capacitor

Abstract

To provide a capacitor including a case including a first surface part opposite to an opening, and a second surface part surrounding the first surface part which can suppress warpage to an inner side of the second surface part.SOLUTION: A film capacitor 1 has a capacitor element 500, bus bars 600 and 700 connected to electrodes 510 and 520 of the capacitor element 500, a case 200 which has an opening 200a and stores the capacitor element 500, and a filled resin which is filled into the case 200. The case 200 includes a bottom face part 201 opposite to the opening 200a, and side face parts 202 and 203 surrounding the bottom face part 201. The bus bars 600 and 700 have flat-plate-shaped electrode terminal parts 610 and 710 opposite to the side face parts 202 and 203, and the electrode terminal parts 610 and 710 include projection parts 615 and 715 which project to the side face parts 202 and 203 and are brought into contact with the side face parts 202 and 203.SELECTED DRAWING: Figure 8

Description

[Technical Field]

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

[0002] Patent document 1 describes a metallized film capacitor in which a capacitor element is housed in a resin case filled with epoxy resin, in which tooth-like protrusions like clogs are formed on the inside of the side of the resin case so as to extend in the direction of the opening of the case. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2007-227696 Summary of the Invention [Problem to be solved by the invention]

[0004] The filling resin filled in the case in a liquid state may shrink when cooled after being heated and hardened, and there is a risk that the side surface of the case may be pulled by the shrinking filling resin and warp toward the inside of the case.

[0005] In view of such problems, the present invention aims to provide a capacitor having a case including a first surface portion facing an opening and a second surface portion surrounding the first surface portion, capable of suppressing inward warping of the second surface portion. [Means for solving the problem]

[0006] A capacitor according to a first aspect of the present invention comprises: Multiple a capacitor element; Multiple a bus bar connected to an electrode of the capacitor element; and an opening. MultipleThe capacitor device includes a case that houses a capacitor element and a filling resin that fills the case. The case includes a bottom surface that faces the opening and side surfaces that surround the bottom surface. The side surfaces include a front side surface and a rear side surface that face each other, and a right side surface and a left side surface that face each other. The front side surface and the rear side surface are wider than the right side surface and the left side surface. The front side surface or the rear side surface has a flat surface that extends along a first direction in which the opening and the bottom surface are aligned. The bus bar is The capacitor includes a flat-plate-shaped facing portion that is located between the plurality of capacitor elements and the front side surface portion or the rear side surface portion and faces the front side surface portion or the rear side surface portion. The facing portions are aligned in the second direction, protruding toward the front side surface or the rear side surface and abutting against the flat surface Multiple It has a protrusion. The plurality of protrusions are located within a range in which the capacitor element is present in the first direction. [Effects of the Invention]

[0008] According to the present invention, in a capacitor having a case including a first surface portion facing an opening and a second surface portion surrounding the first surface portion, inward warping of the second surface portion can be suppressed.

[0009] 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]

[0010] [Figure 1] FIG. 1(a) is a perspective view of a film capacitor according to an embodiment, as viewed from above and the front, and FIG. 1(b) is a perspective view of a film capacitor according to an embodiment, as viewed from below and the front. [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 an embodiment, as viewed from below and in front, and FIG. 3(b) is a partial side cross-sectional view of the first bus bar according to an embodiment, showing the periphery of a first protrusion portion. [Figure 4] FIG. 4(a) is a perspective view of a second bus bar according to an embodiment, as viewed from below and in front, and FIG. 4(b) is a partial side cross-sectional view of the second bus bar according to an embodiment, showing the periphery of a second protrusion portion. [Figure 5] FIG. 5(a) is a perspective view of the case according to the embodiment as seen from above the front, and FIG. 5(b) is a perspective view of the case according to the embodiment as seen from above the rear. [Figure 6] Figure 6(a) is an oblique view of the right side portion of the case as seen from the front and bottom according to the embodiment, and Figure 6(b) is a partial front cross-sectional view of the case showing the area around the first through hole and the second through hole according to the embodiment. [Figure 7] 7(a) and (b) are respectively a perspective view and a plan view of a sealing member according to an embodiment, and FIG. 7(c) is a cross-sectional view taken along line AA' of FIG. 7(b). [Figure 8] FIG. 8(a) is a side cross-sectional view of a film capacitor according to an embodiment before being filled with a filling resin, and FIG. 8(b) is a plan view of the center of a film capacitor according to an embodiment before being filled with a filling resin. [Figure 9] FIG. 9 is a cross-sectional view of a main part of a film capacitor according to an embodiment, showing the periphery of a first through hole before being filled with a filling resin. DETAILED DESCRIPTION OF THE INVENTION

[0011] 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 the "bottom portion" and the "front side portion."

[0012] In this embodiment, the film capacitor 1 corresponds to a "capacitor" in the claims. The bottom surface 201 corresponds to a "first surface" in the claims. The front side surface 202 and the rear side surface 203 correspond to a "second surface" in the claims. The first rib 220 and the second rib 230 correspond to a "rib" in the claims. The upper end surfaces 222 and 232 correspond to an "end surface" in the claims. The first electrode 510 and the second electrode 520 correspond to an "electrode" in the claims. The first bus bar 600 and the second bus bar 700 correspond to a "bus bar" in the claims. The first electrode terminal 610 and the second electrode terminal 710 correspond to an "opposing portion" in the claims. The first protrusion 615 and the second protrusion 715 correspond to an "abutment portion" and a "protrusion" in the claims. Furthermore, the peripheral surfaces 615a and 715a correspond to the "side surfaces" described in the claims.

