Capacitor module and method of manufacturing the capacitor module

Abstract

This capacitor module is provided with: capacitor elements having bodies covered by laminated films, and first terminal electrodes and second terminal electrodes exposed from the bodies; a case for accommodating the capacitor elements; a first bus bar that is integrally incorporated in the case and that is electrically connected to the first terminal electrodes; and a second bus bar that is integrally incorporated in the case and that is electrically connected to the second terminal electrodes. In the case, one or more recesses for accommodating one or more of the capacitor elements are formed. The first bus bar has one or more first connection parts to be connected to the respective first terminal electrodes of the capacitor elements arranged in the recesses. The second bus bar has one or more second connection parts to be connected to the respective second terminal electrodes of the capacitor elements arranged in the recesses.

Description

[Technical Field]

[0001] The present invention relates to a capacitor module and a method for manufacturing the capacitor module. [Background technology]

[0002] Capacitors that use a laminate film as an exterior material are known. For example, a surface-mounted capacitor described in Patent Document 1 has a capacitor element that is exteriorly covered with a laminate film. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 4354240 Summary of the Invention [Problem to be solved by the invention]

[0004] The surface mount capacitor described in Patent Document 1 has room for improvement in terms of insulation properties and miniaturization when modularized.

[0005] The present invention provides a capacitor module with improved insulation and reduced size, and a method for manufacturing the capacitor module. [Means for solving the problem]

[0006] A capacitor module according to one aspect of the present invention comprises: one or more capacitor elements, each having a body covered with a laminate film and a first terminal electrode and a second terminal electrode exposed from the body; a case that houses the one or more capacitor elements; a first bus bar that is integrally built into the case and electrically connected to the first terminal electrode; a second bus bar that is integrally built into the case and electrically connected to the second terminal electrode; Equipped with the case is formed with one or more recesses for accommodating the one or more capacitor elements, respectively; the first bus bar has one or more first connection portions that are connected to the first terminal electrodes of the capacitor elements that are arranged in the recesses, The second bus bar has one or more second connection portions that connect to the second terminal electrodes of the capacitor elements arranged in the recesses, respectively.

[0007] A method for manufacturing a capacitor module according to one aspect of the present invention includes the steps of: preparing a case that integrally houses a first bus bar and a second bus bar and has a recess that accommodates a capacitor element having a first terminal electrode and a second terminal electrode; placing the capacitor element in the recess of the case; connecting the first bus bar to the first terminal electrode and connecting the second bus bar to the second terminal electrode; Includes. [Effects of the Invention]

[0008] According to the present invention, it is possible to provide a capacitor module with improved insulation and a reduced size, and a method for manufacturing the capacitor module. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a perspective view showing a capacitor module according to a first embodiment; [Figure 2] An exploded perspective view of the capacitor module of FIG. 1. [Figure 3] Exploded view of the capacitor module case in Figure 1 [Figure 4] FIG. 2 is a perspective view showing a capacitor element of the capacitor module of FIG. 1; [Figure 5] AA cross section of the capacitor module in Figure 1 [Figure 6]Cross section B-B of the capacitor module in Figure 1 [Figure 7] Flowchart showing a method for manufacturing a capacitor module [Figure 8A] 1 is a diagram illustrating an example of a manufacturing process for the capacitor module 1. [Figure 8B] 1 is a diagram illustrating an example of a manufacturing process for the capacitor module 1. [Figure 8C] 1 is a diagram illustrating an example of a manufacturing process for the capacitor module 1. [Figure 8D] 1 is a diagram illustrating an example of a manufacturing process for the capacitor module 1. [Figure 9] FIG. 10 is a perspective view showing a capacitor module according to a second embodiment. [Figure 10] An exploded perspective view of the capacitor module of FIG. [Figure 11] Exploded view of the first case of the capacitor module in Figure 9 [Figure 12] Exploded view of the second case of the capacitor module in Figure 9 [Figure 13] FIG. 10 is a perspective view showing a capacitor element of the capacitor module of FIG. [Figure 14] A diagram of the capacitor module in Figure 9, omitting the second case. [Figure 15] An enlarged cross-sectional view of region R1 cut along line CC in Figure 14. [Figure 16] Flowchart showing the method for manufacturing the capacitor module of FIG. 9 [Figure 17] FIG. 10 is a perspective view showing a capacitor module according to a first modification of the second embodiment; [Figure 18] 18 is an exploded perspective view of the capacitor module of FIG. 17. [Figure 19] An exploded view of the first case of the capacitor module of Figure 17 [Figure 20] A flowchart showing a method for manufacturing the capacitor module of FIG. 17. DETAILED DESCRIPTION OF THE INVENTION

[0010] (Background to the invention) Film capacitors that use a laminate film as an exterior material for a capacitor element are known. For example, Patent Document 1 discloses a surface-mounted capacitor that includes a capacitor element having lead-out leads and exteriorly covered with a laminate film, and a fixing plate with external connection terminals.

[0011] Because capacitor elements packaged in a laminate film have excellent weather resistance, they do not need to be entirely covered in resin. However, when capacitor elements packaged in a laminate film are connected to a bus bar to be used as a capacitor module, it is difficult to ensure insulation between the terminal electrodes of the capacitor element and to protect the joints between the terminal electrodes and the bus bar.

