Method for manufacturing a film capacitor and film capacitor

Abstract

To provide a manufacturing method of a film capacitor capable of suppressing the decrease in the capacity due to oxidation of an electrode part.SOLUTION: The manufacturing method of a film capacitor includes the steps of: applying mask oil M1 to at least outside an electrode area R1 on a film surface 110a of a first film 110; forming a first electrode part 130 by vapor-depositing metal on the film surface 110a; applying the mask oil M1 to at least outside an electrode area R2 on a film surface 120a of a second film 120; forming a second electrode part 140 by vapor-depositing metal on the film surface 120a; and winding the first film 110 and the second film 120. On the film surface 110a of the first film 110, multiple non-electrode parts 131 having a predetermined shape where the mask oil M1 is applied in the electrode area R1 in the step of applying the mask oil M1 are distributed at intervals larger than the size of the non-electrode part 131.SELECTED DRAWING: Figure 6

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a film capacitor and a film capacitor.

Background Art

[0002] Conventionally, a film capacitor has been known that includes a first film and a second film that are wound or laminated in a stacked state, a first electrode portion formed by vapor deposition of a metal on a first film surface that is one film surface of the first film, and a second electrode portion formed by vapor deposition of a metal on the other film surface of the first film or a second film surface that is a film surface of the second film facing the other film surface of the first film. An example of such a film capacitor is described in Patent Document 1.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the above film capacitor, corona discharge may occur in the first electrode portion and the second electrode portion when a voltage is applied. Further, water may adhere to the first electrode portion and the second electrode portion due to intrusion of water into the capacitor or the like. When corona discharge occurs, the water present on the surfaces of these electrode portions is ionized, and there is a risk that these electrode portions are oxidized due to the hydroxide ions generated by the ionization. As a result, in the above film capacitor, it is feared that a decrease in capacitance due to oxidation may occur during long-term use.

[0005] Therefore, an object of the present invention is to provide a method for manufacturing a film capacitor that can suppress a decrease in capacitance due to oxidation of an electrode portion, and a film capacitor.

Means for Solving the Problem

[0006] A first aspect of the present invention relates to a method for manufacturing a film capacitor including a first film and a second film wound or laminated in a state of being overlapped with each other, a first electrode portion formed by vapor deposition of a metal on a first film surface which is one film surface of the first film, and a second electrode portion formed by vapor deposition of a metal on a second film surface which is the other film surface of the first film or the film surface of the second film facing the other film surface. The manufacturing method according to this aspect includes a step of applying a masking agent that prevents vapor deposition of the metal to at least a portion of the first film surface outside the electrode region that becomes the first electrode portion; a step of vapor-depositing the metal on the first film surface to which the masking agent is applied to form the first electrode portion; a step of applying a masking agent that prevents vapor deposition of the metal to at least a portion of the second film surface outside the electrode region that becomes the second electrode portion; a step of vapor-depositing the metal on the second film surface to which the masking agent is applied to form the second electrode portion; and a step of winding or laminating the first film and the second film on which the first electrode portion and the second electrode portion are formed. Here, on at least one of the first film surface and the second film surface, in the step of applying the masking agent, a plurality of non-electrode portions having a circular, oval, or square shape are dispersedly arranged at intervals larger than the size of the non-electrode portion. in a triangular lattice or a square lattice

[0007] A second aspect of the present invention relates to a film capacitor including a first film and a second film wound or laminated in a state of being overlapped with each other, a first electrode portion formed by vapor deposition of a metal on a first film surface which is one film surface of the first film, and a second electrode portion formed by vapor deposition of a metal on a second film surface which is the other film surface of the first film or the film surface of the second film facing the other film surface. In the film capacitor according to this aspect, among the first electrode portion and the second electrode portion, one electrode portion​is divided into a plurality of divided electrode portions in the longitudinal direction of the one electrode portion by a plurality of width direction slit portions extending in the width direction of the one electrode portion and on which the metal is not deposited. The other electrode portion is not divided in the longitudinal direction of the other electrode portion, and the other electrode portion It has a plurality of non-electrode portions having a predetermined shape, on which a masking agent is applied and the metal is not vapor-deposited, and the non-electrode portions are dispersedly arranged at intervals larger than the size of the non-electrode portions. the other The surface around the non-electrode portion in the electrode portion is covered with a coating layer made of the masking agent that has spread from the non-electrode portion.

Advantages of the Invention

[0008] According to the present invention, it is possible to provide a method for manufacturing a film capacitor capable of suppressing a decrease in capacitance due to oxidation of an electrode portion, and a film capacitor.

[0009] 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

[0010]

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

DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[0012] <Embodiment 1> [Configuration of Film Capacitor] The film capacitor 1A according to Embodiment 1 will be described.

[0013] FIG. 1(a) is a perspective view of the film capacitor 1A. FIG. 1(b) is a cross-sectional view of the film capacitor 1A cut along the axial direction.

[0014] The film capacitor 1A includes a capacitor body 10, a winding core 20, an outer film 30, a first end face electrode 40, and a second end face electrode 50. The film capacitor 1A has a cylindrical shape with a circular cross-section that is a perfect circle.

[0015] The capacitor body 10 is formed by overlapping a first film 110 and a second film 120 and winding them so that the first film 110 is on the inside and the second film 120 is on the outside. On one (upper) film surface 110a of the first film 110, a first electrode portion 130 is formed. On one (upper) film surface 120a of the second film 120, a second electrode portion 140 is formed. The film surface 120a faces the other film surface 110b of the first film 110.

[0016] In the capacitor body 10, the overlapping portion of the first electrode portion 130 and the second electrode portion 140 becomes the effective electrode region W.

[0017] In the capacitor body 10, an elongated cylindrical cavity 11 is formed so as to penetrate the center of the capacitor body 10. A winding core 20 is inserted into the cavity 11. The winding core 20 is formed of a resin material such as polypropylene (PP) and has an elongated cylindrical shape (round bar shape). Both end faces of the winding core 20 are substantially flush with both end faces 12 and 13 of the capacitor body 10.

[0018] The exterior film 30 is wound around the outer peripheral surface of the capacitor body 10 a plurality of times (a plurality of turns). As a result, the outer peripheral surface of the capacitor body 10 is covered with a plurality of layers of the exterior film 30, preventing damage and breakage of the capacitor body 10. Examples of the material of the exterior film 30 include polypropylene (PP), polyethylene terephthalate (PET), and polyethylene naphthalate (PEN).

[0019] The first end face electrode 40 and the second end face electrode 50 are formed by spraying a metal such as aluminum, zinc, or magnesium onto the first end face 12 and the second end face 13 of the capacitor body 10, respectively. Drawing terminals (not shown) such as bus bars and lead wires are connected to the first end face electrode 40 and the second end face electrode 50 to draw electricity from the film capacitor 1A.

[0020] FIG. 2(a) is a plan view of the first film 110 on which the first electrode portion 130 is formed. FIG. 2(b) is a plan view of the second film 120 on which the second electrode portion 140 is formed. In FIGS. 2(a) and 2(b), for the sake of convenience, the first film 110 and the second film 120 are drawn short in their longitudinal directions. Also, the first electrode portion 130 and the second electrode portion 140 are hatched.

[0021] The first film 110 and the second film 120 are transparent dielectric films made of resin materials such as polypropylene (PP), polyethylene terephthalate (PET), and polyethylene naphthalate (PEN). The first film 110 and the second film 120 have substantially equal width dimensions. A first insulating margin portion 111 that extends continuously without interruption in the longitudinal direction is formed at one end of the first film 110 in the width direction. A second insulating margin portion 121 that extends continuously without interruption in the longitudinal direction is formed at the end of the second film 120 on the side opposite to one end of the first film 110 in the width direction. The first insulating margin portion 111 and the second insulating margin portion 121 are margin portions on which a metal, that is, an aluminum-containing layer is not deposited.