[0013] 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.

[0014] FIG. 1(a) is a perspective view of the film capacitor 1 as seen from above the front, and FIG. 1(b) is a perspective view of the film capacitor 1 as seen from below the front.

[0015] As shown in Figures 1(a) and (b), the film capacitor 1 comprises a capacitor element unit 100, a case 200 in which the capacitor element unit 100 is housed, a filling resin 300 filled in the case 200, and two sealing members 400.

[0016] Filling resin 300 is a thermosetting resin such as epoxy resin, which is injected in a liquid state into case 200 housing capacitor element unit 100, and then hardens when the inside of case 200 is heated. Most of capacitor element unit 100, which is buried in filling resin 300, is protected from moisture and impact.

[0017] The three first upper connection terminal portions 630 and the three second upper connection terminal portions 730 of the capacitor element unit 100 are led out to the outside through an opening 200a in the top surface of the case 200. The first upper connection terminal portions 630 and the second upper connection terminal portions 730 are arranged side by side in the left-right direction. The first lower connection terminal portion 650 and the second lower connection terminal portion 750 are led out to the outside through a first through hole 240 and a second through hole 250 provided in the bottom surface portion 201 of the case 200, respectively. Sealing members 400 are interposed between the outer surface of the first lower connection terminal portion 650 and the inner wall surface of the first through hole 240, and between the outer surface of the second lower connection terminal portion 750 and the inner wall surface of the second through hole 250, respectively.

[0018] 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. Fig. 3(a) is a perspective view of the first bus bar 600 seen from below the front, and Fig. 3(b) is a partial cross-sectional side view of the first bus bar 600 showing the periphery of the first protrusion 615. Fig. 4(a) is a perspective view of the second bus bar 700 seen from below the front, and Fig. 4(b) is a partial cross-sectional side view of the second bus bar 700 showing the periphery of the second protrusion 715.

[0019] 2 to 4(b), the capacitor element unit 100 includes three capacitor elements 500, a first bus bar 600, a second bus bar 700, and an insulating plate 800.

[0020] Capacitor element 500 is formed by stacking two metallized films, each consisting of a dielectric film with aluminum vapor-deposited thereon, and then rolling or laminating the stacked metallized films and pressing them flat. Capacitor element 500 has a first electrode 510 formed on one end face by spraying a metal such as zinc, and a second electrode 520 formed on the other end face by also spraying a metal such as zinc. Three capacitor elements 500 are arranged with their peripheral surfaces facing each other, and in this state, a first bus bar 600 and a second bus bar 700 are connected to these capacitor elements 500.

[0021] Although capacitor element 500 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 500 may be formed from a metallized film in which a plurality of these metals are vapor-deposited, or from a metallized film in which an alloy of these metals is vapor-deposited.

[0022] First bus bar 600 is formed from a conductive material, for example, a copper plate, and includes a first electrode terminal portion 610, a first upper relay portion 620, three first upper connection terminal portions 630, a first lower relay portion 640, and a first lower connection terminal portion 650. First bus bar 600 is formed, for example, by appropriately cutting out and bending a single copper plate, and first electrode terminal portion 610, first upper relay portion 620, first upper connection terminal portion 630, first lower relay portion 640, and first lower connection terminal portion 650 are integrated together.

[0023] The first electrode terminal portion 610 has a substantially rectangular plate shape and covers the first electrodes 510 of each capacitor element 500. The first electrode terminal portion 610 has a substantially L-shaped notch 611 formed at its left end, a substantially rectangular opening 612 formed in its center, and a substantially U-shaped notch 613 formed at its right end. A pair of electrode pins 614 is formed at the upper edges of the left and right notches 611, 613 and the opening 612. Each pair of electrode pins 614 is joined to the first electrodes 510 of the corresponding capacitor elements 500 by a joining method such as soldering. This electrically connects the first bus bar 600 to the capacitor elements 500.

[0024] A plurality of first protrusions 615 (four in this embodiment) are formed on the upper part of the first electrode terminal 610 and protrude forward so as to be aligned in the left-right direction. As shown in Fig. 3(b), each first protrusion 615 has a substantially flat truncated cone shape, with a tip 615a formed as a circular flat surface and a peripheral surface 615b having a tapered shape. In addition, two circular holes 616 are formed on the lower part of the first electrode terminal 610.

[0025] The first upper relay portion 620 relays between the first electrode terminal portion 610 and the three first upper connection terminal portions 630. The first upper relay portion 620 extends slightly rearward from the upper edge of the first electrode terminal portion 610 and then extends slightly upward. Two oblong holes 621 are formed in the first upper relay portion 620, aligned in the left-right direction.

[0026] The three first upper connection terminal portions 630 are formed at a predetermined interval on the upper edge of the first upper relay portion 620. Each first upper connection terminal portion 630 extends upward from the upper edge of the first upper relay portion 620, with a wide base end and large R at both corners of the tip. A circular mounting hole 631 is formed in each first upper connection terminal portion 630.

