capacitor

Abstract

To provide a capacitor capable of suppressing the occurrence of molding defects of insulation members.SOLUTION: A film capacitor 1 includes: a capacitor element 400; a first busbar 500 and a second busbar 600 each connected to the capacitor element 400; and a plate-like insulation member 700 interposed between the first busbar 500 and the second busbar 600. The insulation member 700 has a rear surface 710b facing the second busbar 600 and a front surface 710a facing the first busbar 500. The rear surface 710b of the insulation member 700 has a recess 714a recessed in the direction of the front surface 710a and a gate mark 715 formed in the recess 714a.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a capacitor. [Background technology]

[0002] Patent Document 1 describes a film capacitor in which metallikon electrodes are formed on both end surfaces of a capacitor element, bus bars are connected to each of the metallikon electrodes, and portions of the pair of bus bars are overlapped with a holding member made of insulating resin sandwiched between them, thereby reducing mutual inductance (equivalent series inductance).

[0003] In the film capacitor of Patent Document 1, the first portions of the pair of bus bars overlap with each other, sandwiching the flat plate portion of the holding member, and an external connection terminal portion is formed at one end of each first portion. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] International Publication No. 2016 / 027462 Summary of the Invention [Problem to be solved by the invention]

[0005] In the above film capacitor, when the thickness of the flat plate portion is reduced, the distance between the two bus bars in the overlapping direction is reduced, thereby increasing the effect of reducing the equivalent series inductance.

[0006] However, if the thickness of the flat plate portion becomes smaller, when the retaining member is manufactured by injection molding, the resin will have difficulty flowing through the mold portion that forms the flat plate portion in the mold, making it difficult for the resin to spread throughout that mold portion, which raises the concern that molding defects may occur.

[0007] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a capacitor in which molding defects of insulating members are less likely to occur. [Means for solving the problem]

[0008] A first aspect of the present invention relates to a capacitor including a capacitor element, a first bus bar and a second bus bar connected to the capacitor element, and a plate-shaped insulating member interposed between the first bus bar and the second bus bar. In the capacitor according to this aspect, the insulating member has a first surface facing the second bus bar and a second surface facing the first bus bar. The first surface of the insulating member has a recess recessed toward the second surface, and a recess Bottom of Established in , protruding in a direction from the second surface toward the first surface It has gate remains. The second surface has a protrusion provided in a portion corresponding to the recess and protruding on the opposite side from the first surface, and the depth of the recess in the insulating member is greater than the thickness between the first surface and the second surface around the protrusion.

[0009] A second aspect of the present invention relates to a capacitor including a capacitor element, a first bus bar and a second bus bar connected to the capacitor element, and a plate-shaped insulating member interposed between the first bus bar and the second bus bar. In the capacitor according to this aspect, the insulating member has a first surface facing the second bus bar and a second surface facing the first bus bar. . before The second surface of the insulating member ,before The first surface has a protruding portion protruding in a direction opposite to the first surface. The first surface of the insulating member has a rear portion of the protrusion flush with the periphery of the rear portion, and has a gate mark on the rear portion that protrudes in the opposite direction to the second surface.

[0010] A third aspect of the present invention relates to a capacitor including a capacitor element, a first bus bar and a second bus bar connected to the capacitor element, and a plate-shaped insulating member interposed between the first bus bar and the second bus bar. In the capacitor according to this aspect, the insulating member has a first surface facing the second bus bar and a second surface facing the first bus bar. The first surface of the insulating member has a protruding portion protruding in a direction opposite to the second surface, and a protruding portion. Tip surface of Established in protruding in a direction opposite to the second surface gate Traces and,

[0011] A fourth aspect of the present invention relates to a capacitor including a capacitor element, a first bus bar and a second bus bar connected to the capacitor element, and a plate-shaped insulating member interposed between the first bus bar and the second bus bar. In the capacitor according to this aspect, the insulating member has a first surface facing the second bus bar and a second surface facing the first bus bar. The first surface of the insulating member has: a recess recessed toward the second surface; and a protruding portion provided on a bottom surface of the recess and protruding in a direction from the second surface toward the first surface. Gate remains and The second bus bar has the recess and At the position overlapping with the gate mark , having an inner diameter larger than the inner diameter of the recess An opening is formed.

[0012] A fifth aspect of the present invention relates to a capacitor including a capacitor element, a first bus bar and a second bus bar connected to the capacitor element, and a plate-shaped insulating member interposed between the first bus bar and the second bus bar. In the capacitor according to this aspect, the insulating member has a first surface facing the second bus bar and a second surface facing the first bus bar. The insulating member further has a gate mark on the first surface at a position spaced from an end of the insulating member. The first bus bar and the second bus bar have a first overlapping portion and a second overlapping portion that overlap each other. The insulating member has a first portion interposed between the first overlapping portion and the second overlapping portion, a second portion continuous with the first portion, and a third portion continuous with the first portion, and the first portion is located between the second portion and the third portion. The gate mark is provided in the first portion. [Effects of the Invention]

[0013] According to the present invention, a capacitor can be provided in which molding defects of the insulating member are less likely to occur.