[0022] The first electrode portion 130 is a vapor-deposited electrode formed of an aluminum-containing layer. The first electrode portion 130, that is, the aluminum-containing layer, is formed, for example, by vapor-depositing aluminum or an alloy of aluminum and a metal such as magnesium on the film surface 110a of the first film 110. It is desirable that the metal forming the alloy with aluminum does not contain zinc. The first electrode portion 130 is formed so as to be continuous without being divided in the longitudinal direction of the first film 110. The first electrode portion 130 is formed up to the other end of the first film 110 in the width direction and is connected to the first end face electrode 40 (see FIG. 1(b)).

[0023] A plurality of non-electrode portions 131 on which no metal is deposited are dispersedly arranged at intervals larger than the size of the non-electrode portions 131 over the entire area of the first electrode portion 130. The plurality of non-electrode portions 131 have a circular shape.

[0024] The second electrode portion 140 is a vapor-deposited electrode formed of an aluminum-containing layer similar to the first electrode portion 130. The second electrode portion 140 is formed up to the end of the second film 120 on the side opposite to the end on the second insulating margin portion 121 side in the width direction and is connected to the second end face electrode 50 (see FIG. 1(b)).

[0025] In the second electrode portion 140, a longitudinal slit portion 141 extending in its longitudinal direction is formed at an end portion connected to the second end face electrode 50. Further, in the second electrode portion 140, a plurality of widthwise slit portions 142 crossing the second electrode portion 140 in its width direction are formed at predetermined intervals in its longitudinal direction. Each widthwise slit portion 142 is formed from the longitudinal slit portion 141 to the second insulating margin portion 121 so as to be inclined with respect to the width direction. No metal is deposited on the longitudinal slit portion 141 and the widthwise slit portions 142.

[0026] The second electrode portion 140 is divided by the longitudinal slit portion 141 and the plurality of widthwise slit portions 142 into a common electrode portion 143 extending in its longitudinal direction and connected to the second end face electrode 50, and a plurality of divided electrode portions 144 arranged in its longitudinal direction.

[0027] Note that the widths of the first insulating margin portion 111 and the second insulating margin portion 121 are significantly wider than the widths of the longitudinal slit portion 141 and the widthwise slit portions 142.

[0028] A fuse pattern 145 is formed so as to span the longitudinal slit portion 141 between each divided electrode portion 144 and the common electrode portion 143. The pattern width of the fuse pattern 145 is set to about 0.5 mm, for example.

[0029] FIG. 3(a) is an enlarged plan view of a main part of the first film 110 on which the first electrode portion 130 is formed. FIG. 3(b) is an end view taken along line A - A' of FIG. 3(a). FIG. 3(c) is an enlarged plan view of a main part of the second film 120 on which the second electrode portion 140 is formed. FIG. 3(d) is an end view taken along line B - B' of FIG. 3(c). In FIGS. 3(a) and 3(c), the mask oil M1 is indicated by diagonal hatching. Also, in FIGS. 3(a) and 3(c), the coating layers 132, 133, 146, 147, 148 are indicated by broken lines.

[0030] As shown in FIGS. 3(a) and 3(b), a plurality of non-electrode portions 131 are dispersedly arranged in a triangular lattice, and the non-electrode portions 131 adjacent to each other in the width direction are shifted by a half pitch in the longitudinal direction. A mask oil M1, which is a masking agent, is applied to the plurality of non-electrode portions 131. The mask oil M1 is applied in a mask agent application step included in the manufacturing process of the film capacitor 1A described later in order to prevent metal vapor deposition. The mask oil M1 is an oil such as silicone oil, fluorine oil, paraffin oil, ester oil, or vegetable oil.

[0031] The surface around each non-electrode portion 131 in the first electrode portion 130 is covered by a coating layer 132 made of the mask oil M1 that has spread from each non-electrode portion 131. Since the non-electrode portion 131 is circular, the coating layer 132 is likely to have a shape close to a circle. In this way, by arranging the plurality of circular non-electrode portions 131 in a triangular lattice, it becomes difficult for gaps that are not covered by the plurality of coating layers 132 to occur, and the plurality of coating layers 132 can evenly cover many regions of the surface of the first electrode portion 130.

[0032] The pitch P1 in the longitudinal direction of the first film 110 and the pitch P2 in the width direction of the first film 110 among the plurality of non-electrode portions 131 are desirably set such that the coating layers 132 that spread in a circular shape are close to or in contact with each other. The pitch P2 in the width direction is set to a value of the square root of 3 divided by 2 of the pitch P1 in the longitudinal direction. For example, the diameter of the non-electrode portion 131 is set to about 1 mm. In this case, for example, the pitch P1 is set to about 5.0 mm and the pitch P2 is set to about 4.3 mm. The number of non-electrode portions 131 can be appropriately changed according to the width dimension and length dimension of the first film 110.

[0033] Furthermore, the mask oil M1 is also applied to the first insulating margin portion 111. The surface of the vicinity portion of the first insulating margin portion 111 in the first electrode portion 130 is covered by a coating layer 133 made of the mask oil M1 that has spread from the first insulating margin portion 111. Note that the coating layer 132 and the coating layer 133 can partially overlap.

[0034] As shown in FIGS. 3(c) and 3(d), mask oil M1 is applied to the second insulating margin portion 121, the longitudinal slit portion 141, and the widthwise slit portion 142. The surfaces of the respective divided electrode portions 144 in the second electrode portion 140 are covered by coating layers 146, 147, 148 made of mask oil M1 that has spread from the second insulating margin portion 121, the longitudinal slit portion 141, and the respective widthwise slit portions 142. The coating layers 146, 147, 148 can partially overlap each other. Since each divided electrode portion 144 is surrounded by the second insulating margin portion 121, the longitudinal slit portion 141, and the widthwise slit portion 142, most regions of the surface of each divided electrode portion 144 are covered by the coating layers 146, 147, 148.

[0035] Note that since each of the coating layers 132, 133, 146, 147, 148 is formed by the spread of mask oil M1, its shape and coating range are not precisely determined. Therefore, in FIGS. 3(a) to 3(d), approximate shapes and coating ranges of the coating layers 132, 133, 146, 147, 148 are depicted.

[0036] In the film capacitor 1A, corona discharge may occur in the first electrode portion 130 and the second electrode portion 140 when a voltage is applied. In the first embodiment, since the surface of the first electrode portion 130 is protected by the coating layers 132, 133 formed by the spread of mask oil M1 on each non - electrode portion 131 and the first insulating margin portion 111, the adhesion of water to the surface of the first electrode portion 130 is suppressed. As a result, even if corona discharge occurs, hydroxide ions generated by the ionization of water hardly act on the first electrode portion 130, so the oxidation of the first electrode portion 130 is suppressed. Also, the surface of the second electrode portion 140 is protected by the coating layers 146, 147, 148 formed by the spread of mask oil M1 on the second insulating margin portion 121, the longitudinal slit portion 141, and the respective widthwise slit portions 142. Therefore, similar to the first electrode portion 130, the oxidation of the second electrode portion 140 due to corona discharge is suppressed.

[0037] In the first electrode portion 130, if the diameter of each non - electrode portion 131 is too small, the size (range) of the coating layer 132 becomes small and the oxidation - suppressing effect cannot be sufficiently exerted. If the diameter is too large, the effective area of the first electrode portion 130 becomes small and it becomes difficult to obtain a sufficient capacitance. Therefore, in order to sufficiently exert the oxidation - suppressing effect and obtain a sufficient capacitance, it is desirable that the diameter of each non - electrode portion 131 be 0.05 mm or more and 5.0 mm or less.

[0038] [Method for manufacturing a film capacitor] Next, a method for manufacturing the film capacitor 1A will be described.

[0039] FIG. 4 is a flowchart showing the manufacturing process of the film capacitor 1A.

[0040] As shown in FIG. 4, the manufacturing process of the film capacitor 1A includes a mask agent coating process, a vapor deposition electrode formation process, a film winding process, an exterior film coating process, a core body insertion process, a metal spraying process, and an aging process.

[0041] First, using a vapor deposition apparatus 1000 such as a vacuum vapor deposition apparatus, the mask agent coating process and the vapor deposition electrode formation process are performed. As a result, the first electrode portion 130 and the second electrode portion 140 are vapor - deposited and formed on the first film 110 and the second film 120, respectively.