[0027] The first lower relay portion 640 provides a relay between the first electrode terminal portion 610 and the first lower connection terminal portion 650. The first lower relay portion 640 extends rearward from the lower edge of the first electrode terminal portion 610. The first lower relay portion 640 includes a connection portion 641 at its right end portion that extends rearward with the same width as the first lower connection terminal portion 650 and is connected to the first lower connection terminal portion 650.

[0028] The first lower connection terminal portion 650 has a substantially rectangular plate shape and extends downward from the tip of the connection portion 641 of the first lower relay portion 640. The first lower connection terminal portion 650 has a circular mounting hole 651 formed therein.

[0029] The second bus bar 700 is formed from a conductive material, for example, a copper plate, and includes a second electrode terminal portion 710, a second upper relay portion 720, a second upper connection terminal portion 730, a second lower relay portion 740, and a second lower connection terminal portion 750. The second bus bar 700 is formed, for example, by appropriately cutting out and bending a single copper plate, and the second electrode terminal portion 710, the second upper relay portion 720, the three second upper connection terminal portions 730, the second lower relay portion 740, and the second lower connection terminal portion 750 are integrated together.

[0030] The second electrode terminal portion 710 has a substantially rectangular plate shape and covers the second electrodes 520 of each capacitor element 500. The second electrode terminal portion 710 has a substantially U-shaped notch 711 cut out at its left end, and two substantially rectangular openings 712 and 713 formed at its central and right ends. A pair of electrode pins 714 is formed at the upper edges of the notch 711 and the two openings 712 and 713. Each pair of electrode pins 714 is joined to the second electrodes 520 of the corresponding capacitor elements 500 by a joining method such as soldering. This electrically connects the second bus bar 700 to the capacitor elements 500.

[0031] A plurality of second protrusions 715 (four in this embodiment) are formed on the upper part of the second electrode terminal 710, protruding rearward and aligned in the left-right direction. As shown in Fig. 4(b), each second protrusion 715 has a substantially flat truncated cone shape, with a tip 715a formed as a circular flat surface and a tapered peripheral surface 715b. Two circular holes 716 are formed on each of the upper and lower parts of the second electrode terminal 710.

[0032] The second upper relay portion 720 provides a relay between the second electrode terminal portion 710 and the three second upper connection terminal portions 730. The second upper relay portion 720 extends forward from the upper edge of the second electrode terminal portion 710 and then extends slightly upward. Two oval holes 721 and four circular holes 722 are formed in the second upper relay portion 720 so as to be aligned in the left-right direction. Furthermore, three oval holes 723 are formed in the second upper relay portion 720 in front of these six holes 721, 722 so as to be aligned in the left-right direction.

[0033] The three second upper connection terminal portions 730 are formed at a predetermined interval on the upper edge of the second upper relay portion 720. Each second upper connection terminal portion 730 extends upward from the upper edge of the second upper relay portion 720, with a wide base end and large R at both corners of the tip end. A circular mounting hole 731 is formed in each second upper connection terminal portion 730.

[0034] The second lower relay portion 740 provides a relay between the second electrode terminal portion 710 and the second lower connection terminal portion 750. The second lower relay portion 740 extends forward from the lower edge of the second electrode terminal portion 710. The second lower relay portion 740 includes a connection portion 741 at its right end portion that extends rearward with the same width as the second lower connection terminal portion 750 and is connected to the second lower connection terminal portion 750.

[0035] The second lower connection terminal portion 750 has a substantially rectangular plate shape and extends downward from the tip of the connection portion 741 of the second lower relay portion 740. The second lower connection terminal portion 750 has a circular mounting hole 751 formed therein.

[0036] Insulating plate 800 is formed from a resin material such as polyphenylene sulfide (PPS), and is interposed between overlapping portions in the front-to-rear direction of first upper relay portion 620 and three first upper connecting terminal portions 630 of first bus bar 600 and second upper relay portion 720 and three second upper connecting terminal portions 730 of second bus bar 700. Insulating plate 800 ensures insulation between first bus bar 600 and second bus bar 700.

[0037] In capacitor element unit 100, first lower connection terminal portion 650 of first bus bar 600 and second lower connection terminal portion 750 of second bus bar 700 are located at the lower right end.

[0038] Fig. 5(a) is a perspective view of the case 200 as seen from above the front, and Fig. 5(b) is a perspective view of the case 200 as seen from above the rear. Fig. 6(a) is a perspective view of the right portion of the case 200 as seen from below the front, and Fig. 6(b) is a partial front cross-sectional view of the case 200 showing the periphery of the first through-hole 240 and the second through-hole 250.

[0039] 5(a) to 6(b), case 200 is made of resin, for example, polyphenylene sulfide (PPS), and has a generally rectangular box shape that is elongated in the left-right direction and has an open top. Case 200 is composed of a bottom surface 201 that faces opening 200a on the top surface, and front side surface 202, rear side surface 203, left side surface 204, and right side surface 205 that rise from bottom surface 201 and surround bottom surface 201 on the front, back, left, and right sides, respectively. Front side surface 202 and rear side surface 203 are a pair of side surface portions that extend along the longitudinal direction of case 200 and have a relatively large width (dimension in the left-right direction), while left side surface 204 and right side surface 205 are a pair of side surface portions that extend along the lateral direction of case 200 and have a relatively small width (dimension in the front-to-back direction).