[0014] The effects and significance of the present invention will become more apparent from the following description of the embodiments, however, the embodiments shown below are merely examples of how the present invention can be put into practice, and the present invention is not limited to the embodiments described below. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a perspective view of a film capacitor according to an embodiment. [Figure 2]FIG. 2(a) is a perspective view of the capacitor element unit according to the embodiment as seen from above the front, and FIG. 2(b) is a perspective view of the capacitor element unit according to the embodiment as seen from above the rear. [Figure 3] FIG. 3(a) is a perspective view of a first bus bar according to the embodiment, and FIG. 3(b) is a perspective view of a second bus bar according to the embodiment. [Figure 4] FIG. 4(a) is a perspective view of an insulating member according to the embodiment as seen from above the front, and FIG. 4(b) is a perspective view of an insulating member according to the embodiment as seen from above the rear. [Figure 5] FIG. 5 is a front view of a main part of a capacitor element unit according to an embodiment. [Figure 6] FIG. 6(a) is a rear view of a main part of the capacitor element unit according to the embodiment, and FIG. 6(b) is a cross-sectional view taken along line AA' of FIG. 6(a). [Figure 7] FIG. 7 is a cross-sectional view of a mold used for injection molding of an insulating member according to an embodiment. [Figure 8] 8(a) and 8(b) are plan views of the first member and the second member constituting the mold according to the embodiment, respectively, as viewed from their parting surfaces. [Figure 9] FIG. 9 is a plan view of a first member constituting a mold according to a modified example, viewed from the parting surface side. [Figure 10] 10(a) and (c) are cross-sectional views of the main part of a mold according to a modified example, and FIGS. 10(b) and (d) are cross-sectional views of the main part of an insulating member according to a modified example. DETAILED DESCRIPTION OF THE INVENTION

[0016] A film capacitor 1, which is one embodiment of a capacitor of the present invention, will be described below with reference to the drawings. For convenience, the front-rear, left-right, and up-down directions are indicated in each drawing as appropriate. Note that the directions shown in the drawings indicate only relative directions of the film capacitor 1, and do not indicate absolute directions. For convenience of explanation, some components may be given names that correspond to the directions shown in the drawings, such as "front" and "rear."

[0017] In this embodiment, film capacitor 1 corresponds to a "capacitor" in the claims. First bus bar 500 and second bus bar 600 correspond to "bus bars" in the claims. Opening 516 corresponds to a "first opening" in the claims, and opening 614 corresponds to a "second opening" in the claims. Front surface 710a corresponds to a "second surface" in the claims, and rear surface 710b corresponds to a "first surface" in the claims. Protrusion 714 corresponds to a "second protrusion" in the claims, and protrusion 813 corresponds to a "first protrusion" in the claims.

[0018] However, the above description is intended solely to match the configuration of the claims with the configuration of the embodiments, and the above correspondence does not in any way limit the invention described in the claims to the configuration of the embodiments.

[0019] <Film capacitor structure> FIG. 1 is a perspective view of a film capacitor 1. FIG.

[0020] The film capacitor 1 includes a capacitor element unit 100, a case 200 that houses the capacitor element unit 100, and a filled resin 300 that fills the case 200. The portion of the capacitor element unit 100 that is buried in the filled resin 300, particularly the capacitor element 400, is protected from moisture and impact by the case 200 and the filled resin 300.

[0021] FIG. 2(a) is a perspective view of the capacitor element unit 100 seen from above the front, and FIG. 2(b) is a perspective view of the capacitor element unit 100 seen from above the rear.

[0022] The capacitor element unit 100 includes a capacitor element 400 , a first bus bar 500 , a second bus bar 600 , and an insulating member 700 .

[0023] Capacitor element 400 is formed by stacking two metallized films, each made by depositing aluminum on a dielectric film, rolling or laminating the stacked metallized films, and pressing them flat. Capacitor element 400 has first electrode 410 formed on one end face by spraying a metal such as zinc, and second electrode 420 formed on the other end face by spraying a metal such as zinc.

[0024] Although capacitor element 400 of the present embodiment is formed from a metallized film in which aluminum is vapor-deposited on a dielectric film, it may also be formed from a metallized film in which other metals such as zinc, magnesium, etc. Alternatively, capacitor element 400 may be formed from a metallized film in which multiple metals selected from these metals are vapor-deposited, or from a metallized film in which an alloy of these metals is vapor-deposited.

[0025] FIG. 3( a ) is a perspective view of the first bus bar 500 .

[0026] First bus bar 500 is formed by appropriately cutting and bending a metal plate, such as a copper plate, which is a conductive material having a predetermined shape.

[0027] The first bus bar 500 includes a main body portion 510 having a rectangular flat plate shape. The main body portion 510 is divided in the up-down direction into a portion that becomes a first overlapping portion 511 and a portion that becomes a non-overlapping portion 512 that is continuous with the first overlapping portion 511. The non-overlapping portion 512 is located above the first overlapping portion 511. For convenience, the boundary between the first overlapping portion 511 and the non-overlapping portion 512 is indicated by a two-dot chain line in FIG. 3(a).