[0042] FIG. 5(a) is a diagram showing the vapor deposition apparatus 1000, and FIG. 5(b) is a perspective view of the roll body of the raw film F.

[0043] The vapor deposition apparatus 1000 includes a pay - out machine 1100, an oil spray unit 1200, an oil printing unit 1300, an electrode vapor deposition unit 1400, and a take - up machine 1500.

[0044] A roll of the raw film F that will become the first film 110 or the second film 120 is set in the unwinding machine 1100. As shown by the dashed line in Fig. 3(b), after the formation of the electrode portions (the first electrode portion 130 and the second electrode portion 140) by the vapor deposition apparatus 1000, the raw film F is divided into a plurality in the width direction, and each of the divided films becomes the first film 110 on which the first electrode portion 130 is formed or the second film 120 on which the second electrode portion 140 is formed.

[0045] The oil spray unit 1200 includes an oil tank 1210 and a backup roll 1220. The oil tank 1210 has a replaceable nozzle 1211, vaporizes the mask oil M1 stored therein, and sprays it from the nozzle 1211. The mask oil M1 is sprayed onto the surface of the raw film F moving within the oil spray unit 1200. The backup roll 1220 has a cylindrical shape and is arranged to contact the back surface of the raw film F at a position facing the nozzle 1211.

[0046] The oil printing unit 1300 includes an oil tank 1310, a transfer roll 1320, a printing roll 1330, and a backup roll 1340. The oil tank 1310 vaporizes the mask oil M1 stored therein and ejects it from the nozzle 1311. The transfer roll 1320 and the printing roll 1330 have a cylindrical shape. The transfer roll 1320 rotates while adhering the ejected mask oil M1 to its circumferential surface. A relief printing portion having a predetermined pattern shape is formed on the circumferential surface of the printing roll 1330. The circumferential surface of the printing roll 1330 and the circumferential surface of the transfer roll 1320 are in contact with each other, and the mask oil M1 transferred from the transfer roll 1320 adheres to the relief printing portion. The printing roll 1330 rotates in synchronization with the conveyance of the raw film F, and the surface of the raw film F comes into contact with the relief printing portion of the printing roll 1330. Thereby, printing with the mask oil M1 according to the pattern shape of the relief printing portion is performed on the surface of the raw film F. The backup roll 1340 has a cylindrical shape, is arranged to face the printing roll 1330, and contacts the back surface of the raw film F.

[0047] The electrode vapor deposition unit 1400 includes a cooling roll 1410 and a vapor deposition device 1420. The cooling roll 1410 is formed in a cylindrical shape from a metallic material and has a cooling mechanism inside. The raw film F is wound around the cooling roll 1410 and cooled. The vapor deposition device 1420 vapor-deposits a metal containing aluminum on the surface of the raw film F in a state cooled by the cooling roll 1410. Thereby, electrode portions (first electrode portion 130, second electrode portion 140) are formed in regions of the raw film F where the mask oil M1 is not applied.

[0048] The raw film F with the electrode portions formed thereon is wound up by a winding machine 1500.

[0049] FIG. 6(a) is a plan view showing the first film 110 coated with the mask oil M1. FIGS. 6(b) and 6(c) are a plan view and an end view, respectively, showing the first film 110 on which the first electrode portion 130 is vapor-deposited.

[0050] As shown in FIG. 6(a), on the film surface 110a of the first film 110, in the mask agent coating step, the mask oil M1 is applied by the oil spraying unit 1200 to a plurality of portions (regions) that become non-electrode portions 131 within the electrode region R1 that becomes the first electrode portion 130 and to a portion (region) that becomes the first insulating margin portion 111 outside the electrode region R1, thereby forming the plurality of non-electrode portions 131 and the first insulating margin portion 111. The plurality of non-electrode portions 131 are dispersedly arranged in a triangular lattice pattern. The plurality of non-electrode portions 131 are preferably formed such that their diameters are 0.05 mm or more and 5.0 mm or less.

[0051] Note that the oil printing unit 1300 is not used for applying the mask oil M1 to the first film 110.

[0052] Thereafter, as shown in FIG. 6(b), on the film surface 110a of the first film 110 coated with the mask oil M1, in the vapor deposition electrode formation step, the electrode vapor deposition unit 1400 vapor-deposits a metal on the electrode region R1 to form the first electrode portion 130.

[0053] As shown in FIG. 6(c), the thickness of the oil layer of the mask oil M1 applied to each non-electrode portion 131 and the first insulation margin portion 111 is greater than the thickness of the metal layer of the first electrode portion 130.

[0054] FIG. 6(d) is a plan view showing the second film 120 coated with the mask oil M1. FIGS. 6(e) and (f) are a plan view and an end view showing the second film 120 on which the second electrode portion 140 is formed by vapor deposition, respectively.

[0055] As shown in FIG. 6(d), on the film surface 120a of the second film 120, in the mask agent application step, the mask oil M1 is applied to the longitudinal slit portion 141 and the plurality of widthwise slit portions 142 in the electrode region R2 that becomes the second electrode portion 140 and the portion (region) that becomes the second insulation margin portion 121 outside the electrode region R1 by the oil spray unit 1200 and the oil printing unit 1300, and the longitudinal slit portion 141, the plurality of widthwise slit portions 142, and the second insulation margin portion 121 are formed.

[0056] Thereafter, as shown in FIG. 6(e), on the film surface 120a of the second film 120 coated with the mask oil M1, in the vapor deposition electrode formation step, the electrode vapor deposition unit 1400 vapor-deposits metal on the electrode region R2 to form the second electrode portion 140.

[0057] FIG. 6( f ) As shown, the thickness of the oil layer of the mask oil M1 applied to the longitudinal slit portion 141, each widthwise slit portion 142, and the second insulation margin portion 121 is greater than the thickness of the metal layer of the second electrode portion 140.

[0058] After the formation of the first electrode portion 130, when the first film 110 (raw film F) is wound by the winder 1500 and becomes a roll shape, the first film 110 overlaps. Therefore, due to the capillary phenomenon occurring between the first film 110 and the first electrode portion 130, the mask oil M1 applied to each non-electrode portion 131 and the first insulating margin portion 111 spreads around. As a result, coating layers 132 and 133 made of the mask oil M1 as shown in FIGS. 3(a) and 3(b) are formed.

[0059] Similarly, after the formation of the second electrode portion 140, when the second film 120 (raw film F) is wound by the winder 1500 and becomes a roll shape, the second film 120 overlaps. Therefore, due to the capillary phenomenon occurring between the second film 120 and the second electrode portion 140, the mask oil M1 applied to the longitudinal slit portion 141, each widthwise slit portion 142, and the second insulating margin portion 121 spreads around. As a result, coating layers 146, 147, and 148 made of the mask oil M1 as shown in FIGS. 3(c) and 3(d) are formed.

[0060] Next, a film winding process is performed. In the film winding process, the first film 110 having the first electrode portion 130 formed on the upper film surface 110a is fed out from a first pay-off shaft (not shown), and the second film 120 having the second electrode portion 140 formed on the upper film surface 120a is fed out from a second pay-off shaft (not shown). Then, the first electrode portion 130, the first film 110, the second electrode portion 140, and the second film 120 are wound in this order in an overlapping state such that the first electrode portion 130 is on the inside and the second film 120 is on the outside, and are wound by a winding shaft (not shown). As a result, the capacitor body 10 is formed. When the winding shaft is removed from the capacitor body 10, an elongated cylindrical cavity 11 is formed at the center of the capacitor body 10.

[0061] Even when the capacitor body 10 is formed and the first film 110 and the second film 120 are wound in a roll shape, the mask oil M1 can spread. As a result, the sizes (ranges) of the coating layers 132, 133, 146, 147, and 148 can expand.

[0062] Next, an exterior film coating process is performed. In the exterior film coating process, the exterior film 30 is wound around the outer peripheral surface of the capacitor body 10 a plurality of times, and each layer of the exterior film 30 is heat-welded. As a result, the outer peripheral surface of the capacitor body 10 is covered with a plurality of layers of the exterior film 30.