[0012] The present inventors have investigated a capacitor module and a method for manufacturing a capacitor module that can improve the insulation between terminal electrodes and easily protect the joints between the terminal electrodes and bus bars, and have arrived at the following invention.

[0013] The capacitor module according to the first aspect of the present invention comprises: one or more capacitor elements, each having a body covered with a laminate film and a first terminal electrode and a second terminal electrode exposed from the body; a case that houses the one or more capacitor elements; a first bus bar that is integrally built into the case and electrically connected to the first terminal electrode; a second bus bar that is integrally built into the case and electrically connected to the second terminal electrode; Equipped with the case is formed with one or more recesses for accommodating the one or more capacitor elements, respectively; the first bus bar has one or more first connection portions that are connected to the first terminal electrodes of the capacitor elements that are arranged in the recesses, The second bus bar has one or more second connection portions that connect to the second terminal electrodes of the capacitor elements arranged in the recesses, respectively.

[0014] With this configuration, it is possible to provide a compact capacitor module while ensuring insulation between the first bus bar and the second bus bar.

[0015] In the capacitor module according to the second aspect of the present invention, each of the one or more recesses includes a first recess in which the main body portion is disposed, a second recess in which the first terminal electrode is disposed, and a third recess in which the second terminal electrode is disposed; the first connection portion is located in the second recess, The second connection portion may be located in the third recess.

[0016] With this configuration, the capacitor element can be easily positioned relative to the case, and therefore the terminal electrodes and the bus bars can be easily joined.

[0017] In the capacitor module according to the third aspect of the present invention, the second recess and the third recess are formed continuously with the first recess, The second recess and the third recess may be spaced apart from each other.

[0018] With this configuration, insulation between the first terminal electrode and the second terminal electrode can be easily ensured.

[0019] In the capacitor module according to the fourth aspect of the present invention, In the case, the first recesses may be arranged side by side in a first direction, and the second recesses and the third recesses may be arranged side by side alternately in the first direction.

[0020] This configuration allows the space inside the case to be used effectively, contributing to the miniaturization of the capacitor module.

[0021] In the capacitor module according to the fifth aspect of the present invention, The case may include a first case in which the first bus bar is built-in, and a second case in which the second bus bar is built-in.

[0022] With this configuration, a smaller capacitor module can be provided.

[0023] In the capacitor module according to the sixth aspect of the present invention, the first connection portion is disposed on an outer surface of the first case, the second connection portion is disposed on an outer surface of the second case, the first terminal electrode has a first extending portion extending from the capacitor element toward an outer surface of the first case, and a first bent portion bent from the first extending portion along the outer surface of the first case, The second terminal electrode may have a second extending portion extending from the capacitor element toward the outer surface of the second case, and a second bent portion bent from the second extending portion along the outer surface of the second case.

[0024] With this configuration, the terminal electrodes and the bus bars are connected to the outer surface of the case, making it possible to provide a smaller capacitor module.

[0025] In the capacitor module according to the seventh aspect of the present invention, The first case and the second case have the same shape, The first bus bar and the second bus bar may have the same shape.

[0026] Such a configuration allows the number of parts to be reduced, thereby reducing manufacturing costs.

[0027] In the capacitor module according to an eighth aspect of the present invention, an opening for exposing the first connection portion is provided on an outer surface of the first case; An opening for exposing the second connection portion may be provided on an outer surface of the second case.

[0028] With this configuration, the capacitor module can be made smaller, and the terminal electrodes and the bus bars can be easily joined.

[0029] A method for manufacturing a capacitor module according to a ninth aspect of the present invention includes the steps of: preparing a case that integrally houses a first bus bar and a second bus bar and has a recess that accommodates a capacitor element having a first terminal electrode and a second terminal electrode; placing the capacitor element in the recess of the case; connecting the first bus bar to the first terminal electrode and connecting the second bus bar to the second terminal electrode; Includes.

[0030] With this configuration, the terminal electrodes and the bus bars can be easily joined together.

[0031] A manufacturing method of a capacitor module according to a tenth aspect of the present invention includes the steps of: preparing a first case having a recess that integrally incorporates a first bus bar and accommodates a capacitor element having a first terminal electrode and a second terminal electrode; preparing a second case that integrally incorporates a second bus bar and has a recess that accommodates the capacitor element; placing the capacitor element in the recess provided in the first case; bending the first terminal electrode and the second terminal electrode; placing the second case over the first case; connecting the first terminal electrode and the first bus bar; connecting the second terminal electrode and the second bus bar; Includes.

[0032] With this configuration, positioning can be easily performed when assembling the capacitor module, and the terminal electrodes and the bus bars can be easily joined.

[0033] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In each drawing, elements are exaggerated for ease of explanation.

