present invention comprises an electronic component 4, a case 2 having an opening 23 at an upper side for accommodating the electronic component 4, resin 8 filled into the case 2, a plate-like body 5 having an extension portion 62 (72) having one end embedded in the resin 8 and the other end extending to the outside of the case 2 across the side wall portion 22 of the case 2, and an elastic member 3 for suppressing resin leakage to the outside of the case 2 along the underside of the extension portion 62 (72), wherein the elastic member 3 has an abutment portion 32 that abuts against the underside of the extension portion 62 (72) by accommodating the plate-like body 5 in the case 2 from above.

[0008] In the resin-sealed electrical component, it is preferable that the elastic member 3 includes a main body portion 31 that is attached to the case 2 , and the abutment portion 32 is thinner than the main body portion 31 .

[0009] In addition, it is preferable that the contact portion 32 is bent so as to have a spring property that causes it to rebound toward the lower surface of the extension portion 62 (72).

[0010] Furthermore, it is preferable that a concave-convex fitting portion 9 is formed between the elastic member 3 and the case 2, where the elastic member 3 is fitted to the case 2 by being attached from above.

[0011] Moreover, it is preferable that one elastic member 3 abuts against the lower surfaces of a plurality of the extending portions 62 (72). Effect of the Invention

[0012] In the resin-sealed electrical component of the present invention, the abutting portion of the elastic member abuts against the lower surface of the extension portion, so that it is possible to prevent resin leakage out of the case along the lower surface of the extension portion. In addition, since the resin leakage is prevented by the elastic member, which is a separate member from the case, there is no need to manufacture the case with high precision in order to prevent resin leakage. In addition, assembly is also easy, since the lower surface of the extension portion abuts against the abutting portion simply by placing the plate-like body in the case from above.

[0013] When the elastic member has a main body portion that is attached to the case and the abutment portion is thinner than the main body portion, the abutment portion becomes more flexible, and even if the extension portion shifts in the vertical direction due to manufacturing errors, etc., the abutment state between the underside of the extension portion and the abutment portion can be maintained.

[0014] Even when the abutment portion is bent so as to have a spring property that rebounds toward the underside of the extension portion, the abutment portion becomes more flexible, and even if the extension portion shifts in the vertical direction due to manufacturing errors, etc., the abutment state between the underside of the extension portion and the abutment portion can be maintained.

[0015] When a concave-convex fitting portion that fits with the elastic member by attaching the elastic member from above is formed between the elastic member and the case, the elastic member can be easily attached to the case.

[0016] When one elastic member abuts against the lower surfaces of a plurality of extending portions, there is no need to attach an elastic member to each extending portion, and assembly is simplified. [Brief description of the drawings]

[0017] [Figure 1] 1 is an exploded perspective view showing a resin-sealed electrical component according to an embodiment of the present invention; [Diagram 2] FIG. 2 is a perspective view of a resin-sealed electrical component. [Diagram 3] FIG. 4 is a side view of a main portion of the mounting portion and the elastic member. [Figure 4] 11A and 11B are cross-sectional views showing modified examples of the elastic member. [Diagram 5] FIG. 2 is an end view of a main portion of the resin-sealed electrical component. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] Next, one embodiment of a resin-sealed electrical component 1 of the present invention will be described in detail with reference to the drawings. As shown in Figures 1 and 2, the resin-sealed electrical component 1 of the present invention includes a case 2, an elastic member 3 attached to the case 2, an electronic component 4 housed in the case 2, a plate-like body 5 housed in the case 2, and a resin 8 filled in the case 2. Each of the above components will be described below, but the concept of "upper and lower" refers to the time of manufacture, more specifically, the time of resin filling, and does not necessarily define the upper and lower during use.

[0019] [case] 1, the case 2 has a bottom surface 21 that is generally rectangular in plan view, and side wall portions 22 that rise upward from each of the four sides of the bottom surface 21. An opening 23 is provided at the top of the case 2, and electronic components 4 and plate-like bodies 5 are housed in the case 2 from above through this opening 23. Of the four side wall portions 22, two side wall portions 22 located on the long sides of the bottom surface 21 are provided with attachment portions 24 for attaching the elastic members 3.