[0040] Mounting tabs 210 are provided on the outer wall surfaces of the left side surface 204 and the right side surface 205. Each mounting tab 210 has insertion holes 211 formed on the upper and lower sides. Metal collars 212 are fitted into the insertion holes 211 to increase the strength of the holes. When the film capacitor 1 is installed in an installation portion of an external device, these mounting tabs 210 are fixed to the installation portion with screws or the like.

[0041] A plurality of first ribs 220 and second ribs 230 (six in this embodiment) are formed in the left-right direction on the front side surface portion 202 and the rear side surface portion 203, respectively, protruding from the inner wall surface toward the inside of the case 200. That is, the plurality of first ribs 220 and second ribs 230 are arranged so as to be dispersed at predetermined intervals over the entire front side surface portion 202 and the rear side surface portion 203 so as to reinforce these side surfaces.

[0042] Each of the first ribs 220 and each of the second ribs 230 extends from the vicinity of the bottom surface 201 to the vicinity of the opening 200a. Each of the first ribs 220 and each of the second ribs 230 has a generally rectangular parallelepiped shape that is elongated in the vertical direction and flattened in the front-to-rear direction. As a result, the tips 221, 231 of each of the first ribs 220 and each of the second ribs 230 form elongated flat rectangular surfaces. The upper end surfaces 222, 232 (the end surfaces on the opening 200a side) of each of the first ribs 220 and each of the second ribs 230 are inclined so as to move away from the opening 200a as they approach the interior of the case 200.

[0043] Of the six first ribs 220, the positions of four first ribs 220 in the center correspond to the positions of four first protrusions 615 of the first bus bar 600. The left-right dimension of these four first ribs 220 is slightly smaller than the diameter (left-right dimension) of the tip 615a of the first protrusion 615, and the up-down dimension is significantly larger than the diameter (up-down dimension) of the tip 615a of the first protrusion 615.

[0044] Similarly, of the six second ribs 230, the positions of the four second ribs 230 in the center correspond to the positions of the four second protrusions 715 of the second bus bar 700. The left-right dimension of these four second ribs 230 is slightly smaller than the diameter of the tip 715a of the second protrusion 715, and the up-down dimension is significantly larger than the diameter (up-down dimension) of the tip 715a of the second protrusion 715.

[0045] The bottom surface portion 201 has a shape in which the portion 201a near the right end is slightly deeper than the other portions. A substantially rectangular protruding portion 206 that protrudes downward is formed in the portion 201a near the right end, and the thickness of the bottom surface portion 201 at the protruding portion 206 is greater than the thickness of the other portions.

[0046] A first through hole 240 and a second through hole 250 are formed in the protruding portion 206 so as to be aligned in the left-right direction. The first through hole 240 and the second through hole 250 include first holes 241, 251 and second holes 242, 252 that are continuous with the first holes 241, 251. The second holes 242, 252 are larger and longer (deeper) than the first holes 241, 251. The first holes 241, 251 are located inside the case 200, and the second holes 242, 252 are located outside the case 200.

[0047] First holes 241, 251 have a shape corresponding to the horizontal cross-sectional shape of first lower connection terminal portion 650 and second lower connection terminal portion 750, respectively, i.e., an elongated rectangular shape. The inner wall surfaces of first holes 241, 251 have slopes 241a, 251a so that the holes widen toward the inside of case 200. The diameters (front-to-back dimensions, left-to-right dimensions) of the smallest openings at the bottom ends of first holes 241, 251 are slightly larger than the diameters (thickness dimensions, width dimensions) of first lower connection terminal portion 650 and second lower connection terminal portion 750, respectively.

[0048] The second holes 242, 252 have a shape corresponding to the planar shape of the sealing member 400, i.e., an oval shape. The inner wall surfaces of the second holes 242, 252 are formed with a slight draft angle due to the mold used when molding the case 200.

[0049] 7(a) and (b) are a perspective view and a plan view of the sealing member 400, respectively, and FIG. 7(c) is a cross-sectional view taken along line AA' of FIG. 7(b).

[0050] The two sealing members 400 are made of an elastic material, for example, a rubber material such as silicone rubber, and have an oval cylindrical shape.

[0051] Each sealing member 400 has an elastically deformable annular fin portion 410 formed around its outer periphery at its tip and middle portions. As shown in FIG. 7(c), the fin portion 410 has a cross section resembling a right triangle, with a surface 411 facing the tip (upward) being gently convexly curved and inclined, and a surface 412 facing the base (downward) being gently concavely curved. To match the draft angles of the second holes 242 and 252 of the case 200, the height of the fin portion 410 at the tip is slightly lower than the height of the fin portion 410 at the middle portion. Each sealing member 400 also has a flange portion 420 formed at its base end. Furthermore, each sealing member 400 has two elastically deformable annular ribs 430 formed around its inner periphery. Each rib 430 has a semicircular cross section. In the longitudinal direction (vertical direction) of the sealing member 400, the rib 430 on the tip side is located between the two fin portions 410, and the rib 430 on the base side is located between the fin portion 410 in the middle and the flange portion 420. That is, in the longitudinal direction of the sealing member 400, the positions of the two fin portions 410 and the positions of the two ribs 430 are different.