[0034] (Embodiment 1) [Overall configuration] Fig. 1 is a perspective view showing a capacitor module 1 according to a first embodiment. Fig. 2 is an exploded perspective view of the capacitor module 1 of Fig. 1. Fig. 3 is an exploded view of a first case 21 of the capacitor module 1 of Fig. 1. Fig. 4 is a perspective view showing a capacitor element 11 of the capacitor module 1 of Fig. 1. Note that the X, Y, and Z directions in the drawings indicate the horizontal, vertical, and height directions of the capacitor module 1, respectively.

[0035] As shown in FIGS. 1 to 3, the capacitor module 1 includes a plurality of capacitor elements 11 (FIG. 2), a case 20, a first bus bar 31 (FIGS. 3 and 2), and a second bus bar .

[0036] <Capacitor element> 4, capacitor element 11 has a main body 12, a first terminal electrode 13, and a second terminal electrode 14. Main body 12 of capacitor element 11 is covered with a laminate film 15.

[0037] Capacitor element 11 is a film capacitor formed, for example, of a wound or laminated body of dielectric film. In this embodiment, capacitor element 11 is a columnar film capacitor having an oval cross section. The dielectric film constituting capacitor element 11 can be, for example, a plastic film such as polyethylene terephthalate, polypropylene, polyphenylene sulfide, or polyethylene naphthalate. The metal vapor deposition film formed on the surface of the plastic film can be, for example, a metal such as aluminum or zinc.

[0038] End surface electrodes (not shown) are formed by metal spraying on both end surfaces of capacitor element 11. Flat plate-shaped first terminal electrode 13 and second terminal electrode 14 are electrically connected to the end surface electrodes, respectively.

[0039] The first terminal electrode 13 and the second terminal electrode 14 are exposed from the main body 12 to the outside of the laminate film 15. In the present embodiment, the first terminal electrode 13 and the second terminal electrode 14 are formed to extend outward from the side surfaces of the columnar main body 12.

[0040] Covering the main body 12 of the capacitor element 11 with the laminate film 15 ensures moisture resistance of the capacitor element 11. The laminate film 15 can be a film formed by laminating a resin film and aluminum foil. Specifically, an aluminum laminate film can be used in which aluminum foil is laminated between a heat-sealable resin film such as unoriented polypropylene (CPP) and a strong resin film such as nylon or polyethylene terephthalate using an adhesive or thermocompression bonding. The aluminum layer has excellent water vapor barrier properties, and covering the main body 12 with an aluminum laminate film having an aluminum layer can improve the moisture resistance of the capacitor element 11. The effects of the present invention are not limited by the constituent materials of the laminate film; any laminate film material that has high adhesion between laminate films, water vapor barrier properties, strength, or durability can be appropriately used.

[0041] In this embodiment, three capacitor elements 11 are housed in case 20.

[0042] <Case> Case 20 is a member that houses capacitor element 11. In this embodiment, case 20 includes a first case 21 that is formed with three recesses 22 that house capacitor element 11, and a second case 26 that covers first case 21. First case 21 of case 20 has first bus bar 31 and second bus bar 36 built in as an integral unit. First case 21 corresponds to the main body of case 20, and second case 26 corresponds to the lid of case 20.

[0043] 3, in the present embodiment, the recess 22 of the first case 21 includes a first recess 23, a second recess 24, and a third recess 25. The first recess 23 is a recess for arranging the main body 12, the second recess 24 is a recess for arranging the first terminal electrode 13, and the third recess 25 is a recess for arranging the second terminal electrode 14.

[0044] When the main body 12 of the capacitor element 11 is housed in the first recess 23, the first terminal electrode 13 of the capacitor element 11 is disposed in the second recess 24, and the second terminal electrode 14 of the capacitor element 11 is disposed in the third recess 25. The first recess 23 and the second recess 24, and the first recess 23 and the third recess 25 are respectively formed continuously.

[0045] In this embodiment, the first recesses 23 are formed in a line in the horizontal direction (first direction) so that three capacitor elements 11 can be arranged in a line. The second recesses 24 and the third recesses 25 are arranged alternately in the first direction with a gap between them.

[0046] The second case 26 is a member that covers the first case 21 and accommodates the capacitor elements 11 inside the case 20. In this embodiment, the capacitor elements 11 can be accommodated inside the case 20 by sandwiching three capacitor elements 11 between the first case 21 and the second case 26. As shown in FIG. 2 , the second case 26 is provided with hooks 26a, and the first case 21 is provided with recesses 21a. The second case 26 can be fixed to the first case 21 by engaging the hooks 26a with the recesses 21a. The first case 21 and the second case 26 can be fixed to each other by any means other than the hooks, such as fastening the first case 21 and the second case 26 together with screws.

[0047] In this embodiment, fixing portions 21b for fixing the capacitor module 1 to an external substrate or device, etc. are provided on the outer surface of the first case 21. For example, by fastening screws or the like to the fixing portions 21b, the capacitor module 1 can be fixed to the external substrate or device, etc.

[0048] For example, synthetic resins such as polyphenylene sulfide, polybutylene terephthalate, or liquid crystal polymer can be used as materials for forming first case 21 and second case 26. These materials preferably contain glass fiber or inorganic filler to improve dimensional stability or strength.