[0063] Next, a core body insertion process is performed. In the core body insertion process, the core body 20 is inserted into the cavity 11 of the capacitor body 10. The diameter of the core body 20 is larger than the diameter of the cavity 11 of the capacitor body 10, and the core body 20 is press-fitted into the cavity 11. The outer peripheral surface of the core body 20 contacts the inner peripheral surface of the cavity 11.

[0064] Next, a metal spraying process is performed. In the metal spraying process, metal is sprayed from a spraying device (not shown) onto the first end face 12 and the second end face 13 of the capacitor body 10 in which the cavity 11 is filled with the core body 20. As a result, the first end face electrode 40 is formed on the first end face 12, and the second end face electrode 50 is formed on the second end face 13.

[0065] Thereby, the film capacitor 1A is formed.

[0066] Finally, an aging process is performed, and the film capacitor 1A is heated to a predetermined temperature. When the film capacitor 1A becomes hot, the first film 110 and the second film 120 thermally contract, and the viscosity of the mask oil M1 decreases. As a result, the mask oil M1 spreads, and the sizes (ranges) of the coating layers 132, 133, 146, 147, 148 spread.

[0067] Thus, the manufacturing process is completed, and the film capacitor 1A is completed.

[0068] <Effect of Embodiment 1> As described above, according to the present Embodiment 1, the following effects are achieved.

[0069] (1) The manufacturing method of the film capacitor 1A includes a step of applying a mask oil M1 that prevents metal vapor deposition to a portion of the film surface 110a of the first film 110 outside the electrode region R1 that becomes at least the first electrode portion 130; a step of vapor-depositing metal on the film surface 110a coated with the mask oil M1 to form the first electrode portion 130; a step of applying a mask oil M1 that prevents metal vapor deposition to a portion of the film surface 120a of the second film 120 outside the electrode region R2 that becomes at least the second electrode portion 140; a step of vapor-depositing metal on the film surface 120a coated with the mask oil M1 to form the second electrode portion 140; and a step of winding the first film 110 and the second film 120 on which the first electrode portion 130 and the second electrode portion 140 are formed. On the film surface 110a of the first film 110, in the step of applying the mask oil M1, a plurality of non-electrode portions 131 having a predetermined shape (circular shape) coated with the mask oil M1 are dispersedly arranged at intervals larger than the size of the non-electrode portions 131 within the electrode region R1 that becomes the first electrode portion 130.

[0070] The second electrode portion 140 is divided into a plurality of divided electrode portions 144 in the longitudinal direction of the second electrode portion 140 by a plurality of widthwise slit portions 142 in which no metal is vapor-deposited and extending in the width direction of the second electrode portion 140, and the first electrode portion 130 is not divided in the longitudinal direction of the first electrode portion 130.

[0071] According to this manufacturing method, in the film capacitor 1A, the surface of the first electrode portion 130 is covered with a coating layer 132 made of the mask oil M1 spreading from the plurality of non-electrode portions 131 and is protected by these coating layers 132. Thereby, oxidation of the first electrode portion 130 due to corona discharge generated when a voltage is applied to the film capacitor 1A can be suppressed, and a decrease in capacitance due to oxidation can be suppressed.

[0072] In the film capacitor 1A, the surface of each divided electrode portion 144 of the second electrode portion 140 is covered by a coating layer 147 made of mask oil M1 that has spread from the widthwise slit portion 142 and a coating layer 148 made of mask oil M1 that has spread from the second insulating margin portion 121 outside the electrode region R2 that becomes the second electrode portion 140, and is protected by these coating layers 147 and 148. Thereby, oxidation of each divided electrode portion 144 of the second electrode portion 140 due to corona discharge can be suppressed, and a decrease in capacitance due to oxidation can be suppressed.

[0073] (2) In the method for manufacturing the film capacitor 1A, the plurality of non-electrode portions 131 are formed such that their diameters are 0.05 mm or more and 5.0 mm or less.

[0074] According to this manufacturing method, by setting the diameters of the non-electrode portions 131 within the above range, the size (range) of the coating layer 132 does not become too small, the first electrode portion 130 can be sufficiently covered by the plurality of coating layers 132, and the oxidation suppression effect can be sufficiently exhibited. Also, the effective area of the first electrode portion 130 does not become too small, and a sufficient capacitance can be obtained.

[0075] (3) In the method for manufacturing the film capacitor 1A, the plurality of non-electrode portions 131 are arranged in a lattice pattern. In particular, the plurality of non-electrode portions 131 are formed in a circular shape and arranged in a triangular lattice pattern.

[0076] According to this manufacturing method, the occurrence of gaps not covered by the plurality of coating layers 132 is reduced, and the plurality of coating layers 132 can uniformly cover many regions of the surface of the first electrode portion 130.

[0077] (4) The method for manufacturing the film capacitor 1A further includes an aging process as a process of heating the wound first film 110 and second film 120.

[0078] According to this manufacturing method, when heated, the first film 110 and the second film 120 thermally contract, and at the same time, the viscosity of the mask oil M1 decreases. As a result, the mask oil M1 spreads, so that the size (range) of the coating layer 132 can be increased.

[0079] (5) The film capacitor 1A includes a first film 110 and a second film 120 that are wound in a state of being overlapped with each other, a first electrode portion 130 formed by vapor deposition of a metal on the film surface 110a of the first film 110, and a second electrode portion 140 formed by vapor deposition of a metal on the film surface 120a of the second film 120. A plurality of non-electrode portions 131 having a predetermined shape (circular shape), on which the mask oil M1 is applied and no metal is vapor-deposited, are dispersedly arranged at intervals larger than the size of the non-electrode portions 131, and the surface around the non-electrode portions 131 in the first electrode portion 130 is covered with a coating layer 132 made of the mask oil M1 that has spread from the non-electrode portions 131.

[0080] The second electrode portion 140 is divided into a plurality of divided electrode portions 144 in the longitudinal direction of the second electrode portion 140 by a plurality of widthwise slit portions 142 extending in the widthwise direction of the second electrode portion 140 and on which no metal is vapor-deposited, and the first electrode portion 130 is not divided in the longitudinal direction of the first electrode portion 130.

[0081] According to this configuration, the surface of the first electrode portion 130 is protected by the plurality of coating layers 132. Thereby, oxidation of the first electrode portion 130 due to corona discharge generated when a voltage is applied to the film capacitor 1A can be suppressed, and a decrease in capacitance due to oxidation can be suppressed.

[0082] Note that the surfaces of the divided electrode portions 144 of the second electrode portion 140 are covered by a coating layer 147 made of mask oil M1 that has spread from the width-direction slit portion 142 and a coating layer 148 made of mask oil M1 that has spread from the second insulating margin portion 121 outside the electrode region R2 that becomes the second electrode portion 140, and are protected by these coating layers 147 and 148. Thereby, oxidation of each divided electrode portion 144 of the second electrode portion 140 due to corona discharge can be suppressed, and a decrease in capacitance due to oxidation can be suppressed.

[0083] <Embodiment 2> [Configuration of Film Capacitor] The film capacitor 1B according to Embodiment 2 will be described.

[0084] FIG. 7(a) is a perspective view of the film capacitor 1B. FIG. 7(b) is a cross-sectional view of the film capacitor 1B cut along the axial direction.

[0085] The film capacitor 1B has a cylindrical shape with a circular cross-section, and includes a capacitor body 60, a winding core body 20, an exterior film 30, a first end face electrode 40, and a second end face electrode 50. The configuration of the capacitor body 60 of the film capacitor 1B is different from that of the capacitor body 10 of the above-described Embodiment 1.

[0086] The capacitor body 60 is configured by overlapping a first film 210 and a second film 220 and winding them such that the first film 210 is on the inside and the second film 220 is on the outside. On one (upper) film surface 210a of the first film 210, a first electrode portion 230 is formed. On one (upper) film surface 220a of the second film 220, a second electrode portion 240 is formed. The film surface 220a faces the other film surface 210b of the first film 210.