[0020] The mounting portion 24 is formed by cutting out an upper portion of the side wall portion 22 in an approximately U-shape and extending a protrusion 26 from the inner surface of the cutout 25 (bottom portion 25a and a pair of side portions 25b) that can be inserted into a recess 33 provided in the elastic member 3.

[0021] The protrusion 26 is located outside the inner surface of the side wall 22 in a plan view. This is to ensure that the inner surface of the side wall 22 and the inner surface of the main body 31 of the elastic member 3, which will be described later, are located on the same plane (flush) when the elastic member 3 is attached to the attachment portion 24. The protruding portion 27 for positioning the protrusion 26 outside the side wall 22 may extend laterally beyond the protrusion 26 so as to support the entire lower surface of the main body 31 of the elastic member 3 from below, as shown in FIG. 5. The protrusion 26 is continuous in a substantially U-shape in a side view. The protrusion length of the protrusion 26 is uniform at the bottom 25a of the cutout 25 and is different at the side 25b of the cutout 25, as shown in FIG. 3. Specifically, the protrusion length of the protrusion 26 provided on the side 25b becomes shorter as it goes upward. However, near the upper end, a protruding portion 26a is provided with a protruding length that is approximately the same as the original length, and the overall shape is generally hook-shaped when viewed from the side.

[0022] The case 2 having the above-mentioned structure is made of a non-conductive material such as synthetic resin, etc. However, it may be made of a conductive material such as metal.

[0023] [Elastic member] The elastic member 3 includes a main body portion 31 and a contact portion 32 extending upward from the upper surface of the main body portion 31.

[0024] The shape and size (height in the vertical direction, width in the horizontal direction) of the main body 31 when viewed from the side are substantially the same as the shape and size of the cutout of the case. As shown in FIG. 3, the main body 31 has a recess 33 that fits with the protrusion 26 on a surface facing the inner peripheral surface of the cutout 25 of the case 2, specifically, on the lower surface 31a and both end surfaces 31b in the longitudinal direction. The recess 33 is also continuous in a substantially U-shape when viewed from the side, similar to the protrusion 26. Therefore, the concave-convex fitting portion 9 (see FIG. 5) formed by fitting the recess 33 of the elastic member 3 to the protrusion 26 is continuous in a substantially U-shape when viewed from the side. The groove depth of the recess 33 is uniform on the lower surface. On the end surface, the groove depth becomes shorter toward the top, but the groove depth near the upper end is approximately the same as the original depth, and a step 33a is formed. The step 33a and the lower surface of the protrusion 26a of the protrusion 26 are adapted to engage with each other.

[0025] The upper surface of the main body 31 is set so as to be at the same level as or higher than the resin surface, for example, at the same level as the upper end surface of the side wall 22, when the convex portion 26 of the case 2 is fitted into the concave portion 33 of the main body 31. Therefore, the notch 25 provided in the side wall 22 is blocked by the main body 31 as shown in Figures 2 and 5. In other words, the main body 31 of the elastic member 3 functions as a part of the side wall 22, and prevents the resin 8 from flowing out from the notch 25. In addition, since a labyrinth is formed by the fitting of the concave and convex portions, resin leakage from the fitting portion 9 is unlikely to occur.

[0026] The abutment portion 32 protrudes upward from the upper surface of the main body portion 31. The shape of the upper end of the abutment portion 32 is the same shape (flat) as the lower surface of the extension portion 62, 72 so that it can be in close contact with the lower surface of the extension portion 62, 72 without any gap. In addition to being flat, the shape may be the same. The abutment portion 32 is thinner than the main body portion 31. There is no particular limitation on the thickness as long as the abutment portion 32 can continue to abut against the lower surface of the extension portion 62, 72 with a repulsive force that tries to return to its original shape while deforming when the extension portion 62, 72 of the plate-like body 5 described later abuts against it from above. The length of the abutment portion 32 protruding upward is set to be long enough to naturally abut against the plate-like body 5 when it is housed in the case 2 from above. 1, the length (width in the horizontal direction) of the abutment portion 32 is set to be larger than the width of the extension portions 62, 72, so that the abutment portion 32 protrudes from the side edges of the extension portions 62, 72 when assembled. It is also preferable to provide one extension portion 62, 72 to abut against one abutment portion 32, in other words, to provide a cut-off 32a for each extension portion 62, 72. This allows the abutment portion 32 to abut against the lower surfaces of the extension portions 62, 72 reliably, even if the heights of the extension portions 62, 72 are different.