[0049] <Busbar> The first bus bar 31 is connected to the first terminal electrode 13 of the capacitor element 11. The second bus bar 36 is connected to the second terminal electrode 14 of the capacitor element 11. The first bus bar 31 and the second bus bar 36 are connected to, for example, an electrode (not shown) of an external substrate or device, thereby electrically connecting the capacitor element 11 to the external substrate or device. As shown in FIG. 2 , the first bus bar 31 and the second bus bar 36 are integrally built into the first case 21 by, for example, insert molding, and are partially exposed from the first case 21. The first bus bar 31 and the second bus bar 36 are isolated from each other by the resin of the first case 21.

[0050] The first bus bar 31 and the second bus bar 36 are formed from a plate-shaped conductive material such as copper, brass, or aluminum. Among these, oxygen-free copper or pure copper known as tough pitch copper, which has excellent conductivity, is preferably used. The surfaces of the first bus bar 31 and the second bus bar 36 may be coated with a metal film of nickel, tin, or the like by plating or other treatment.

[0051] 2 and 3, the first bus bar 31 has a first connection portion 32 that is connected to the first terminal electrode 13. The first connection portion 32 is exposed from the first case 21 so as to be located in the second recess 24. The second bus bar 36 has a second connection portion 37 that is connected to the second terminal electrode 14. The second connection portion 37 is exposed from the first case 21 so as to be located in the third recess 25.

[0052] Fig. 5 is a cross-sectional view of the capacitor module 1 taken along line AA in Fig. 1. Fig. 6 is a cross-sectional view of the capacitor module 1 taken along line BB in Fig. 1.

[0053] 5, when the main body 12 of the capacitor element 11 is accommodated in the recess 22 of the first case 21, the first terminal electrode 13 is accommodated in the second recess 24, and the first terminal electrode 13 is disposed on the first connection portion 32 of the first bus bar 31. That is, the first terminal electrode 13 and the first connection portion 32 overlap and contact each other in the height direction (Z direction). Therefore, by disposing the main body 12 of the capacitor element 11 in the first recess 23 (recess 22), the first terminal electrode 13 can be positioned with respect to the first connection portion 32 of the first bus bar 31. The first terminal electrode 13 is positioned by the second recess 24. The first terminal electrode 13 and the first connection portion 32 of the first bus bar 31 are electrically connected by, for example, ultrasonic welding.

[0054] 6, when the main body 12 of the capacitor element 11 is accommodated in the recess 22 of the first case 21, the second terminal electrode 14 is accommodated in the third recess 25, and the second terminal electrode 14 is disposed on the second connection portion 37 of the second bus bar 36. That is, the second terminal electrode 14 and the second connection portion 37 overlap and contact each other in the height direction (Z direction). Therefore, by disposing the capacitor element 11 in the recess 22, the second terminal electrode 14 can be positioned on the second connection portion 37 of the second bus bar 36. The second terminal electrode 14 is positioned by the third recess 25. The second connection portion 37 of the second bus bar 36 and the second terminal electrode 14 are similarly electrically connected to each other by, for example, ultrasonic welding.

[0055] By accommodating capacitor element 11 in recess 22, terminal electrodes 13 and 14 can be positioned, thereby improving the workability during ultrasonic welding.

[0056] 5 and 6, inside first case 21, first bus bar 31 and second bus bar 36 are isolated by the resin of first case 21. This ensures insulation between first bus bar 31 and second bus bar 36.

[0057] [Manufacturing method] Fig. 7 is a flowchart showing a method for manufacturing the capacitor module 1. Figs. 8A to 8D are diagrams illustrating an example of a manufacturing process for the capacitor module 1. The method for manufacturing the capacitor module 1 will be described with reference to Figs. 7 to 8D.

[0058] First, as shown in FIGS. 8A and 8B, the case 20 is prepared (step S11). In this embodiment, a first case 21 and a second case 26 are formed in step S11. The first case 21 can be formed integrally with the first bus bar 31 and the second bus bar 36 by, for example, insert molding. Three recesses 22 (a first recess 23, a second recess 24, and a third recess 25) are formed in the first case 21. Furthermore, in the first case 21, the first connection portion 32 of the first bus bar 31 is disposed in the second recess 24, and the second connection portion 37 of the second bus bar 36 is disposed in the third recess 25. At this time, the first connection portion 32 of the first bus bar 31 is exposed from the second recess 24 of the first case 21, and the second connection portion 37 of the second bus bar 36 is exposed from the third recess 25 of the first case 21. The second case 26 can be formed by, for example, injection molding.

[0059] 8C, capacitor elements 11 are placed in the three recesses 22 of first case 21 (step S12). By placing capacitor elements 11 in the recesses 22, first terminal electrodes 13 overlap first connecting portions 32 in the height direction, and second terminal electrodes 14 overlap second connecting portions 37 in the height direction. Note that an adhesive or the like may be used when placing capacitor elements 11 in first case 21.