[0087] In the capacitor body 60, the portion where the first electrode portion 230 and the second electrode portion 240 overlap becomes the effective electrode region W. A winding core body 20 is inserted into the cavity portion 61 of the capacitor body 60.

[0088] FIG. 8(a) is a plan view of the first film 210 on which the first electrode portion 230 is formed. FIG. 8(b) is a plan view of the second film 220 on which the second electrode portion 240 is formed. In FIGS. 8(a) and 8(b), for convenience, the first film 210 and the second film 220 are drawn short in their longitudinal directions. Also, the first electrode portion 230 and the second electrode portion 240 are hatched.

[0089] The first film 210 and the second film 220 are transparent dielectric films, similar to the first film 110 and the second film 120 of the above-described Embodiment 1, and have substantially equal width dimensions. On one end of the first film 210 in its width direction, a first insulating margin portion 211 that extends continuously without interruption in its longitudinal direction is formed. On the end of the second film 220 in its width direction opposite to one end of the first film 210, a second insulating margin portion 221 that extends continuously without interruption in its longitudinal direction is formed. The first insulating margin portion 211 and the second insulating margin portion 221 are margin portions on which no metal is deposited.

[0090] The first electrode portion 230 and the second electrode portion 240 are vapor-deposited electrodes composed of an aluminum-containing layer, similar to the first electrode portion 130 and the second electrode portion 140 of the above-described Embodiment 1.

[0091] In the first electrode portion 230, a longitudinal slit portion 231 that extends in its longitudinal direction is formed substantially at the center. Also, in the first electrode portion 230, a plurality of widthwise slit portions 232 that extend in its width direction are formed at predetermined intervals in its longitudinal direction. Each widthwise slit portion 232 has one end connected to the longitudinal slit portion 231 and the other end connected to the first insulating margin portion 211. No metal is deposited on the longitudinal slit portion 231 and the widthwise slit portions 232.

[0092] By forming the longitudinal slit portion 231 and the plurality of widthwise slit portions 232, the first electrode portion 230 includes, on both sides of the longitudinal slit portion 231, a plurality of divided electrode portions 233 longitudinally divided by the plurality of widthwise slit portions 232, and an undivided electrode portion 234 that is not longitudinally divided.

[0093] Between each divided electrode portion 233 and the undivided electrode portion 234, a fuse pattern 235 is formed so as to span the longitudinal slit portion 231. The pattern width of the fuse pattern 235 is set to about 0.5 mm, for example.

[0094] In the undivided electrode portion 234, a plurality of non - electrode portions 236 where no metal is deposited are dispersedly arranged at intervals larger than the size of the non - electrode portion 236 over the entire area. The plurality of non - electrode portions 236 have a circular shape.

[0095] The second electrode portion 240 has a form in which the first electrode portion 230 is inverted in the width direction, and includes, on both sides of the longitudinal slit portion 241, a plurality of divided electrode portions 243 longitudinally divided by the plurality of widthwise slit portions 242, and an undivided electrode portion 244 that is not longitudinally divided. A fuse pattern 235 is formed between each divided electrode portion 243 and the undivided electrode portion 244. In the undivided electrode portion 244, a plurality of circular non - electrode portions 246 are dispersedly arranged at intervals larger than the size of the non - electrode portion 246 over the entire area.

[0096] As shown in Fig. 7(b), in a state where the first film 210 and the second film 220 are overlapped and wound (a state where the capacitor body 60 is formed), a plurality of divided electrode portions 233 of the first electrode portion 230 overlap with the non-divided electrode portion 244 of the second electrode portion 240, and the non-divided electrode portion 234 of the first electrode portion 230 overlaps with a plurality of divided electrode portions 243 of the second electrode portion 240. Further, the longitudinal slit portion 231 of the first electrode portion 230 overlaps with the longitudinal slit portion 241 of the second electrode portion 240. The non-divided electrode portion 234 of the first electrode portion 230 is connected to the second end face electrode 50 formed on the second end face 63 of the capacitor body 60. The non-divided electrode portion 244 of the second electrode portion 240 is connected to the first end face electrode 40 formed on the first end face 62 of the capacitor body 60.

[0097] Fig. 9(a) is an enlarged plan view of a main part of the first film 210 on which the first electrode portion 230 is formed. Fig. 9(b) is an end view taken along the line A - A' of Fig. 9(a). Fig. 9(c) is an enlarged plan view of a main part of the second film 220 on which the second electrode portion 240 is formed. Fig. 9(d) is an end view taken along the line B - B' of Fig. 9(c). In Figs. 9(a) and 9(c), the mask oil M1 is shown by diagonal hatching. Also, in Figs. 9(a) and 9(c), the coating layers 251, 252, 253, 254, 261, 262, 263, 264 are shown by broken lines.

[0098] As shown in Figs. 9(a) to 9(d), in the non-divided electrode portions 234 and 244 of the first electrode portion 230 and the second electrode portion 240, a plurality of non-electrode portions 236 and 246 are dispersedly arranged in a triangular lattice pattern. The mask oil M1 is applied to the plurality of non-electrode portions 236 and 246. Further, the mask oil M1 is also applied to the longitudinal slit portions 231 and 241 and the widthwise slit portions 232 and 242 of the first electrode portion 230 and the second electrode portion 240, and the insulating margin portions 211 and 221.

[0099] The surfaces around each non - electrode part 236, 246 in the non - divided electrode parts 234, 244 are covered by coating layers 251, 261 which are nearly circular in shape and consist of mask oil M1 spreading from each non - electrode part 236, 246. Also, the surfaces of the vicinity parts of the longitudinal slit parts 231, 241 of the non - divided electrode parts 234, 244 are covered by coating layers 252, 262 which consist of mask oil M1 spreading from the longitudinal slit parts 231, 241. Further, each divided electrode part 233, 243 is covered by coating layer 252, 262, coating layers 253, 263 which consist of mask oil M1 spreading from the width - direction slit parts 232, 242, and coating layers 254, 264 which consist of mask oil M1 spreading from the insulating margin parts 211, 221.

[0100] In this way, in the first electrode part 230, since the surface of the non - divided electrode part 234 is protected by the coating layers 251, 252 and the surface of each divided electrode part 233 is protected by the coating layers 252, 253, 254, the adhesion of water to the surfaces of the non - divided electrode part 234 and each divided electrode part 233 is suppressed. Similarly, in the second electrode part 240, since the surface of the non - divided electrode part 244 is protected by the coating layers 261, 262 and the surface of each divided electrode part 243 is protected by the coating layers 262, 263, 264, the adhesion of water to the surfaces of the non - divided electrode part 244 and each divided electrode part 243 is suppressed. Thereby, even if corona discharge occurs when a voltage is applied to the film capacitor 1B, the oxidation of the non - divided electrode parts 234, 244 and each divided electrode part 233, 243 due to the corona discharge is suppressed.

[0101] Note that, similar to the above - mentioned Embodiment 1, in order for the oxidation - suppressing effect to be sufficiently exhibited and for a sufficient capacitance to be obtained, it is desirable that the diameter of each non - electrode part 236, 246 be 0.05 mm or more and 5.0 mm or less.

[0102] [Manufacturing Method of Film Capacitor] Next, the manufacturing method of the film capacitor 1B will be described.

[0103] The film capacitor 1B is manufactured by the manufacturing process shown in FIG. 6, similar to the film capacitor 1A of the above-described Embodiment 1. In the mask agent application step and the vapor deposition electrode formation step, the vapor deposition apparatus 1000 shown in FIG. 5(a) is used.

[0104] FIG. 10(a) is a plan view showing a first film 210 coated with a mask oil M1. FIGS. 10(b) and 10(c) are a plan view and an end view, respectively, showing the first film 210 on which a first electrode portion 230 is vapor-deposited.