[0028] At the top of main body 510 included in non-overlapping portion 512, a portion of main body 510 is cut and raised to form four rectangular connection terminal portions 520 lined up in the left-right direction. A rectangular opening 513 larger than connection terminal portion 520 is formed in the portion of main body 510 where each connection terminal portion 520 is cut and raised. Each opening 513 is adjacent to the corresponding connection terminal portion 520 and lined up in the left-right direction.

[0029] Four rectangular openings 514 are formed in the middle of the main body 510 included in the first overlapping portion 511 at the same positions in the left-right direction as the four openings 513. The four openings 514 have the same size as the four openings 513. Furthermore, rectangular through-holes 515 that are long in the vertical direction are formed at the left and right ends of the middle of the main body 510.

[0030] A circular opening 516 is formed in the center of the lower part of the main body 510 included in the first overlapping part 511.

[0031] Furthermore, first bus bar 500 includes electrode terminal portion 530 that is bent from the lower end of main body portion 510 at a right angle to main body portion 510. Electrode terminal portion 530 has a rectangular plate shape that is elongated in the left-right direction.

[0032] Furthermore, first bus bar 500 includes bent portions 540 that are bent at right angles to main body portion 510 from the left end and the right end of first overlapping portion 511 and non-overlapping portion 512. Each bent portion 540 has a rectangular plate shape that is elongated in the vertical direction. Each bent portion 540 contacts each of through holes 515.

[0033] FIG. 3( b ) is a perspective view of the second bus bar 600 .

[0034] Second bus bar 600 is formed by appropriately cutting and bending a metal plate, such as a copper plate, which is a conductive material having a predetermined shape.

[0035] The second bus bar 600 includes a main body portion 610 having a rectangular flat plate shape. The main body portion 610 is divided in the up-down direction into a portion that becomes a second overlapping portion 611 and a portion that becomes a non-overlapping portion 612 that is continuous with the second overlapping portion 611. The non-overlapping portion 612 is located below the second overlapping portion 611. For convenience, the boundary between the second overlapping portion 611 and the non-overlapping portion 612 is indicated by a two-dot chain line in FIG. 3(b).

[0036] At the top of the main body 610 included in the second overlapping portion 611, a portion of the main body 610 is cut and raised, thereby forming four rectangular connection terminal portions 620 lined up in the left-right direction. In the portion of the main body 610 where each connection terminal portion 620 is cut and raised, a rectangular opening portion 613 larger than the connection terminal portion 620 is formed. Each opening portion 613 is adjacent to the corresponding connection terminal portion 620 and lined up in the left-right direction. The four opening portions 613 have the same size as the four opening portions 514 of the first bus bar 500.

[0037] A circular opening 614 is formed in the center of the middle portion of the main body portion 610 included in the second overlapping portion 611.

[0038] Furthermore, second bus bar 600 includes electrode terminal portion 630 that is bent from the lower end of main body portion 610 at a right angle to main body portion 610. Electrode terminal portion 630 has a rectangular plate shape that is elongated in the left-right direction.

[0039] FIG. 4(a) is a perspective view of the insulating member 700 as seen from above the front, and FIG. 4(b) is a perspective view of the insulating member 700 as seen from above the rear.

[0040] The insulating member 700 is made of a resin such as polyphenylene sulfide (PPS) and is formed by injection molding, which will be described later.

[0041] The insulating member 700 includes a main body 710 having a substantially rectangular plate shape that is long in the left-right direction. The main body 710 is divided in the up-down direction into a first portion 711, a second portion 712 that is continuous with the first portion 711, and a third portion 713 that is continuous with the first portion 711. The second portion 712 is located above the first portion 711, and the third portion 713 is located below the first portion 711. For convenience, the boundaries between the first portion 711 and the second portion 712 and the boundaries between the first portion 711 and the third portion 713 are indicated by two-dot chain lines in Figures 4(a) and (b).

[0042] A substantially cylindrical protruding portion 714 is formed in the center of the first portion 711 of the main body 710, with a portion of the front surface 710a of the main body 710 protruding and a portion of the rear surface 710b of the main body 710 being recessed. The protruding portion 714 has a recess 714a on its back side. A substantially cylindrical gate mark 715 is formed on the surface of the rear surface 710b of the main body 710 recessed by the protruding portion 714, i.e., on the bottom surface of the recess 714a. The gate mark 715 is formed by injection molding. The outer diameter of the protruding portion 714 is smaller than the inner diameters of the openings 516 of the first bus bar 500 and the openings 614 of the second bus bar 600.

[0043] Furthermore, four rectangular openings 716 are formed in the upper portion of first portion 711, aligned in the left-right direction. The four openings 716 have the same size as the four openings 514 of first bus bar 500.