[0027] The elastic member 3 in the above configuration is made of, for example, synthetic rubber. However, various elastic materials, such as silicone resin and natural rubber, that are elastic in themselves, can be used. In addition, the entire elastic member 3 does not need to be made of the same material. For example, the main body 31 may be made of synthetic resin and the contact portion 32 may be made of synthetic rubber. In short, it is sufficient that the contact portion 32 is elastic. Furthermore, even if the material itself does not have elasticity, the contact portion 32 can be made of a material that is elastic in shape, specifically, a material that is bent into an approximately L-shape as shown in FIG. 4A, a material that is bent into an approximately C-shape as shown in FIG. 4B, or a material that is bent at an angle as a whole by bending the base as shown in FIG. 4C, so that the material has a springiness that rebounds toward the lower surface of the extension portion 62, 72. The bending direction may be inward or outward with respect to the case. In this case, the material of the contact portion 32 is not limited to soft materials such as synthetic rubber and silicone resin, but may be hard materials such as synthetic resin and metal.

[0028] [Electronic components] The electronic component 4 is a capacitor element (film capacitor) formed by winding a metallized film in which metal is vapor-deposited on an insulating film, for example, and as shown in FIG. 1, electrode portions 4a, 4b formed by spraying metal on both axial end surfaces are formed. When viewed from the axial direction, the capacitor element 4 is shaped like a bale, specifically, R (radius) is provided at the four corners, and a side surface consisting of a flat portion 4c and a curved portion 4d is formed between the electrode portions 4a, 4b (peripheral surface). The electrode portions 4a, 4b are oriented in the vertical direction, and a plurality of the electrode portions 4a, 4b (five in the figure) are arranged side by side so that the flat portions 4c face each other. The capacitor element 4 is not limited to a film capacitor, and various capacitor elements such as a ceramic capacitor may be used. The electronic component is not limited to a capacitor, and various electronic components such as a resistor and a coil may be used. Various shapes such as a cylindrical shape and a rectangular column shape may be adopted. The number of pieces may also be changed as appropriate.

[0029] [Plate] The plate-like body 5 is, for example, a pair of positive and negative electrode plates 6 and 7 connected to the electrode portions 4a and 4b of the electronic component 4.

[0030] The first electrode plate (eg, positive electrode side) 6 includes a substrate portion 61 that overlaps the upper surface of the electronic component 4, and an extension portion 62 that extends from the outer edge of the substrate portion 61.

[0031] The substrate portion 61 has a generally rectangular shape in a plan view, and includes a tongue-shaped connection portion 61a for connection to an upper electrode portion 4a of the electronic component 4.

[0032] The extending portion 62 includes a rising portion 62a rising upward from the substrate portion 61, and a horizontal portion 62b extending laterally from the upper end of the rising portion 62a. The rising portion 62a is along the inner surface of the side wall portion 22 of the case 2 and the main body portion 31 of the elastic member 3, and faces closely to each other. The extending portions 62 extend from two long sides of the substrate portion 61, which is substantially rectangular. Specifically, one extending portion 62 extends from one long side and three extending from the other long side, and function as external connection terminals for connection to an external device (not shown).

[0033] The second electrode plate (eg, negative electrode side) 7 includes a substrate portion 71 overlapping the lower side of the electronic component 4, and an extension portion 72 extending from the outer edge of the substrate portion 71.

[0034] The substrate portion 71 has a generally rectangular shape in a plan view, and includes a tongue-shaped connection portion 71a for connection to the electrode portion 4b on the lower side of the electronic component 4.

[0035] The extension portion 72 includes a rising portion 72a rising upward from the substrate portion 71 and a horizontal portion 72b extending laterally from the upper end of the rising portion 72a. The rising portion 72a is along the inner surface of the side wall portion 22 of the case 2 and the main body portion 31 of the elastic member 3, and is closely opposed to each other. The extension portions 72 extend from two long sides of the substrate portion 71, which is substantially rectangular. Specifically, one extends from one long side, and three extend from the other long side, and function as external connection terminals for connection to an external device (not shown). The rising portions 72a of the three extension portions extending from the other long side are integrated up to the vicinity of the upper end of the electronic component 4. However, they may be separated into three from the beginning. The extending position is laterally shifted from the extending portion 72 of the first electrode plate 6, and the horizontal portions 62b and 72b do not overlap each other in a plan view.