[0105] As shown in FIG. 10(a), on the film surface 210a of the first film 210, in the mask agent application step, by the oil spray unit 1200 and the oil printing unit 1300, in the electrode region R3 that becomes the first electrode portion 230, in the portions (regions) that become a plurality of non-electrode portions 236, the portion (region) that becomes the longitudinal slit portion 231, and the portion (region) that becomes the widthwise slit portion 232, and in the portion (region) that becomes the first insulating margin portion 211 outside the electrode region R3, the mask oil M1 is applied, and a plurality of non-electrode portions 236, the longitudinal slit portion 231, a plurality of widthwise slit portions 232, and the first insulating margin portion 211 are formed. The plurality of non-electrode portions 236 are dispersedly arranged in a triangular lattice pattern. The plurality of non-electrode portions 236 are preferably formed such that their diameters are 0.05 mm or more and 5.0 mm or less.

[0106] Thereafter, as shown in FIG. 10(b), on the film surface 210a of the first film 210 coated with the mask oil M1, in the vapor deposition electrode formation step, by the electrode vapor deposition unit 1400, metal vapor deposition is performed on the electrode region R3 to form the first electrode portion 230, that is, the non-divided electrode portion 234 and the plurality of divided electrode portions 233.

[0107] As shown in FIG. 10(c), the thickness of the oil layer of the mask oil M1 applied to each non-electrode portion 236, the longitudinal slit portion 231, each widthwise slit portion 232, and the first insulating margin portion 211 is larger than the thickness of the metal layer of the first electrode portion 230.

[0108] FIG. 10(d) is a plan view showing the second film 220 coated with the mask oil M1. FIGS. 10(e) and (f) are a plan view and an end view, respectively, showing the second film 220 on which the second electrode portion 240 is formed by vapor deposition.

[0109] As shown in FIG. 10(d), on the film surface 220a of the second film 220, in the mask agent coating step, by the oil spraying unit 1200 and the oil printing unit 1300, in the electrode region R4 that becomes the second electrode portion 240, in the portions (regions) that become the plurality of non-electrode portions 246, the portion (region) that becomes the longitudinal slit portion 241, and the portion (region) that becomes the widthwise slit portion 242, and in the portion (region) that becomes the second insulating margin portion 221 outside the electrode region R4, the mask oil M1 is applied, and the plurality of non-electrode portions 246, the longitudinal slit portion 241, the plurality of widthwise slit portions 242, and the second insulating margin portion 221 are formed. The plurality of non-electrode portions 246 are dispersedly arranged in a triangular lattice pattern. The plurality of non-electrode portions 246 are preferably formed so that their diameters are 0.05 mm or more and 5.0 mm or less.

[0110] Thereafter, as shown in FIG. 10(e), on the film surface 220a of the second film 220 coated with the mask oil M1, in the vapor deposition electrode formation step, by the electrode vapor deposition unit 1400, metal vapor deposition is performed on the electrode region R4 to form the second electrode portion 240, that is, the non-divided electrode portion 244 and the plurality of divided electrode portions 243.

[0111] As shown in FIG. 10(f), the thickness of the oil layer of the mask oil M1 applied to each non-electrode portion 246, the longitudinal slit portion 241, each widthwise slit portion 242, and the second insulating margin portion 221 is larger than the thickness of the metal layer of the second electrode portion 240.

[0112] After the formation of the first electrode portion 230, when the first film 210 is wound by the winder 1500 and becomes a roll shape, the first film 210 overlaps. Due to the capillary phenomenon occurring between the first film 210 and the first electrode portion 230, the mask oil M1 applied to each non-electrode portion 236, the longitudinal slit portion 231, each widthwise slit portion 232, and the first insulating margin portion 211 spreads around. As a result, coating layers 251, 252, 253, 254 made of the mask oil M1 as shown in FIGS. 9(a) and 9(b) are formed.

[0113] Similarly, after the formation of the second electrode portion 240, when the second film 220 is wound by the winder 1500 and becomes a roll shape, the second film 220 overlaps. Due to the capillary phenomenon occurring between the second film 220 and the second electrode portion 240, the mask oil M1 applied to each non-electrode portion 246, the longitudinal slit portion 241, each widthwise slit portion 242, and the second insulating margin portion 221 spreads around. As a result, coating layers 261, 262, 263, 264 made of the mask oil M1 as shown in FIGS. 9(c) and 9(d) are formed.

[0114] Note that thereafter, when the capacitor body 60 is formed in the film winding process and the first film 210 and the second film 220 are wound in a roll shape, the mask oil M1 can also spread. As a result, the sizes (ranges) of the coating layers 251, 252, 253, 254, 261, 262, 263, 264 can expand.

[0115] Furthermore, in the aging process, when the film capacitor 1B is at a high temperature, the first film 210 and the second film 220 thermally contract, and at the same time, the viscosity of the mask oil M1 decreases, the mask oil M1 spreads, and the sizes (ranges) of the coating layers 251, 252, 253, 254, 261, 262, 263, 264 expand.

[0116] <Effect of Embodiment 2> As described above, according to the present Embodiment 2, the following effects are achieved.

[0117] The manufacturing method of the film capacitor 1B includes a step of applying a mask oil M1 that prevents metal deposition to a portion of the film surface 210a of the first film 210 outside the electrode region R3 that becomes at least the first electrode portion 230, a step of depositing metal on the film surface 210a coated with the mask oil M1 to form the first electrode portion 230, a step of applying a mask oil M1 that prevents metal deposition to a portion of the film surface 220a of the second film 220 outside the electrode region R3 that becomes at least the second electrode portion 240, a step of depositing metal on the film surface 220a coated with the mask oil M1 to form the second electrode portion 240, and a step of winding the first film 210 and the second film 220 on which the first electrode portion 230 and the second electrode portion 240 are formed. On the film surface 210a of the first film 210 and the film surface 220a of the second film 220, in the step of applying the mask oil M1, a plurality of non-electrode portions 236, 246 having a predetermined shape (circular shape) coated with the mask oil M1 are dispersed and arranged at intervals larger than the sizes of the non-electrode portions 236, 246 within the electrode region R3 that becomes the first electrode portion 230 and within the electrode region R4 that becomes the second electrode portion 240.

[0118] The first electrode portion 230 and the second electrode portion 240 include a plurality of divided electrode portions 233, 243 that are divided in their longitudinal direction by a plurality of widthwise slit portions 232, 242 that extend in their width direction and where metal is not deposited on both sides of the longitudinal slit portions 231, 241 where metal is not deposited and that extend in their longitudinal direction, and non-divided electrode portions 234, 244 that are not divided in their longitudinal direction. A plurality of divided electrode portions 233 of the first electrode portion 230 overlap with the non-divided electrode portion 244 of the second electrode portion 240, and the non-divided electrode portion 234 of the first electrode portion 230 overlaps with a plurality of divided electrode portions 243 of the second electrode portion 240. A plurality of non-electrode portions 236, 246 are dispersed and arranged within the regions that become the non-divided electrode portions 234, 244 within the electrode regions R3, R4.

[0119] According to this manufacturing method, in the film capacitor 1B, the surfaces of the non-divided electrode portions 234 and 244 in the first electrode portion 230 and the second electrode portion 240 are covered with the coating layers 251 and 261 made of the mask oil M1 that has spread from the plurality of non-electrode portions 236 and 246, and are protected by these coating layers 251 and 261. Thereby, oxidation of the non-divided electrode portions 234 and 244 due to corona discharge generated when a voltage is applied to the film capacitor 1B can be suppressed, and a decrease in capacitance due to oxidation can be suppressed.

[0120] In the film capacitor 1B, the surfaces of the respective divided electrode portions 233 and 243 in the first electrode portion 230 and the second electrode portion 240 are covered with the coating layers 252 and 262 made of the mask oil M1 that has spread from the longitudinal slit portions 231 and 241, the coating layers 253 and 263 made of the mask oil M1 that has spread from the widthwise slit portions 232 and 242, and the coating layers 254 and 264 made of the mask oil M1 that has spread from the insulating margin portions 211 and 221 outside the electrode regions R3 and R4, and are protected by these coating layers 252, 253, 254, 262, 263, and 264. Thereby, oxidation of the respective divided electrode portions 233 and 243 due to corona discharge can be suppressed, and a decrease in capacitance due to oxidation can be suppressed.

[0121] Furthermore, according to the manufacturing method of the film capacitor 1B, the same effects as those of (2) to (4) achieved by the manufacturing method of the film capacitor 1A of the above Embodiment 1 are achieved.