[0060] Next, as shown in FIG. 8D , the first bus bar 31 and the first terminal electrode 13 are connected, and the second bus bar 36 and the second terminal electrode 14 are connected (step S13). The first connection portion 32 of the first bus bar 31 and the first terminal electrode 13 are welded to each other by applying, for example, ultrasonic vibration to the overlapping portion of the first connection portion 32 and the first terminal electrode 13. A first welded portion 13a is formed by ultrasonic welding. Similarly, the second connection portion 37 of the second bus bar 36 and the second terminal electrode 14 are welded to each other by applying, for example, ultrasonic vibration to the overlapping portion of the second connection portion 37 and the second terminal electrode 14. A second welded portion 14a is formed by ultrasonic welding. The connection portions 32, 37 and the terminal electrodes 13, 14 are electrically connected by welding.

[0061] The capacitor module 1 is completed by attaching the second case 26 to the first case 21.

[0062] [effect] The capacitor module 1 and the method for manufacturing the capacitor module 1 according to the first embodiment can provide the following effects.

[0063] The capacitor module 1 includes three capacitor elements 11, a case 20, a first bus bar 31, and a second bus bar 36. Each capacitor element 11 has a body 12 covered with a laminate film 15, and a first terminal electrode 13 and a second terminal electrode 14 exposed from the body 12. The case 20 houses the capacitor elements 11. The case 20 has three recesses 22 formed therein to house each of the capacitor elements 11. The first bus bar 31 is integrally built into the case 20 and has a first connection portion 32 electrically connected to the first terminal electrode 13. The second bus bar 36 is integrally built into the case 20 and has a second connection portion 37 electrically connected to the second terminal electrode 14.

[0064] This configuration ensures insulation between bus bars 31, 36, thereby providing a capacitor module 1 with improved insulation. Furthermore, because bus bars 31, 36 are integrally built into first case 21 (case 20), a compact capacitor module 1 can be provided.

[0065] The recess 22 includes a first recess 23, a second recess 24, and a third recess 25. The first recess 23 accommodates the body 12 of the capacitor element 11. The second recess 24 accommodates the first terminal electrode 13 of the capacitor element 11. The third recess 25 accommodates the second terminal electrode 14 of the capacitor element 11. The first connection portion 32 of the first bus bar 31 is located in the second recess 24. The second connection portion 37 of the second bus bar 36 is located in the third recess 25.

[0066] With this configuration, terminal electrodes 13, 14 of capacitor element 11 and bus bars 31, 36 can be easily joined together.

[0067] The second recess 24 and the third recess 25 are formed continuously with the first recess 23. The second recess 24 and the third recess 25 are arranged with a gap between them.

[0068] With this configuration, insulation between first terminal electrode 13 and second terminal electrode 14 of capacitor element 11 can be easily ensured.

[0069] In the first case 21 of the case 20, the first recesses 23 are arranged side by side in the first direction (X direction), and the second recesses 24 and the third recesses 25 are arranged side by side alternately in the first direction.

[0070] Such a configuration allows the space inside the case 20 to be used effectively, which contributes to making the capacitor module 1 smaller.

[0071] The method for manufacturing capacitor module 1 includes the steps of forming case 20, arranging capacitor element 11 in case 20, and connecting bus bars 31, 36 to terminal electrodes 13, 14.

[0072] By using this method, positioning of the capacitor module 1 during assembly can be easily performed, and the terminal electrodes 13, 14 and the bus bars 31, 36 can be easily joined.

[0073] In the above-described embodiment, an example has been described in which the capacitor module 1 includes three capacitor elements 11, but the present invention is not limited to this. The capacitor module 1 may include one or more capacitor elements 11.

[0074] In the above-described embodiment, the capacitor element 11 is formed in a columnar shape having an oval cross section, but the present invention is not limited to this. The capacitor element 11 may be formed in a cylindrical shape, for example. The capacitor element 11 may also be a wound film capacitor or a laminated film capacitor.

[0075] In the above-described embodiment, an example has been described in which capacitor element 11 has one first terminal electrode 13 and one second terminal electrode 14, but this is not limiting. Capacitor element 11 may have a plurality of first terminal electrodes 13 and second terminal electrodes 14. Metal terminals that are not connected to the end surface electrodes may be exposed from main body 12 of capacitor element 11. In this case, the heat dissipation performance of capacitor module 1 can be improved. When metal terminals are provided, recesses for arranging and positioning the metal terminals may be provided in the case.

[0076] In the above-described embodiment, the bus bars 31, 36 and the terminal electrodes 13, 14 are joined by ultrasonic welding, but the present invention is not limited to this. The bus bars 31, 36 and the terminal electrodes 13, 14 can be electrically connected by, for example, soldering, resistance welding, laser welding, or the like.

[0077] In the above-described embodiment, the first case 21 and the second case 26 are fixed together by the hooks 26a provided on the second case 26 and the recesses 21a provided on the first case 21, but the present invention is not limited to this. The first case 21 and the second case 26 can be fixed together by screws, adhesive, or the like, for example.

[0078] Furthermore, a thermal pad or the like having high thermal conductivity and flexibility may be disposed between capacitor element 11 and case 20. By disposing a thermal pad or the like, it is possible to improve the heat dissipation properties of capacitor module 1. Furthermore, because the thermal pad is flexible, it is possible to absorb impacts on capacitor element 11, thereby improving the durability of capacitor module 1.

[0079] (Embodiment 2) A capacitor module 2 according to a second embodiment of the present invention will be described.