[0036] The plate-like body 5 having the above-mentioned configuration is formed by cutting a conductive metal plate such as aluminum or copper into a predetermined shape and bending it appropriately. The plate-like body 5 is not limited to an electrode plate, and may be a heat sink for dissipating heat from the electronic component 4 to the outside of the case 2, or an insulating plate for ensuring insulation from the electrode plate and external devices. In this case, the material is a thermally conductive material, an insulating material, or any other material suitable for the purpose of installation.

[0037] [resin] The resin 8 filled in the case 2 is, for example, an epoxy resin. However, it is not limited to this, and various known resins such as urethane resin can be used. It is preferable to use a resin with excellent moisture resistance or high thermal conductivity. Furthermore, changing the resin thickness (the distance from the resin surface to the electronic components) depending on the type and characteristics of the resin used is of course something that should be taken into consideration in design.

[0038] [Manufacturing method] Next, the assembly of the resin-sealed electrical component 1 will be described. First, the elastic member 3 is attached to the case 2. Specifically, the elastic member 3 is pressed down from above so that the convex portion 26 of the attachment portion 24 of the case 2 is inserted into the concave portion 33 of the elastic member 3. As a result, the notch 25 of the case 2 is blocked by the main body portion 31 of the elastic member 3. In addition, a concave-convex fitting portion 9 that fits together by attaching the elastic member 3 from above is formed between the case 2 and the elastic member 3. The abutment portion 32 protrudes above the side wall portion 22 of the case 2.

[0039] Next, the substrate portion 61 of the first electrode plate 6 is connected to the upper electrode portion 4a of the capacitor element 4, and the substrate portion 71 of the second electrode plate 7 is connected to the lower electrode portion 4b of the capacitor element 4 to form a capacitor module that integrates the capacitor element 4, the first electrode plate 6, and the second electrode plate 7. At this time, the extension portion 62 of the first electrode plate 6 and the extension portion 72 of the second electrode plate 7 are attached so that they are both positioned upward.

[0040] Next, the capacitor module is housed in the case 2 from above. At this time, the extending portions 62, 72 are housed with the extending portions 62, 72 facing up so that the horizontal portions 62b, 72b of the extending portions 62, 72 extend outside the case 2 across the upper ends of the side wall portions 22 of the case 2. The capacitor element 4 is then lowered to a predetermined position, and the upper ends of the abutting portions 32 are brought into contact with the lower surfaces of the horizontal portions 62b, 72b of the extending portions 62, 72. The case 2 is then filled with resin 8 to seal the capacitor element 4, thereby completing the manufacture of the resin-sealed electrical component 1.

[0041] As shown in FIG. 5, one end side (part of the rising portion) of the extension portion 62, 72 after the resin filling is embedded in the resin 8. The other end side rises along the side wall portion 22 of the case 2, protrudes from the resin 8, and extends to the outside of the case 2 across the side wall portion 22 of the case 2. As shown in the figure, the rising portions 62a, 72a and the inner surface of the side wall portion 22 of the case 2 (specifically, the inner surface of the main body portion 31 of the elastic member 3 functioning as a part of the side wall portion 22) are close to each other, so that the resin 8 may creep up between them due to capillary action. However, even if the resin 8 creeps up, the abutment portion 32 abuts against the lower surface of the horizontal portions 62b, 72b that are continuous with the rising portions 62a, 72a without any gaps, so that the resin 8 is blocked by the abutment portion 32 and does not leak out of the case 2 along the lower surface of the horizontal portions 62b, 72b. Furthermore, to bring the abutting portion 32 into contact with the lower surfaces of the extensions 62, 72, it is sufficient to simply accommodate the plate-like body 5 in the case 2 from above, and no special operation is required, such as passing an annular sealing member through the extensions 62, 72. Furthermore, even if the vertical positions of the extensions 62, 72 are slightly misaligned due to manufacturing or assembly errors, the abutting state is maintained by the elastic deformation of the abutting portion 32, so manufacturing and assembly can be easily performed.