[0044] Two first ribs 717 are formed on the rear surface 710b of the second portion 712 of the main body 710, protruding rearward and extending in the left-right direction from the left end to the right end. The two first ribs 717 are aligned vertically with a predetermined distance between them. The predetermined distance is set to a distance equal to or greater than the distance (1 mm) at which the two first ribs 717 are considered to be apart according to regulations related to creepage distance.

[0045] The two first ribs 717 are connected at their left and right ends by second ribs 718. The height of each second rib 718 is the same as the height of each first rib 717.

[0046] Furthermore, the insulating member 700 includes a clamping portion 720 at each of the left and right ends of the front surface 710a of the main body 710. The clamping portion 720 is composed of a first contact portion 721 located on the outer side of the insulating member 700 and a second contact portion 722 located on the inner side. The first contact portion 721 has a rectangular plate shape that is elongated in the vertical direction. The second contact portion 722 has a rectangular parallelepiped shape that is elongated in the vertical direction. The vertical dimension of the first contact portion 721 is larger than the vertical dimension of the second contact portion 722, and the horizontal dimension of the first contact portion 721 is smaller than the horizontal dimension of the second contact portion 722. The first contact portion 721 and the second contact portion 722 have the same front-to-rear dimension. The front-to-rear dimension of the bent portion 540 of the first bus bar 500 is larger than the front-to-rear dimensions of the first contact portion 721 and the second contact portion 722.

[0047] The first contact portion 721 includes two first ribs 721a. The two first ribs 721a are formed on the side surface of the first contact portion 721 facing the second contact portion 722, at positions above and below the second contact portion 722, and extend in the front-rear direction. The second contact portion 722 includes one second rib 722a. The second rib 722a is formed on the side surface of the second contact portion 722 facing the first contact portion 721, between the two first ribs 721a, and extends in the front-rear direction. The gap between the first rib 721a and the second rib 722a is set slightly smaller than the thickness (dimension in the left-right direction) of the bent portion 540 of the first bus bar 500.

[0048] 2(a) and 2(b), the first bus bar 500 is attached to the front side of the insulating member 700. The main body 510 of the first bus bar 500 contacts the front surface 710a of the main body 710 of the insulating member 700. The protruding portions 714 of the insulating member 700 pass through the openings 516 of the first bus bar 500. The bent portions 540 on both the left and right sides of the first bus bar 500 are clamped by the clamping portions 720 of the insulating member 700. The four openings 514 of the first bus bar 500 overlap the four openings 716 of the insulating member 700.

[0049] The second bus bar 600 is attached to the rear side of the insulating member 700. The main body 610 of the second bus bar 600 contacts the rear surface 710b of the main body 710 of the insulating member 700. The recess 714a of the insulating member 700 overlaps the opening 614 of the second bus bar 600, and the gate mark 715 overlaps the opening 614. There may be some variation in the height of the gate mark 715. If the gate mark 715 becomes higher and protrudes rearward from the recess 714a, the tip of the protruding gate mark 715 is inserted into the opening 614 and does not interfere with the main body 610 of the second bus bar 600.

[0050] The four openings 613 of the second bus bar 600 overlap with the four openings 716 of the insulating member 700, and each connection terminal portion 620 of the second bus bar 600 passes through each of the three overlapping openings 514, 716, 613 and protrudes forward of the first bus bar 500. The terminal row of the four connection terminal portions 620 is located below the four connection terminal portions 520. The positions of the front ends of the four connection terminal portions 520 and the positions of the front ends of the four connection terminal portions 620 are aligned.

[0051] The first overlapping portion 511 of the first bus bar 500 and the second overlapping portion 611 of the second bus bar 600 overlap in the front-to-rear direction. The non-overlapping portion 512 of the first bus bar 500 does not overlap with the second overlapping portion 611, and the non-overlapping portion 612 of the second bus bar 600 does not overlap with the first overlapping portion 511. A first portion 711 of the insulating member 700 is interposed between the first overlapping portion 511 and the second overlapping portion 611. A second portion 712 of the insulating member 700 overlaps with the non-overlapping portion 512 of the first bus bar 500. A third portion 713 of the insulating member 700 is interposed between the non-overlapping portion 612 of the second bus bar 600 and the circumferential surface of the capacitor element 400.

[0052] The capacitor element 400 is disposed between the electrode terminal portion 530 of the first bus bar 500 and the electrode terminal portion 630 of the second bus bar 600. The electrode terminal portion 530 is joined to the first electrode 410 of the capacitor element 400 by a joining method such as soldering. This electrically connects the first bus bar 500 to the first electrode 410. Similarly, the electrode terminal portion 630 is joined to the second electrode 420 of the capacitor element 400 by a joining method such as soldering. This electrically connects the second bus bar 600 to the second electrode 420. Note that pin-shaped terminals may be formed on the electrode terminal portions 530, 630, and these terminals may be joined to the electrodes 410, 420 by soldering or the like.

[0053] FIG. 5 is a front view of the main part of the capacitor element unit 100. As shown in FIG.