[0052] The outer diameter of the sealing member 400 including the fin portion 410 is larger than the diameters of the first through-hole 240 and the second holes 242, 252 of the second through-hole 250. The inner diameter of the sealing member 400 including the rib 430 is smaller than the diameters (thickness, width) of the first lower connecting terminal portion 650 and the second lower connecting terminal portion 750.

[0053] Fig. 8(a) is a side cross-sectional view of the film capacitor 1 before being filled with the filling resin 300, and Fig. 8(b) is a plan view of the central part of the film capacitor 1 before being filled with the filling resin 300. Fig. 9 is a cross-sectional view of the main part of the film capacitor 1 before being filled with the filling resin 300, showing the periphery of the first through-hole 240. For convenience, Fig. 9 shows the sealing member 400 in a state before the fin portions 410 and the ribs 430 are deformed.

[0054] Capacitor element unit 100 is accommodated in case 200 through opening 200a on the top surface of case 200. At this time, first lower connection terminal portion 650 of first bus bar 600 is passed through first through hole 240 and led out to the outside, and second lower connection terminal portion 750 of second bus bar 700 is passed through second through hole 250 and led out to the outside. At this time, first holes 241, 251 of first through hole 240 and second through hole 250 widen toward the inside of case 200, so that first lower connection terminal portion 650 and second lower connection terminal portion 750 can be easily inserted into first through hole 240 and second through hole 250 inside case 200. The positions of first lower connection terminal portion 650 and second lower connection terminal portion 750 passed through first through hole 240 and second through hole 250 are restricted by first holes 241, 251.

[0055] When the capacitor element unit 100 is inserted into the case 200, the first electrode terminal 610 of the first bus bar 600 faces the front side surface 202, and the four first protrusions 615 of the first electrode terminal 610 abut against the four first ribs 220 in the center of the front side surface 202 at a position closer to the opening 200a than the top of the case 200, i.e., the bottom surface 201. Similarly, the second electrode terminal 710 of the second bus bar 700 faces the rear side surface 203, and the four second protrusions 715 of the second electrode terminal 710 abut against the four second ribs 230 in the center of the rear side surface 203 at the top of the case 200.

[0056] At this time, the flat surfaces of the tips 221, 615a of the first rib 220 and the first protrusion 615 abut against each other, and the flat surfaces of the tips 231, 715a of the second rib 230 and the second protrusion 715 abut against each other. Therefore, even if the positions of the first rib 220 and the first protrusion 615 or the positions of the second rib 230 and the second protrusion 715 are slightly misaligned in the left-right direction, they can be reliably abutted against each other. Furthermore, since the diameter (left-right dimension) of the tips 615a, 715a of the first protrusion 615 and the second protrusion 715 is larger than the width (left-right dimension) of the tips 221, 231 of the first rib 220 and the second rib 230, an increase in the amount of resin in the case 200 due to the wider width of the first rib 220 and the second rib 230 is suppressed, and the first rib 220 and the first protrusion 615, and the second rib 230 and the second protrusion 715 can be more reliably abutted against each other.

[0057] Note that the upper end surfaces 222, 232 of the first rib 220 and the second rib 230 and the lower sides of the peripheral surfaces 615b, 715b of the first protrusion 615 and the second protrusion 715, i.e., the bottom surface 201 side, are inclined so as to move away from the opening 200a toward the inside of the case 200. This makes it difficult for the first protrusion 615 and the second protrusion 715 to get caught on the upper end portions 222, 232 of the first rib 220 and the second rib 230 when the capacitor element unit 100 is inserted into the case 200 from above. This allows the capacitor element unit 100 to be smoothly accommodated in the case 200.

[0058] After the capacitor element unit 100 is accommodated in the case 200, the sealing member 400 is inserted from the outside of the case 200 into the first lower connection terminal portion 650 and the second lower connection terminal portion 750, and into the second holes 242, 252 of the first through hole 240 and the second through hole 250. When the sealing member 400 is pushed into the second holes 242, 252 until the flange portion 420 abuts against the wall surface surrounding the second holes 242, 252 in the protruding portion 206 of the case 200, the attachment of the sealing member 400 is complete. By confirming that the flange portion 420 abuts against the wall surface of the protruding portion 206, it can be confirmed that the sealing member 400 is completely attached.

[0059] 9 , sealing member 400 is interposed between the outer surface of first lower connection terminal portion 650 and the inner wall surface of second hole 242 of first through hole 240, thereby sealing the gap between first lower connection terminal portion 650 and first through hole 240. Two fin portions 410 on the outer peripheral surface of sealing member 400 are tilted downward, i.e., in the direction opposite to the insertion direction of sealing member 400 into first through hole 240, and are deformed so as to contract inward, so that the entire periphery of each fin portion 410 abuts against the inner wall surface of second hole 242. Each fin portion 410 is pressed against the inner wall surface of second hole 242.