[0080] In the second embodiment, differences from the first embodiment will be mainly described. In the second embodiment, the same or equivalent configurations as those in the first embodiment will be denoted by the same reference numerals. Also, in the second embodiment, descriptions that overlap with those in the first embodiment will be omitted.

[0081] FIG. 9 is a perspective view showing a capacitor module 2 according to a second embodiment. FIG. 10 is an exploded perspective view of the capacitor module 2 of FIG. 9. FIG. 11 is an exploded view of a first case 121 of the capacitor module 2 of FIG. 9. FIG. 12 is an exploded view of a second case 126 of the capacitor module 2 of FIG. 9. FIG. 13 is a perspective view showing a capacitor element 111 of the capacitor module 2 of FIG. 9. FIG. 14 is a view of the capacitor module 2 of FIG. 9 without the second case 126. FIG. 15 is an enlarged cross-sectional view of a region R1 taken along line CC in FIG. 13.

[0082] The second embodiment differs from the first embodiment in that case 120 includes first case 121 and second case 126, first bus bar 131 is built in first case 121, and second bus bar 136 is built in second case 126. That is, the second embodiment differs from the first embodiment in that bus bars 131 and 136 are built in separately in both cases, rather than being built in one of two cases of case 120.

[0083] Also, the present embodiment differs from the first embodiment in that first connection portion 132 of first bus bar 131 is located on the outer surface of first case 121, and second connection portion 137 of second bus bar 136 is located on the outer surface of second case 126. That is, the present embodiment differs from the first embodiment in that the connection points between bus bars 131, 136 and capacitor element 111 are exposed to the outer surface of case 120, rather than being provided inside case 120.

[0084] Also, it differs from the first embodiment in that first terminal electrode 113 and second terminal electrode 114 of capacitor element 111 have extending portions 113a, 114a and bending portions 113b, 114b. That is, it differs from the first embodiment in that terminal electrodes 113, 114 do not extend in one direction but are bent.

[0085] As shown in FIGS. 9 to 12, in this embodiment, case 120 of capacitor module 2 is composed of first case 121 and second case 126. First bus bar 131 is integrally built into first case 121 (FIG. 11), and second case 126 is integrally built into second bus bar 136 (FIG. 12). In this embodiment, first case 121 and second case 126 are fixed to each other by fastening screws or the like to fixing portions 121a and 126a provided on each case. Fixing portions 121a and 126a can also be used to fix capacitor module 2 to an external board or device. In this embodiment, first case 121 and second case 126 have the same shape, and first bus bar 131 and second bus bar 136 also have the same shape.

[0086] Similar to the first embodiment, recess 122 is formed in first case 121. Specifically, recess 122 includes first recess 123, second recess 124, and third recess 125. First recess 123 and second recess 124 are formed continuously, and first recess 123 and third recess 125 are formed continuously. Similarly, second case 126 has first recess, second recess, and third recess formed.

[0087] In this embodiment, opening 121b is provided in outer surface 121c of first case 121. Similarly, opening 126b is provided in outer surface 126c of second case 126. First connection portion 132 of first bus bar 131 is located in opening 121b of first case 121. Similarly, second connection portion 137 of second bus bar 136 is located in opening 126b of second case 126.

[0088] 13, the first terminal electrode 113 of the capacitor element 111 has a first extending portion 113a extending from the main body 112 of the capacitor element 111 toward the outer surface 121c of the first case 121, and a first bent portion 113b bent from the first extending portion 113a along the outer surface 121c of the first case 121. The second terminal electrode 114 of the capacitor element 111 has a second extending portion 114a extending from the main body 112 of the capacitor element 111 toward the outer surface 126c of the second case 126, and a second bent portion 114b bent from the second extending portion 114a along the outer surface 126c of the second case 126. The first bent portion 113b of the first terminal electrode 113 and the second bent portion 114b of the second terminal electrode 114 extend in opposite directions. That is, the first extending portion 113a of the first terminal electrode 113 extends downward (-Z direction), and the second extending portion 114a of the second terminal electrode 114 extends upward (+Z direction).

[0089] As shown in FIGS. 14 and 15 , opening 121b of first case 121 communicates with second recess 124 via slit 124a. Inserting first bent portion 113b of first terminal electrode 113 into slit 124a allows first connecting portion 132 of first bus bar 131 and first bent portion 113b of first terminal electrode 113 to overlap in the vertical direction (Y direction) at opening 121b. The overlapping portion of first connecting portion 132 and first bent portion 113b can be joined by ultrasonic welding via opening 121b, for example, to electrically connect first terminal electrode 113 and first bus bar 131. Second terminal electrode 114 and second bus bar 136 are electrically connected in a similar manner. In second case 126, a third recess (not shown) in which second terminal electrode 114 is disposed communicates with opening 126b via a slit.

[0090] [Manufacturing method]

[0091] Fig. 16 is a flowchart showing a method for manufacturing the capacitor module 2 of Fig. 9. The method for manufacturing the capacitor module 2 will be described with reference to Fig. 16.