[0054] 5 , in each clamping portion 720 of the insulating member 700, a first rib 721a of the first contact portion 721 contacts the bent portion 540 from the outside of the first bus bar 500, and a second rib 722a of the second contact portion 722 that passes through the through hole 515 of the first bus bar 500 contacts the bent portion 540 from the inside of the first bus bar 500. The first rib 721a and the second rib 722a are so-called crush ribs, and when the bent portion 540 is inserted between the first contact portion 721 and the second contact portion 722, the tip portions of the crush ribs are scraped or deformed by the bent portion 540. The first contact portion 721 and the second contact portion 722 contact the bent portion 540 from both sides, and thus a force that holds the first bus bar 500 in the front-rear direction (a force that suppresses movement) is generated in the insulating member 700.

[0055] First bus bar 500 is positioned relative to insulating member 700 in the front-rear and left-right directions by a positioning structure formed by bent portion 540 and clamping portion 720 .

[0056] The vertical dimension of through hole 515 is larger than the vertical dimension of second contact portion 722, and relatively large gaps are generated above and below between second contact portion 722 and through hole 515. Therefore, in this embodiment, another positioning structure (not shown) is provided between first bus bar 500 and insulating member 700, and this positioning structure positions first bus bar 500 in the vertical direction relative to insulating member 700. Furthermore, another positioning structure (not shown) is provided between second bus bar 600 and insulating member 700, and this positioning structure positions second bus bar 600 in the vertical, front-rear, and left-right directions relative to insulating member 700.

[0057] FIG. 6(a) is a rear view of the main part of the capacitor element unit 100, and FIG. 6(b) is a cross-sectional view taken along line AA' of FIG. 6(a).

[0058] 6(a) and 6(b), the four connection terminal portions 520 of the first bus bar 500 protrude from the non-overlapping portion 512 to the side opposite (the front side of) the second portion 712 of the insulating member 700. The upper ends of the second portions 712 are at the same height as the lower ends of the four openings 513 of the first bus bar 500, and the second portions 712 do not overlap with the four openings 513 or the four connection terminal portions 520 in the front-to-rear direction. Note that the second portions 712 may overlap the lower ends of the four openings 513, if only slightly.

[0059] In the second portion 712 of the insulating member 700, the two first ribs 717 protrude to the side opposite (rear side of) the non-overlapping portion 512 of the first bus bar 500 and have a dimension that is slightly longer in the left-right direction than the overlapping range R so that they are present in the overlapping range R where the non-overlapping portion 512 and the second overlapping portion 611 of the second bus bar 600 overlap when viewed from the top-bottom direction. In addition, the two second ribs 718 connect the two first ribs 717 outside the overlapping range R in the left-right direction.

[0060] As shown by the thick line in Figure 6(b), a creepage distance D is ensured in the up-down direction between the non-overlapping portion 512 of the first bus bar 500 and the second overlapping portion 611 of the second bus bar 600 by the second portion 712 of the insulating member 700 and the two first ribs 717. The rear surface side of the second portion 712 has an uneven surface due to the two first ribs 717. Therefore, the creepage distance D is longer than when the rear surface side of the second portion 712 is flat.

[0061] 1, case 200 is made of resin, for example, polyphenylene sulfide (PPS), which is a thermoplastic resin. Case 200 is formed in the shape of a substantially rectangular box, and has an opening 201 on the top surface.

[0062] The case 200 is provided with mounting tabs 210 on the left and right outer surfaces and the outer bottom surface. Each mounting tab 210 has an insertion hole 211 formed therethrough in the front-to-rear direction. A metal collar 212 is fitted into the insertion hole 211 to increase the strength of the hole. When the film capacitor 1 is installed in an installation location such as an external device, these mounting tabs 210 are fixed to the installation location with screws or the like.

[0063] The filling resin 300 is a thermosetting resin such as an epoxy resin.

[0064] The capacitor element unit 100 is housed in the case 200 through the opening 201. Filling resin 300 in a liquid state is injected through the opening 201 into the case 200 with the capacitor element unit 100 housed therein. The filling resin 300 fills the case 200 up to the vicinity of the opening 201, and when the injection of the filling resin 300 is completed, the case 200 is heated. This causes the filling resin 300 in the case 200 to harden. In this way, the film capacitor 1 is completed.

[0065] The film capacitor 1 is mounted on an external device or the like. The external device or the like is provided with four positive external terminals 2a and four negative external terminals 2b, each of which takes the form of a bus bar. For example, if the first bus bar 500 is the positive bus bar and the second bus bar 600 is the negative bus bar, as shown in FIG. 1 , the four external terminals 2a pass through the openings 513 from the rear and come into contact with the four connection terminals 520 of the first bus bar 500, and are connected to these connection terminals 520 by a joining method such as soldering. Furthermore, the four external terminals 2b pass through the three overlapping openings 613, 716, and 514 from the rear and come into contact with the four connection terminals 620 of the second bus bar 600, and are connected to these connection terminals 620 by a joining method such as soldering.