[0060] Furthermore, the two ribs 430 on the inner peripheral surface of the sealing member 400 deform so as to shrink inward, and come into contact with the outer surface of the first lower connecting terminal portion 650 around the entire circumference. Each rib 430 is pressed against the outer surface of the first lower connecting terminal portion 650. Portions of the inner peripheral surface of the sealing member 400 other than the ribs 430 do not come into contact with the outer surface of the first lower connecting terminal portion 650. This makes it easier to insert the sealing member 400 into the first lower connecting terminal portion 650.

[0061] The length from the tip of sealing member 400 to just before flange portion 420 is shorter than the length of second hole 242. As a result, a small gap is formed between the wall surface between first hole 241 and second hole 242 of first through-hole 240 and the tip surface of sealing member 400.

[0062] Similarly, sealing member 400 is interposed between the outer surface of second lower connection terminal portion 750 and the inner wall surface of second hole 252 of second through hole 250, sealing the space between second lower connection terminal portion 750 and second through hole 250. Two fin portions 410 deform to abut the entire periphery against the inner wall surface of second hole 252, and two ribs 430 deform to abut the entire periphery against the outer surface of second lower connection terminal portion 750. A small gap is formed between the wall surface between first hole 251 and second hole 252 of second through hole 250 and the tip surface of sealing member 400.

[0063] The fin portion 410 of the sealing member 400 has a surface 411 that is inclined toward the tip, i.e., the insertion direction. This reduces the resistance that occurs when inserting the sealing member 400 into the second holes 242, 252, making it easier to insert the sealing member 400 into the second holes 242, 252.

[0064] Filling resin 300 in a liquid state is injected through opening 200a into case 200, which houses capacitor element unit 100, and is stored therein. At this time, sealing member 400 seals the gap between first lower connection terminal portion 650 and first through hole 240, and sealing member 400 seals the gap between second lower connection terminal portion 750 and second through hole 250. This prevents filling resin 300 in a liquid state from leaking out of case 200 from first through hole 240 and second through hole 250.

[0065] In particular, the fin portions 410 of the sealing member 400 adhere strongly to the inner wall surfaces of the second holes 242, 252 of the first through-hole 240 and the second through-hole 250 due to the pressing force (stress) generated by the deformation of the fin portions 410, thereby tightly sealing the gap between the sealing member 400 and the inner wall surfaces of the second holes 242, 252. This effectively prevents leakage of the filling resin 300 from between the sealing member 400 and the second holes 242, 252.

[0066] Furthermore, the ribs 430 of the sealing member 400 adhere strongly to the outer surfaces of the first and second lower connection terminal portions 650 and 750 due to the pressing force (stress) generated by the deformation of the ribs 430, thereby tightly sealing the gaps between the sealing member 400 and the outer surfaces of the first and second lower connection terminal portions 650 and 750. This effectively prevents leakage of the filling resin 300 from between the sealing member 400 and the first and second lower connection terminal portions 650 and 750.

[0067] Furthermore, since the second holes 242, 252 are blocked from the outside of the case 200 by the flange portion 420 of the sealing member 400, leakage of the filling resin 300 from the first through-hole 240 and the second through-hole 250 to the outside of the case 200 is further prevented.

[0068] A portion of the filling resin 300 injected into the case 200 flows between the front side surface portion 202 and the first electrode terminal portion 610 and between the rear side surface portion 203 and the second electrode terminal portion 710 .

[0069] The vertical dimension of the first protrusion 615 (the direction in which the opening 200a and the bottom surface 201 are aligned) is smaller than the vertical dimension of the first ribs 220, and at the positions of the four first ribs 220 in the center, a gap is generated between the first electrode terminal 610 and the first ribs 220 in the vertical direction, except for the portion where the first ribs 220 and the first protrusion 615 are in contact with each other. Similarly, the vertical dimension of the second protrusion 715 is smaller than the vertical dimension of the second ribs 230, and at the positions of the four second ribs 230 in the center, a gap is generated between the second electrode terminal 710 and the second ribs 230 in the vertical direction, except for the portion where the second ribs 230 and the second protrusion 715 are in contact with each other. Therefore, the filling resin 300 can move smoothly in the left-right direction at the positions of the first rib 220 and the second rib 230, and is distributed well between the front side surface portion 202 and the first electrode terminal portion 610 and between the rear side surface portion 203 and the second electrode terminal portion 710.

[0070] In addition, if the first protrusion 615 and the second protrusion 715 are not provided on the first electrode terminal 610 and the second electrode terminal 710, and the tips 221, 231 of the first rib 220 and the second rib 230 are configured so that almost the entirety of the tips 221, 231 abut against the flat outer surfaces of the first electrode terminal 610 and the second electrode terminal 710, there will be almost no gap between the first electrode terminal 610 and the first rib 220 and between the second electrode terminal 710 and the second rib 230, so the filling resin 300 will not be able to move smoothly in the left-right direction and will be difficult to spread between the front side surface 202 and the first electrode terminal 610 and between the rear side surface 203 and the second electrode terminal 710.

[0071] Furthermore, the filling resin 300 that flows into the case 200 flows through the holes 616, 621 provided in the first bus bar 600 and the holes 716, 721, 722, 723 provided in the second bus bar 700, and thereby spreads well to the inside of the capacitor element unit 100, i.e., between the first bus bar 600, the second bus bar 700 and the three capacitor elements 500.