[0092] First, first case 121 is prepared (step S21). First case 121 can be formed by, for example, insert molding. First case 121 has recess 122 formed therein to accommodate capacitor element 111. Recess 122 includes first recess 123, second recess 124, and third recess 125, as shown in FIG.

[0093] Next, the second case 126 is prepared (step S22). The second case 126 can be formed by insert molding, for example. The second case 126 also has a recess formed therein, similar to the first case 121.

[0094] In this embodiment, first case 121 and second case 126 have the same shape, and therefore, first case 121 and second case 126 can be formed using the same mold.

[0095] Next, capacitor element 111 is placed in recess 122 of first case 121 (step S23). At this time, the tip of first terminal electrode 113 is bent to form first bent portion 113b in advance. Similarly, the tip of second terminal electrode 114 is bent to form second bent portion 114b in advance. When main body 112 of capacitor element 111 is placed in recess 122 of first case 121, first bent portion 113b is inserted into slit 124a.

[0096] After capacitor element 111 is placed in first case 121, second case 126 is placed over first case 121 and fixed (step S24). At this time, second bent portion 114b is inserted into the slit of second case 126.

[0097] Next, first bus bar 131 is connected to first terminal electrode 113 (step S25). Similarly, second bus bar 136 is connected to second terminal electrode 114 (step S26). By forming first bent portion 113b and second bent portion 114b, terminal electrodes 113, 114 and bus bars 131, 136 are arranged to overlap in the vertical direction (Y direction). This makes it possible to easily join terminal electrodes 113, 114 and bus bars 131, 136 by, for example, welding.

[0098] Bus bars 131, 136 can be connected to terminal electrodes 113, 114 by, for example, ultrasonic welding. Once bus bars 131, 136 and terminal electrodes 113, 114 are connected, capacitor module 2 is completed.

[0099] [effect] The capacitor module 2 according to the second embodiment can provide the following effects.

[0100] In the capacitor module 2, the case 120 includes a first case 121 and a second case 126. A first bus bar 131 is built in the first case 121. A second bus bar 136 is built in the second case 126.

[0101] With this configuration, bus bars 131, 136 are built into first case 121 and second case 126, respectively, so the size in the vertical direction (Y direction) can be reduced compared to embodiment 1, which contributes to the miniaturization of capacitor module 2.

[0102] First connection portion 132 of first bus bar 131 is disposed on outer surface 121c of first case 121, and second connection portion 137 of second bus bar 136 is disposed on outer surface 126c of second case 126. First terminal electrode 113 has a first extending portion 113a extending from capacitor element 111 toward outer surface 121c of first case 121 and a first bent portion 113b bent from first extending portion 113a along outer surface 121c of first case 121. Second terminal electrode 114 has a second extending portion 114a extending from capacitor element 111 toward outer surface 126c of second case 126 and a second bent portion 114b extending from second extending portion 114a toward outer surface 126c of second case 126.

[0103] By bending the terminal electrodes 113 and 114, space can be saved, which contributes to making the capacitor module 2 smaller.

[0104] First case 121 and second case 126 have the same shape, and first bus bar 131 and second bus bar 136 have the same shape.

[0105] Since the first case 121 and the second case 126 have the same shape, and the first bus bar 131 and the second bus bar 136 have the same shape, the number of parts and molds of the capacitor module 2 can be reduced, thereby reducing manufacturing costs.

[0106] An opening 121b is provided on an outer surface 121c of the first case 121 to expose the first connection portion 132, and an opening 126b is provided on an outer surface 126c of the second case 126 to expose the second connection portion 137.

[0107] Terminal electrodes 113, 114 and bus bars 131, 136 can be joined to outer surfaces 121c, 126c of cases 121, 126, and therefore capacitor module 2 can be further reduced in size.

[0108] The manufacturing method of the capacitor module 2 includes the steps of preparing a first case 121, preparing a second case 126, placing the capacitor element 111 in the first case 121, covering the first case 121 with the second case 126, and connecting the bus bars 131, 136 to the terminal electrodes 113, 114.

[0109] When assembling capacitor module 2, capacitor element 111 is positioned by recess 122, facilitating assembly. Furthermore, since terminal electrodes 113 and 114 have bent portions 113b and 114b, bent portions 113b and 114b can be exposed from outer surfaces 121c and 126c of cases 121 and 126, respectively, and therefore terminal electrodes and bus bars can be easily joined.

[0110] [Variations] Fig. 17 is a perspective view showing a capacitor module 3 according to a first modification of the second embodiment. Fig. 18 is an exploded perspective view of the capacitor module 3 of Fig. 17. Fig. 19 is an exploded view of a first case 221 of the capacitor module 3 of Fig. 17.

[0111] 17 to 19, in capacitor module 3, second recess 224 and opening 221b of first case 221 may be formed continuously without a slit. In other words, opening 221b of first case 221 may be a recess formed on outer surface 221c of first case 221 and continuous with first recess 223. In capacitor module 3, second case 226 has the same shape as first case 221, and is formed with recesses (not shown) including first to third recesses and opening 226b.

[0112] Furthermore, first connection portion 232 of first bus bar 231 is located at opening 221b of first case 221, and second connection portion 237 of second bus bar 236 is located at opening 226b of second case 226.