[0066] <Method of manufacturing insulating members> Next, a method for manufacturing the insulating member 700 will be described.

[0067] Fig. 7 is a cross-sectional view of a mold 800 used for injection molding of the insulating member 700. Figs. 8(a) and 8(b) are plan views of a first member 801 and a second member 802 constituting the mold 800, respectively, as viewed from their parting surfaces. Note that for convenience, Fig. 8(a) shows the outline of a first molding surface 811 with a dashed line, and Fig. 8(b) shows a gate 820 with a dashed line.

[0068] The insulating member 700 is formed by injection molding using a mold 800 in a molding process.

[0069] The mold 800 is made of steel and is configured by joining a first member 801, which is a core, and a second member 802, which is a cavity. A mold section 810 having the shape of the insulating member 700 is formed inside the mold 800. The mold section 810 includes a first molding surface 811 for forming a rear surface 710b of the main body section 710 of the insulating member 700, and a second molding surface 812 for forming a front surface 710a of the main body section 710 facing away from the rear surface 710b.

[0070] First molding surface 811 includes a substantially cylindrical protruding portion 813 that protrudes toward second molding surface 812 at a position corresponding to the center of main body 710. Second molding surface 812 also includes a substantially cylindrical recessed portion 814 that houses protruding portion 813. A gap is formed between protruding portion 813 and recessed portion 814. The distance between tip surface 813a of protruding portion 813 and bottom surface 814a of recessed portion 814 is larger than the distance between first molding surface 811 and second molding surface 812 around it, and the portion between tip surface 813a and bottom surface 814a forms large gap portion 815.

[0071] A gate 820, which is an inlet for injecting resin into the mold portion 810, is formed on the tip surface 813a of the protrusion 813 on the first molding surface 811. The gate 820 is circular and opens to the large gap portion 815. A runner 830 connected to the gate 820 is formed in the first member 801 of the mold 800.

[0072] In the molding process, gate 820 is opened by a valve (not shown), and molten resin is injected from gate 820 through runner 830 into mold section 810. As shown by the arrows in FIGS. 7 and 8, the resin first flows into large gap section 815 of mold section 810. Then, the resin flows radially from large gap section 815 and spreads around. This causes the entire mold section 810 to be filled with resin.

[0073] Here, because gate 820 is provided on first molding surface 811 of mold portion 810 that constitutes the surface (rear surface 710b) of main body portion 710 of insulating member 700, resin can be injected from a portion close to the center of plate-shaped main body portion 710. This shortens the distance that resin flows within mold portion 810, making it easier for the resin to spread throughout the entire interior of mold portion 810. Furthermore, large gap portion 815 serves as a reservoir for the resin that has flowed into mold portion 810 from gate 820, improving the fluidity of the resin within mold portion 810 and shortening the time it takes for the resin to spread throughout the entire interior of mold portion 810.

[0074] The resin filled in mold part 810 cools to form insulating member 700. When filling of mold part 810 with resin is completed, gate 820 is closed by a valve. At this time, resin remains near gate 820, and this resin cools to form gate mark 715. Thereafter, mold 800 is separated, and insulating member 700 is removed from the inside.

[0075] 4(a) and 4(b) is completed. A protruding portion 714 is formed in the main body portion 710 of the insulating member 700 by filling the space between the protruding portion 813 and the recessed portion 814 of the mold portion 810 with resin. The tip of the protruding portion 714 is thicker than the other portions of the main body portion 710. A gate mark 715 protruding rearward is formed in the recessed surface on the back side of the protruding portion 714.

[0076] <Effects of the embodiment> As described above, according to this embodiment, the following effects are achieved.

[0077] Insulating member 700 includes a plate-shaped main body 710 having a portion interposed between first bus bar 500 and second bus bar 600, and is manufactured by injection molding using a mold 800 in a molding process. A mold portion 810 having the shape of insulating member 700 is formed inside mold 800. Mold portion 810 includes a first molding surface 811 for forming a rear surface 710b of main body 710, and a second molding surface 812 for forming a front surface 710a of main body 710 facing away from rear surface 710b. In the molding process, molten resin is injected into mold portion 810 through a gate 820 provided in first molding surface 811, thereby forming insulating member 700.

[0078] Gate 820 is provided on first molding surface 811 of mold portion 810 that forms the surface (rear surface 710b) of main body 710 of insulating member 700, so that resin can be injected from a portion near the center of plate-shaped main body 710. This shortens the distance that resin flows within mold portion 810, making it easier for resin to spread throughout the entire interior of mold portion 810 and reducing the likelihood of molding defects in insulating member 700.

[0079] Furthermore, mold section 810 includes large gap section 815 in which the gap between first molding surface 811 and second molding surface 812 is larger than the surrounding area, and gate 820 opens into large gap section 815.

[0080] Since large gap portion 815 serves as a reservoir for the resin that flows into mold portion 810 from gate 820, the fluidity of the resin within mold portion 810 improves, shortening the time it takes for the resin to spread throughout mold portion 810. This further reduces the likelihood of molding defects in insulating member 700.