[0122] Furthermore, the film capacitor 1B includes a first film 210 and a second film 220 that are wound in a state of being overlapped with each other, a first electrode portion 230 formed on the film surface 210a of the first film 210 by vapor deposition of a metal, and a second electrode portion 240 formed on the film surface 220a of the second film 220 by vapor deposition of a metal. A plurality of non-electrode portions 236, 246 having a predetermined shape (circular shape), on which mask oil M1 is applied and no metal is vapor-deposited, are dispersedly arranged at intervals larger than the sizes of the non-electrode portions 236, 246, and the surfaces around the non-electrode portions 236, 246 in the first electrode portion 230 and the second electrode portion 240 are covered with coating layers 251, 261 made of mask oil M1 that has spread from the non-electrode portions 236, 246.

[0123] The first electrode portion 230 and the second electrode portion 240 are each divided in the longitudinal direction into a plurality of divided electrode portions 233, 243 and non-divided electrode portions 234, 244 that are not divided in the longitudinal direction, by a plurality of widthwise slit portions 232, 242 that extend in the width direction on both sides of longitudinal slit portions 231, 241 where no metal is vapor-deposited and that extend in the longitudinal direction thereof. A plurality of divided electrode portions 233 of the first electrode portion 230 overlap with the non-divided electrode portion 244 of the second electrode portion 240, and the non-divided electrode portion 234 of the first electrode portion 230 overlaps with a plurality of divided electrode portions 243 of the second electrode portion 240. A plurality of non-electrode portions 236, 246 are dispersedly arranged in the regions that become the non-divided electrode portions 234, 244 within the electrode regions R3, R4.

[0124] According to this configuration, the surfaces of the non-divided electrode portions 234, 244 in the first electrode portion 230 and the second electrode portion 240 are protected by the plurality of coating layers 251, 261. Thereby, oxidation of the non-divided electrode portions 234, 244 due to corona discharge generated when a voltage is applied to the film capacitor 1B can be suppressed, and a decrease in capacitance due to oxidation can be suppressed.

[0125] Note that the surfaces of the divided electrode portions 233 and 243 in the first electrode portion 230 and the second electrode portion 240 are covered by a coating layer 252 and 262 made of mask oil M1 that spreads from the longitudinal slit portions 231 and 241, a coating layer 253 and 263 made of mask oil M1 that spreads from the widthwise slit portions 232 and 242, and a coating layer 254 and 264 made of mask oil M1 that spreads from the insulation margin portions 211 and 221 outside the electrode regions R3 and R4, and are protected by these coating layers 252, 253, 254, 262, 263, and 264. Thereby, oxidation of each of the divided electrode portions 233 and 243 due to corona discharge can be suppressed, and a decrease in capacitance due to oxidation can be suppressed.

[0126] As described above, Embodiments 1 and 2 of the present invention have been described. However, the present invention is not limited to the above embodiments, and various modifications are possible for the application examples of the present invention in addition to the above embodiments.

[0127] For example, in the above Embodiment 1, no non-electrode portion is formed in each of the divided electrode portions 144 of the second electrode portion 140. Similarly, in the above Embodiment 2, no non-electrode portion is formed in each of the divided electrode portions 233 and 243 of the first electrode portion 230 and the second electrode portion 240.

[0128] However, in the above Embodiment 1, as shown in FIG. 11, a non-electrode portion 150 may be formed at the center of each of the divided electrode portions 144 that are difficult to be covered by the coating layers 146, 147, and 148. In this case, the central region of the surface of each of the divided electrode portions 144 is covered by a coating layer 151 made of mask oil M1 that spreads from the non-electrode portion 150. Note that a plurality of non-electrode portions 150 may be provided in one divided electrode portion 144.

[0129] Similarly, in the above-described Embodiment 2, as shown in FIG. 12(a), a non-electrode portion 237 may be formed at the center of each divided electrode portion 233 of the first electrode portion 230 that is difficult to be covered by the coating layers 252, 253, and 254. Further, as shown in FIG. 12(b), a non-electrode portion 247 may be formed at the center of each divided electrode portion 243 of the second electrode portion 240 that is difficult to be covered by the coating layers 262, 263, and 264. In this case, the central regions of the surfaces of the divided electrode portions 233 and 243 are covered with coating layers 255 and 265 made of mask oil M1 that has spread from the non-electrode portions 237 and 247. Note that a plurality of non-electrode portions 237 and 247 may be provided in one divided electrode portion 233 or 243.

[0130] Furthermore, in the above-described Embodiments 1 and 2, the non-electrode portions 131, 236, and 246 are formed in a circular shape. However, the non-electrode portions 131, 236, and 246 may have any shape, for example, they may be formed in an oval shape or a rectangular shape.

[0131] Furthermore, in the above-described Embodiments 1 and 2, the plurality of non-electrode portions 131, 236, and 246 are dispersedly arranged in a triangular lattice. However, the plurality of non-electrode portions 131, 236, and 246 may be dispersedly arranged in a square lattice. Also, as long as the plurality of non-electrode portions 131, 236, and 246 are dispersedly arranged, they do not have to be dispersedly arranged in a lattice.

[0132] Furthermore, in the above-described Embodiment 1, the width-direction slit portion 142 of the second electrode portion 140 is formed so as to incline from the width direction, but it may be formed to be parallel to the width direction. Also, in the above-described Embodiment 2, the width-direction slit portions 232 and 242 of the first electrode portion 230 and the second electrode portion 240 are formed to be parallel to the width direction, but they may be formed to incline from the width direction.

[0133] Furthermore, in the above-described Embodiments 1 and 2, the second electrode portions 140 and 240 are formed on the film surfaces 120a and 220a of the second films 120 and 220. However, as shown in FIGS. 13(a) and 13(b), the second electrode portions 140 and 240 may be formed on the other film surfaces 110b and 210b of the first films 110 and 210 that face away from one of the film surfaces 110a and 210a.

[0134] Furthermore, in the above-described Embodiment 1, the configurations of the first electrode portion 130 and the second electrode portion 140 may be interchanged. That is, the first electrode portion 130 may be configured to be divided into a plurality of divided electrode portions in its longitudinal direction by a plurality of widthwise slit portions, and the second electrode portion 140 may be configured not to be divided in its longitudinal direction.

[0135] Furthermore, in the above-described Embodiments 1 and 2, the film capacitors 1A and 1B are formed in a cylindrical shape with a circular cross-section. However, as shown in FIG. 13(c), the film capacitors 1A and 1B may be formed in a flat cylindrical shape with an oval cross-section. In this case, the winding core 20 is eliminated, and in the manufacturing process, instead of the winding core insertion process, a pressing process for crushing the capacitor bodies 10 and 60 is performed. When the capacitor bodies 10 and 60 are crushed, the coating layers 132, 251, 261, etc. can expand.

[0136] Furthermore, the film capacitor of the present invention is not limited to the film capacitors 1A and 1B of the above-described Embodiments 1 and 2. For example, the film capacitor may be configured such that both the first electrode portion and the second electrode portion do not include divided electrode portions. In this case, a plurality of non-electrode portions may be dispersedly arranged on both the first electrode portion and the second electrode portion.

[0137] Furthermore, in the above-described Embodiments 1 and 2, the first films 110 and 210 and the second films 120 and 220 are wound in a state where they are overlapped with each other, thereby forming the capacitor bodies 10 and 60 (film capacitors 1A and 1B). However, the capacitor bodies 10 and 60 may be formed by laminating the first films 110 and 210 and the second films 120 and 220 in a state where they are overlapped with each other.

[0138] 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

[0139] The present invention is useful for film capacitors used in various electronic devices, electrical devices, industrial devices, vehicle electrical systems, etc., and manufacturing methods of such film capacitors.