[0113] Furthermore, the first case 221 and the second case 226 can be fastened and fixed together using fixing portions 221a and 226a provided on the respective cases 221 and 226, for example, with screws or the like.

[0114] Fig. 20 is a flowchart showing a method for manufacturing the capacitor module 3 of Fig. 17. A method for manufacturing the capacitor module 3 will be described with reference to Fig. 20. Note that steps S31 to S32 and steps S35 to S37 are the same as steps S21 to S22 and steps S24 to S26 of Fig. 16, and therefore description thereof will be omitted.

[0115] After preparing first case 221 and second case 226, capacitor element 211 is placed in recess 222 of first case 221 (step S33). At this time, capacitor element 211 has flat terminal electrodes as shown in Fig. 4. The provision of recess 222 in first case 221 makes it easy to position capacitor element 211.

[0116] Next, the tip of the first terminal electrode 213 is bent along the outer surface 221c of the first case 221 to form the first bent portion 213b, and the tip of the second terminal electrode 214 is bent along the outer surface 226c of the second case 226 to form the second bent portion 214b (step S34).

[0117] After forming first bent portion 213b and second bent portion 214b, second case 226 is placed, and bus bars 231, 236 are connected to terminal electrodes 213, 214, completing capacitor module 3 (steps S5 to S37).

[0118] Since the opening 221b is formed continuously with the second recess 224, the capacitor element 211 can be placed in the recess 222 of the first case 221, and after forming the bent portions 213b and 214b, the second case 226 can be placed in the first case 221, making it easier to assemble the capacitor module 3. [Industrial Applicability]

[0119] The present invention is useful for capacitor modules used in various electronic devices, electrical devices, industrial devices, vehicle devices, etc. [Explanation of symbols]

[0120] 1, 2, 3 Capacitor Module 11, 111, 211 capacitor elements 12, 112 Main body 13, 113, 213 1st terminal electrode 14, 114, 214 2nd terminal electrode 15, 115 Laminate film 20, 120 cases 22, 122, 222 recesses 23, 123, 223 First recess 24, 124, 224 Second recess 25, 125, 225 3rd recess 31, 131, 231 First bus bar 32, 132, 232 First connection part 36, 136, 236 2nd bus bar 37, 137, 237 Second connection part 113a 1st extension section 113b, 213b 1st bending part 114a 2nd extension section 114b, 214b 2nd bend 121, 221 Case 1 121b, 121b opening 121c, 221c outer surface 126, 226 Case 2 126b, 226b opening 126c, 226c outer surface

Claims

1. one or more capacitor elements, each having a body covered with a laminate film and a first terminal electrode and a second terminal electrode exposed from the body; a case that houses the one or more capacitor elements; a first bus bar that is integrally built into the case and electrically connected to the first terminal electrode; a second bus bar that is integrally built into the case and electrically connected to the second terminal electrode; Equipped with the case is formed with one or more recesses for accommodating the one or more capacitor elements, respectively; the first bus bar has one or more first connection portions connected to the first terminal electrodes of the capacitor elements arranged in the recesses, the second bus bar has one or more second connection portions connected to the second terminal electrodes of the capacitor elements arranged in the recesses, respectively; The case includes a first case in which the first bus bar is built-in, and a second case in which the second bus bar is built-in. Capacitor module.

2. each of the one or more recesses includes a first recess in which the main body portion is disposed, a second recess in which the first terminal electrode is disposed, and a third recess in which the second terminal electrode is disposed; the first connection portion is located in the second recess, the second connection portion is located in the third recess; The capacitor module according to claim 1 .

3. the second recess and the third recess are formed continuously with the first recess, The second recess and the third recess are spaced apart from each other. The capacitor module according to claim 2 .

4. In the case, the first recesses are arranged side by side in a first direction, and the second recesses and the third recesses are arranged side by side alternately in the first direction. The capacitor module according to claim 3 .

5. the first connection portion is disposed on an outer surface of the first case, the second connection portion is disposed on an outer surface of the second case, the first terminal electrode has a first extending portion extending from the capacitor element toward an outer surface of the first case, and a first bent portion bent from the first extending portion along the outer surface of the first case, the second terminal electrode has a second extending portion extending from the capacitor element toward the outer surface of the second case, and a second bent portion bent from the second extending portion along the outer surface of the second case. The capacitor module according to claim 1 .

6. The first case and the second case have the same shape, The first bus bar and the second bus bar have the same shape. The capacitor module according to claim 1 .

7. an opening for exposing the first connection portion is provided on an outer surface of the first case; An opening for exposing the second connection portion is provided on an outer surface of the second case. The capacitor module according to claim 1 .

8. preparing a first case having a recess that integrally houses a first bus bar and that houses a capacitor element having a first terminal electrode and a second terminal electrode; preparing a second case that integrally incorporates a second bus bar and has a recess that accommodates the capacitor element; placing the capacitor element in the recess provided in the first case; bending the first terminal electrode and the second terminal electrode; placing the second case over the first case; connecting the first terminal electrode and the first bus bar; connecting the second terminal electrode and the second bus bar; Including, A method for manufacturing a capacitor module.

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