[0081] Furthermore, first molding surface 811 includes protruding portion 813 that protrudes toward second molding surface 812, and second molding surface 812 includes recessed portion 814 that accommodates protruding portion 813. Gate 820 is provided on tip surface 813a of protruding portion 813. Resin is filled between protruding portion 813 and recessed portion 814 in main body 710 of insulating member 700, thereby recessing a portion of rear surface 710b and forming protruding portion 714 where a portion of front surface 710a protrudes. Gate mark 715 is formed on the recessed surface of rear surface 710b.

[0082] Since the gate mark 715 is accommodated in the recess 714a formed on the rear side of the protruding portion 714, the gate mark 715 is less likely to protrude from the rear surface 710b of the main body portion 710.

[0083] Furthermore, openings 516 through which protrusions 714 pass are formed in first bus bar 500 that contacts front surface 710a of main body 710. This makes it possible to avoid interference between protrusions 714 and first bus bar 500.

[0084] Opening 614 is formed in second bus bar 600 in contact with rear surface 710b of main body 710 at a position aligned with gate mark 715 formed on rear surface 710b. This makes it possible to avoid interference between gate mark 715 and second bus bar 600.

[0085] Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and application examples of the present invention can be modified in various ways in addition to the above-described embodiments.

[0086] For example, in the above embodiment, gate 820 is provided at one location in mold portion 810 of mold die 800. However, gate 820 may be provided at multiple locations, for example, two locations, in mold portion 810. For example, because main body portion 710 of insulating member 700 is long in the left-right direction, gate 820 may be provided at two locations in mold portion 810, corresponding to the center position of the right half and the center position of the left half of main body portion 710, as shown in FIG.

[0087] Furthermore, in the above embodiment, mold portion 810 of mold 800 has protrusion 813 on first molding surface 811 and recess 814 on second molding surface 812. As a result, main body portion 710 of insulating member 700 is formed with protrusion 714 that protrudes from front surface 710a and has recess 714a on its back surface, and gate mark 715 is formed on the bottom surface of recess 714a. As a result, gate mark 715 does not protrude, or is unlikely to protrude, from rear surface 710b of main body portion 710.

[0088] However, if the gate mark 715 is allowed to protrude from the rear surface 710b of the main body 710, as shown in Fig. 10(a), a recess 816 for forming the large gap portion 815 may be formed in the second molding surface 812 of the mold portion 810 of the mold die 800, and the protruding portion 813 may not be formed in the first molding surface 811. In this case, as shown in Fig. 10(b), the main body 710 of the insulating member 700 has a protruding portion 719a that protrudes from the front surface 710a by an amount that is thicker than the other portions, and the gate mark 715 protrudes from the rear surface 710b. The protruding amount of the protruding portion 719a is smaller than the protruding amount of the protruding portion 714 in the above embodiment. When first bus bar 500 , second bus bar 600 and insulating member 700 are combined, protrusion 719 a penetrates opening 516 of first bus bar 500 , and gate mark 715 penetrates opening 614 of second bus bar 600 .

[0089] Alternatively, as shown in FIG. 10( c), a mold portion 810 of a mold die 800 may have a recess 817 formed in a first molding surface 811 to define a large gap portion 815, and no protrusion 813 may be formed. In this case, as shown in FIG. 10( d), a protrusion 719b is formed in the main body 710 of the insulating member 700, protruding from a rear surface 710b by an amount corresponding to a thickness greater than that of other portions, and a gate mark 715 protrudes from this protrusion 719b. In this case, the front surface 710a of the main body 710 is flat, and therefore no opening 516 is formed in the first bus bar 500. When the first bus bar 500, the second bus bar 600, and the insulating member 700 are assembled, the protrusion 719b and the gate mark 715 pass through the opening 614 of the second bus bar 600.

[0090] Furthermore, in the above embodiment, in order to form a reservoir for the resin, the large gap portion 815 is provided in the mold portion 810 of the mold 800. However, if sufficient fluidity of the resin can be obtained without a reservoir, the large gap portion 815 does not need to be provided in the mold portion 810.

[0091] Furthermore, in the above embodiment, opening 614 is formed in main body 610 of second bus bar 600. However, if the depth of recess 714a in main body 710 of insulating member 700, i.e., the protrusion amount of protrusion 714, is increased to such an extent that gate trace 715 does not protrude from rear surface 710b of main body 710 even if the height of gate trace 715 varies, opening 614 does not have to be formed in main body 610 of second bus bar 600.

[0092] Furthermore, in the above embodiment, the rear surface 710b and the front surface 710a of the main body 710 of the insulating member 700 are respectively formed by the first molding surface 811 and the second molding surface 812 of the mold portion 810 of the mold 800. However, conversely, the front surface 710a and the rear surface 710b of the main body 710 of the insulating member 700 may be respectively formed by the first molding surface 811 and the second molding surface 812 of the mold portion 810. In this case, the insulating member 700 has a protrusion 714 formed on the rear surface 710b side of the main body 710, and a gate mark 715 formed on the front surface 710a side.