Explanation of Reference Numerals

[0140] 1A, 1B Film capacitors 110, 210 First films 110a, 210a Film surfaces (first film surfaces) 120, 220 Second films 120a, 220a Film surfaces (second film surfaces) 130, 230 First electrode portions 131, 236, 246 Non-electrode portions 132, 251, 261 Coating layers 140, 240 Second electrode portions 141, 231, 241 Longitudinal slit portions 142, 232, 242 Widthwise slit portions 144, 233, 243 Divided electrode portions 234, 244 Non-divided electrode portions M1 Mask oil (masking agent) R1, R2, R3, R4 Electrode regions

Claims

1. A first film and a second film wound or laminated in a state of being overlapped with each other, a first electrode portion formed by vapor deposition of a metal on a first film surface which is one film surface of the first film, a second electrode portion formed by vapor deposition of a metal on the other film surface of the first film or a second film surface which is a film surface of the second film facing the other film surface, and a method for manufacturing a film capacitor, a step of applying a masking agent for preventing vapor deposition of the metal to a portion outside at least the electrode region that becomes the first electrode portion on the first film surface, a step of forming the first electrode portion by vapor depositing the metal on the first film surface coated with the masking agent, a step of applying a masking agent for preventing vapor deposition of the metal to a portion outside at least the electrode region that becomes the second electrode portion on the second film surface, a step of forming the second electrode portion by vapor depositing the metal on the second film surface coated with the masking agent, a step of winding or laminating the first film and the second film on which the first electrode portion and the second electrode portion are formed, and comprising, on at least one of the first film surface and the second film surface, in the step of applying the masking agent, a plurality of non-electrode portions having a circular shape, an oval shape or a square shape coated with the masking agent are dispersed and arranged in a triangular lattice or a square lattice at intervals larger than the size of the non-electrode portions within the electrode region, A method for manufacturing a film capacitor, characterized in that.

2. The plurality of non-electrode portions have a circular shape and are formed such that their diameter is 0.05 mm or more and 5.0 mm or less, A method for manufacturing a film capacitor according to claim 1, characterized in that.

3. A first film and a second film wound or laminated in a state of being overlapped with each other, a first electrode portion formed by vapor deposition of a metal on a first film surface which is one film surface of the first film, a second electrode portion formed by vapor deposition of a metal on the other film surface of the first film or a second film surface which is a film surface of the second film facing the other film surface, and a method for manufacturing a film capacitor, a step of applying a masking agent for preventing vapor deposition of the metal to a portion outside at least the electrode region that becomes the first electrode portion on the first film surface, A step of depositing the metal on the first film surface coated with the masking agent to form the first electrode portion; A step of applying a masking agent that prevents deposition of the metal to a portion of the second film surface other than at least the electrode region that becomes the second electrode portion; A step of depositing the metal on the second film surface coated with the masking agent to form the second electrode portion; A step of winding or laminating the first film and the second film on which the first electrode portion and the second electrode portion are formed; and On one of the first film surface and the second film surface, in the step of applying the masking agent, a plurality of non-electrode portions having a predetermined shape coated with the masking agent are dispersed and arranged at intervals larger than the size of the non-electrode portions within the electrode region; One of the first electrode portion and the second electrode portion is divided into a plurality of divided electrode portions in the longitudinal direction of the one electrode portion by a plurality of widthwise slit portions in which the metal is not deposited and which extend in the width direction of the one electrode portion; The other electrode portion is not divided in the longitudinal direction of the other electrode portion; The plurality of non-electrode portions are dispersed and arranged within the electrode region that becomes the other electrode portion; A method for manufacturing a film capacitor, characterized by the above.

4. A first film and a second film wound or laminated in a state of being overlapped with each other, A first electrode portion formed by deposition of a metal on a first film surface that is one film surface of the first film; A method for manufacturing a film capacitor, comprising: a second electrode portion formed by deposition of a metal on a second film surface that is the other film surface of the first film or the film surface of the second film facing the other film surface, A step of applying a masking agent that prevents deposition of the metal to a portion of the first film surface other than at least the electrode region that becomes the first electrode portion; A step of depositing the metal on the first film surface coated with the masking agent to form the first electrode portion; A step of applying a masking agent that prevents deposition of the metal to a portion of the second film surface other than at least the electrode region that becomes the second electrode portion; A step of depositing the metal on the second film surface coated with the masking agent to form the second electrode portion; A step of winding or laminating the first film and the second film on which the first electrode portion and the second electrode portion are formed, In the step of applying the masking agent to at least one of the first film surface and the second film surface, a plurality of non-electrode portions having a predetermined shape coated with the masking agent are dispersed and arranged at intervals larger than the size of the non-electrode portions within the electrode region. The first electrode portion and the second electrode portion include a plurality of divided electrode portions divided in their longitudinal direction by a plurality of widthwise slit portions extending in their width direction on both sides of a longitudinal slit portion where the metal is not vapor-deposited, which extends in their longitudinal direction, and an undivided electrode portion not divided in their longitudinal direction. The plurality of divided electrode portions of the first electrode portion overlap with the undivided electrode portion of the second electrode portion, and the undivided electrode portion of the first electrode portion overlaps with the plurality of divided electrode portions of the second electrode portion. The plurality of non-electrode portions are dispersed and arranged within a region that becomes the undivided electrode portion within the electrode region. A method for manufacturing a film capacitor, characterized by the above.

5. A first film and a second film wound or laminated in a state of being overlapped with each other, A first electrode portion formed by vapor deposition of a metal on a first film surface, which is one film surface of the first film, A film capacitor comprising a second electrode portion formed by vapor deposition of a metal on the other film surface of the first film or a second film surface, which is a film surface of the second film facing the other film surface, One of the first electrode portion and the second electrode portion is divided into a plurality of divided electrode portions in the longitudinal direction of the one electrode portion by a plurality of widthwise slit portions extending in the width direction of the one electrode portion where the metal is not vapor-deposited. The other electrode portion is not divided in the longitudinal direction of the other electrode portion. A plurality of non-electrode portions having a predetermined shape, which are coated with a masking agent and on which the metal is not vapor-deposited, are dispersed and arranged at intervals larger than the size of the non-electrode portions on the other electrode portion. The surface around the non-electrode portion in the other electrode portion is covered with a coating layer made of the masking agent that has spread from the non-electrode portion. A film capacitor, characterized by the above. **Claim 6**: A film capacitor including a first film and a second film wound or laminated so as to overlap each other, a first electrode portion formed by vapor deposition of a metal on a first film surface which is one film surface of the first film, a second electrode portion formed by vapor deposition of a metal on the other film surface of the first film or on a second film surface which is a film surface of the second film facing the other film surface of the first film, wherein the first electrode portion and the second electrode portion each include a plurality of divided electrode portions extending in the width direction thereof and longitudinally divided by a plurality of widthwise slit portions where no metal is deposited on both sides of a longitudinal slit portion where no metal is deposited and extending in the longitudinal direction thereof, and an undivided electrode portion not longitudinally divided, wherein the plurality of divided electrode portions of the first electrode portion overlap the undivided electrode portion of the second electrode portion, and the undivided electrode portion of the first electrode portion overlaps the plurality of divided electrode portions of the second electrode portion, wherein a plurality of non-electrode portions having a predetermined shape, on which a masking agent is applied and on which no metal is deposited, are dispersedly arranged at intervals larger than the size of the non-electrode portions in the undivided electrode portion, wherein the surface around the non-electrode portions in the undivided electrode portion is covered with a coating layer made of the masking agent spreading from the non-electrode portions, characterized in that it is a film capacitor. **Claim 7**: A film capacitor including a first film and a second film wound or laminated so as to overlap each other, a first electrode portion formed by vapor deposition of a metal on a first film surface which is one film surface of the first film, a second electrode portion formed by vapor deposition of a metal on the other film surface of the first film or on a second film surface which is a film surface of the second film facing the other film surface of the first film, wherein a plurality of non-electrode portions having a circular shape, an oval shape or a square shape, on which a masking agent is applied and on which no metal is deposited, are dispersedly arranged in a triangular lattice or a square lattice at intervals larger than the size of the non-electrode portions in at least one of the first electrode portion and the second electrode portion, wherein the surface around the non-electrode portions in the at least one electrode portion is covered with a coating layer made of the masking agent spreading from the non-electrode portions, characterized in that it is a film capacitor.

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