[0042] In addition, since one elastic member 3 abuts against the undersides of multiple extension portions 62, 72, i.e., one elastic member 3 is long enough to accommodate the undersides of multiple extension portions 62, 72, installation of the elastic member 3 is easier than when an elastic member 3 is provided for each extension portion 62, 72.

[0043] Although the embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and various modifications can be made within the scope of the present invention. For example, in the above embodiment, the elastic member 3 is attached to the notch 25, but the elastic member 3 may be attached to the side wall portion 22 that does not have the notch 25. As a method of attachment, for example, a recess is provided in the lower portion of the elastic member 3, and the upper portion of the side wall portion 22 is inserted into the recess, but various methods can be adopted as long as the elastic member 3 can be fixed to the case 2. In addition, in the above embodiment, the convex portion 26 is provided on the case 2 and the concave portion 33 is provided on the elastic member 3, but a concave portion may be provided on the case and a convex portion on the elastic member. Even in this case, a concave-convex fitting portion 9 is formed between the two. In addition, it is not necessarily necessary to have a continuous convex portion and a continuous concave portion fitting, and it may be a fitting between one or more convex portions and a hole portion. In addition, it is not limited to a concave-convex fitting, but it may be engagement by a step or abutment between flat surfaces. An adhesive or the like may be used appropriately for fixing. Furthermore, the length of the elastic member 3 and the number of the contacting extensions 62, 72 can be changed as appropriate. The horizontal parts 62b, 72b of the extensions 62, 72 may extend laterally or may be bent downward at the tip side. Furthermore, the electrode plate includes the substrate parts 61, 71, but does not necessarily need to include the substrate parts 61, 71. In particular, when a heat sink or insulating plate is used as the plate-like body 5, it does not necessarily need to be in contact with the electronic component. [Explanation of symbols]

[0044] 1. Resin-sealed electrical components 2 Cases 21 Bottom part 22 Side wall 23 Aperture 24 Mounting part 25 Cutout 25a bottom 25b Side 26 Convex 26a Protrusion 27 Overhang 3 Elastic member 31 Main body 31a Bottom surface 31b End face 33 Recess 33a Step 32 Contact part 32a Severing ties 4. Electronic components (capacitor elements) 4a Upper electrode part 4b Lower electrode part 4c flat area 4d curved part 5 Plate-shaped body 6 First electrode plate 61 Circuit Board 61a Connection 62 Extension part 62a Rising part 62b Horizontal part 7 Second electrode plate 71 Circuit Board 71a Connection 72 Extension part 72a Rising part 72b Horizontal part 8. Resin 9 Concave-convex fitting part

Claims

1. Electronic components, a case having an opening at an upper portion thereof and configured to accommodate electronic components; A resin filled in the case; a plate-like body having one end embedded in the resin and the other end extending beyond the side wall of the case; an elastic member that suppresses leakage of resin out of the case along the lower surface of the extension portion; the elastic member includes a contact portion that protrudes above the side wall of the case and contacts the lower surface of the extension portion when the plate-like body is accommodated in the case from above, A resin-sealed electrical component in which the contact portion is made of an elastic material that itself has elasticity.

2. Electronic components, a case having an opening at an upper portion thereof and configured to accommodate electronic components; A resin filled in the case; a plate-like body having one end embedded in the resin and the other end extending beyond the side wall of the case; an elastic member that suppresses leakage of resin out of the case along the lower surface of the extension portion; the elastic member includes a contact portion that contacts the lower surface of the extension portion by housing the plate-like body in the case from above, A resin-sealed electrical component in which the contact portion is bent so as to have a spring property that causes the contact portion to rebound toward the lower surface of the extension portion.

3. 3. The resin-sealed electrical component according to claim 1, wherein the elastic member has a main body portion attached to the case, and the contact portion is thinner than the main body portion.

4. 4. The resin-sealed electrical component according to claim 1, wherein a concave-convex fitting portion is formed between the elastic member and the case, the concave-convex fitting portion being fitted with the elastic member by attaching the elastic member from above.

5. 5. The resin-sealed electrical component according to claim 1, wherein one elastic member abuts against the lower surfaces of a plurality of the extending portions.

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