[0093] Furthermore, in the above embodiment, the film capacitor 1 is provided with one capacitor element 400. However, the number of capacitor elements 400 may be two or more, and may be changed as appropriate.

[0094] Furthermore, in the above embodiment, capacitor element 400 is formed by stacking two metallized films with aluminum vapor-deposited on a dielectric film and then rolling or laminating the stacked metallized films. However, capacitor elements 400 may also be formed by stacking a metallized film with aluminum vapor-deposited on both sides of a dielectric film and an insulating film, and then rolling or laminating the resulting film.

[0095] Furthermore, in the above embodiment, the film capacitor 1 is given as an example of the capacitor of the present invention. However, the present invention can also be applied to capacitors other than the film capacitor 1.

[0096] In addition, the embodiments of the present invention can be modified in various ways as appropriate within the scope of the technical ideas set forth in the claims.

[0097] In the description of the above embodiment, terms indicating directions such as "upper" and "lower" indicate relative directions that depend only on the relative positional relationship of the components, and do not indicate absolute directions such as vertical or horizontal. [Industrial Applicability]

[0098] The present invention is useful for capacitors used in various electronic devices, electrical devices, industrial devices, vehicle electrical equipment, and the like. [Explanation of symbols]

[0099] 1. Film capacitor (capacitor) 400 Capacitor element 500 1st bus bar (bus bar) 516 Opening (First Opening) 600 Second bus bar (bus bar) 614 Opening (Second Opening) 700 Insulating materials 710 Main body 710a Front (2nd surface) 710b Rear surface (1st surface) 714 Projection (second projection) 715 Gate Remains 800 molds 810 mold section 811 1st molding surface 812 2nd molding surface 813 Projection (first projection) 813a Tip surface 814 recess 820 Gates

Claims

1. a capacitor element; a first bus bar and a second bus bar connected to the capacitor element; a plate-shaped insulating member interposed between the first bus bar and the second bus bar; A capacitor comprising: the insulating member has a first surface facing the second bus bar and a second surface facing the first bus bar; the first surface of the insulating member has a recess recessed toward the second surface, and a gate mark provided on a bottom surface of the recess and protruding in a direction from the second surface toward the first surface, the second surface has a protrusion provided in a portion corresponding to the recess and protruding to an opposite side to the first surface, The depth of the recess of the insulating member is greater than the thickness between the first surface and the second surface around the protrusion. Capacitor.

2. An opening is formed in the second bus bar at a position overlapping with the gate mark. The capacitor of claim 1 .

3. a capacitor element; a first bus bar and a second bus bar connected to the capacitor element; a plate-shaped insulating member interposed between the first bus bar and the second bus bar; A capacitor comprising: the insulating member has a first surface facing the second bus bar and a second surface facing the first bus bar; the second surface of the insulating member has a protruding portion protruding in a direction opposite to the first surface, the first surface of the insulating member has a rear side portion of the protrusion flush with the periphery of the rear side portion, and has a gate mark on the rear side portion protruding in a direction opposite to the second surface; Capacitor.

4. a capacitor element; a first bus bar and a second bus bar connected to the capacitor element; a plate-shaped insulating member interposed between the first bus bar and the second bus bar; A capacitor comprising: the insulating member has a first surface facing the second bus bar and a second surface facing the first bus bar; the first surface of the insulating member has a protruding portion protruding in a direction opposite to the second surface, and a gate mark provided on a tip surface of the protruding portion and protruding in a direction opposite to the second surface; Capacitor.

5. an opening through which the gate mark passes is formed in the second bus bar; The capacitor according to claim 3 or 4.

6. a capacitor element; a first bus bar and a second bus bar connected to the capacitor element; an insulating member interposed between the first bus bar and the second bus bar; A capacitor comprising: the insulating member has a first surface facing the second bus bar and a second surface facing the first bus bar; the first surface of the insulating member has a recess recessed toward the second surface, and a gate mark provided on a bottom surface of the recess and protruding in a direction from the second surface toward the first surface, an opening having an inner diameter larger than an inner diameter of the recessed portion is formed in the second bus bar at a position overlapping the recessed portion and the gate mark; Capacitor.

7. a capacitor element; a first bus bar and a second bus bar connected to the capacitor element; an insulating member interposed between the first bus bar and the second bus bar; A capacitor comprising: the insulating member has a first surface facing the second bus bar and a second surface facing the first bus bar; the insulating member further has a gate mark at a position on the first surface spaced from an end of the insulating member; the first bus bar and the second bus bar have a first overlapping portion and a second overlapping portion that overlap each other, the insulating member has a first portion interposed between the first overlapping portion and the second overlapping portion, a second portion continuous with the first portion, and a third portion continuous with the first portion, the first portion is located between the second portion and the third portion, The gate mark is provided in the first portion. Capacitor.

8. the gate trace protrudes from the first surface in a direction from the second surface toward the first surface; The capacitor of claim 7.

Images