[0072] Once the injection of the filled resin 300 into the case 200 is complete, the case 200 is heated, which hardens the filled resin 300 inside the case 200. The hardened filled resin 300 is then cooled, during which time the filled resin 300 may shrink. At this time, the front side surface 202, rear side surface 203, left side surface 204, and right side surface 205 of the case 200 are subjected to stress that pulls them toward the inside of the case 200 due to the shrinking filled resin 300.

[0073] The front side surface portion 202 and the rear side surface portion 203 are reinforced by six first ribs 220 and six second ribs 230. Furthermore, the four first ribs 220 and four second ribs 230 in the center abut against the first protrusions 615 and the second protrusions 715, respectively, so that the front side surface portion 202 and the rear side surface portion 203 are supported by the first protrusions 615 and the second protrusions 715 from the inside of the case 200. This firmly prevents the front side surface portion 202 and the rear side surface portion 203 from warping toward the inside of the case 200. In particular, the front side surface portion 202 and the rear side surface portion 203 are prone to warping at the upper sides near the opening 200a, but because the first protrusions 615 and the second protrusions 715 are located at the upper parts, warping of the front side surface portion 202 and the rear side surface portion 203 can be effectively prevented.

[0074] On the other hand, left side surface portion 204 and right side surface portion 205 have small dimensions in the front-to-rear direction, and are reinforced by mounting tabs 210 formed on the outer wall surfaces. This prevents left side surface portion 204 and right side surface portion 205 from warping toward the inside of case 200, even without the configuration of first rib 220, second rib 230, and first protrusion 615 and second protrusion 715.

[0075] In this way, the film capacitor 1 is completed as shown in FIGS. 1(a) and 1(b).

[0076] The film capacitor 1 is mounted on various external devices such as an inverter device provided in an electric vehicle. A pair of external terminals (not shown) provided on the external device or the like and corresponding to the connection terminals 630, 730 are connected to the first upper connection terminal portion 630 and the second upper connection terminal portion 730. Furthermore, a pair of external terminals (not shown) provided on the external device and corresponding to the connection terminals 650, 750 are connected to the first lower connection terminal portion 650 and the second lower connection terminal portion 750.

[0077] Note that the front-rear and left-right directions of the film capacitor 1 when mounted on an external device are not necessarily the same as those shown in this embodiment, i.e., the opening 200a of the case 200 faces upward and the bottom surface 201 faces downward. For example, the film capacitor 1 may be mounted on an external device so that the rear side surface 203 faces downward. If strong cooling of the film capacitor 1 is required, a cooler (not shown) is attached to the outer surface of the rear side surface 203. In this case, the flatness of the rear side surface 203 of the film capacitor 1 is increased, improving the adhesion of the cooler and achieving good cooling performance.

[0078] <Effects of the embodiment> As described above, according to this embodiment, the following effects are achieved.

[0079] The film capacitor 1 includes a capacitor element 500, a first bus bar 600 (second bus bar 700) connected to a first electrode 510 (second electrode 520) of the capacitor element 500, a case 200 having an opening 200a and accommodating the capacitor element 500, and a filling resin 300 filled in the case 200. The case 200 includes a bottom surface 201 facing the opening 200a and a front side surface 202 (rear side surface 203) surrounding the bottom surface 201. A first rib 220 (second rib 230) is formed on the inner wall surface of the front side surface 202 (rear side surface 203) and extends in a direction in which the opening 200a and the bottom surface 201 are aligned. The first bus bar 600 (second bus bar 700) has a first electrode terminal 610 (second electrode terminal 710) facing the front side surface portion 202 (rear side surface portion 203), and the first electrode terminal 610 (second electrode terminal 710) includes a first protrusion 615 (second protrusion 715) that abuts against the first rib 220 (second rib 230). The first protrusion 615 (second protrusion 715) protrudes toward the first electrode terminal 610 (second electrode terminal 710), and the dimension in the direction in which the opening 200a and the bottom surface portion 201 are aligned is shorter than the dimension of the first rib 220 (second rib 230) in this direction.

[0080] According to this configuration, the first rib 220 (second rib 230) can increase the strength of the front side surface portion 202 (rear side surface portion 203), and the first protrusion 615 (second protrusion 715) abuts against the first rib 220 (second rib 230), so that the front side surface portion 202 (rear side surface portion 203) can be supported from the inside of the case 200 by the first protrusion 615 (second protrusion 715). This makes it possible to firmly suppress warping of the front side surface portion 202 (rear side surface portion 203) toward the inside of the case 200.

[0081] Moreover, the dimension of the first protrusion 615 (second protrusion 715) in the direction in which the opening 200a and the bottom surface 201 are aligned (up-down direction) is smaller than the dimension of the first rib 220 (second rib 230) in this direction, and at the position of the first rib 220 (second rib 230), a gap is generated between the first electrode terminal 610 (second electrode terminal 710) and the first rib 220 (second rib 230) in the alignment direction except for the portion where the first rib 220 (second rib 230) and the first protrusion 615 (second protrusion 715) are in contact. This allows the filling resin 300 in a liquid phase to move smoothly back and forth in the direction perpendicular to the alignment direction (left-right direction) at the position of the first rib 220 (second rib 230). Therefore, the filled resin 300 that has flowed in can be smoothly spread between the front side surface portion 202 and the first electrode terminal portion 610 (between the rear side surface portion 203 and the second electrode terminal portion 710).

[0082] In the film capacitor 1, the first rib 220 (second rib 230) and the first protrusion 615 (second protrusion 715) have their respective tips 221 (231), 615a (715a) formed on flat surfaces.

[0083] According to this configuration, the flat surfaces of the tips 221 (231), 615a (715a) of the first rib 220 (second rib 230) and the first protrusion 615 (second protrusion 715) abut against each other. Therefore, even if the positions of the first rib 220 (second rib 230) and the first protrusion 615 (second protrusion 715) are slightly misaligned in the direction (left-right direction) perpendicular to the direction in which the opening 200a and the bottom surface 201 are aligned, they can be reliably abutted against each other.

[0084] Furthermore, in the film capacitor 1, the upper end surface 222 (232) of the first rib 220 (second rib 230) and the peripheral surface 615b (715b) on the bottom surface 201 side of the first protrusion 615 (second protrusion 715) are inclined so as to move away from the opening 200a as they move toward the inside of the case 200.

[0085] According to this configuration, when the capacitor element unit 100 is inserted into the case 200 through the opening 200a, the first protrusion 615 (second protrusion 715) is less likely to get caught on the upper end surface 222 (232) of the first rib 220 (second rib 230), and the capacitor element unit 100 can be smoothly accommodated in the case 200.

[0086] Furthermore, the film capacitor 1 is configured so that the position of the first protrusion 615 (second protrusion 715) is closer to the opening 200a than the bottom surface 201.

[0087] According to this configuration, the front side portion 202 (rear side portion 203) is prone to warping on the side closer to the opening 200a, but since the position of the first protrusion portion 615 (second protrusion portion 715) is closer to the opening 200a than the bottom surface portion 201, warping of the front side portion 202 (rear side portion 203) can be effectively suppressed.

[0088] 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.

[0089] For example, in the above embodiment, the first protrusions 615 and the second protrusions 715 are formed on the first electrode terminal 610 and the second electrode terminal 710 as abutment portions that abut against the first rib 220 and the second rib 230. However, the first protrusions 615 and the second protrusions 715 may not be formed on the first electrode terminal 610 and the second electrode terminal 710, and the outer surfaces of the first electrode terminal 610 and the second electrode terminal 710 may abut against the first rib 220 and the second rib 230 as abutment portions. However, in this case, it becomes difficult to obtain gaps between the first electrode terminal portion 610 and the first rib 220 and between the second electrode terminal portion 710 and the second rib 230, and as a result, it may become difficult for the liquid-phase filling resin 300 injected into the case 200 to spread between the front side surface portion 202 and the first electrode terminal portion 610 and between the rear side surface portion 203 and the second electrode terminal portion 710.

[0090] In the above embodiment, the first protrusions 615 and the second protrusions 715 are configured to abut against some (four) of the plurality (six) of first ribs 220 and second ribs 230. However, the first protrusions 615 and the second protrusions 715 may be configured to abut against all of the plurality of first ribs 220 and second ribs 230. Furthermore, the numbers of first ribs 220 and second ribs 230, and the numbers of first protrusions 615 and second protrusions 715 are not limited to those in the above embodiment and can be changed as appropriate.

[0091] Furthermore, in the above embodiment, the tips 615a, 715a of the first protrusion 615 and the second protrusion 715 are flat surfaces. However, the tips 615a, 715a may be arcuate surfaces instead of flat surfaces. Similarly, the tips 221, 231 of the first rib 220 and the second rib 230 may be arcuate surfaces instead of flat surfaces.

[0092] Furthermore, the shapes of first protrusion 615 and second protrusion 715 are not limited to those in the above embodiment. For example, first protrusion 615 and second protrusion 715 may have a shape other than a circle, such as an oval, square, or rectangle, when viewed from the front.

[0093] Furthermore, in the above embodiment, both the upper end surfaces 222, 232 of the first rib 220 and the second rib 230 and the peripheral surfaces 615b, 715b on the bottom surface 201 side of the first protrusion 615 and the second protrusion 715 are inclined so as to move away from the opening 200a as they move toward the inside of the case 200, but only one of them may be inclined.

[0094] Furthermore, in the above embodiment, the first protrusions 615 and the second protrusions 715 are formed on the upper parts of the first electrode terminal 610 and the second electrode terminal 710 so as to be closer to the opening 200a than the bottom surface 201. However, the first protrusions 615 and the second protrusions 715 may be formed not only on the upper parts but also on the lower parts of the first electrode terminal 610 and the second electrode terminal 710. Also, a configuration may be adopted in which three or more first protrusions 615 and second protrusions 715 abut against one first rib 220 and one second rib 230 in the direction in which the rib extends.

[0095] Furthermore, in the above embodiment, the first electrode terminal 610 of the first bus bar 600 faces the front side surface 202, and the second electrode terminal 710 of the second bus bar 700 faces the rear side surface 203. However, the portion of the first bus bar 600 other than the first electrode terminal 610 may face the front side surface 202, and the portion of the second bus bar 700 other than the second electrode terminal 710 may face the rear side surface 203. In this case, the first protrusion 615 is formed on the portion of the first bus bar 600 facing the front side surface 202, and the second protrusion 715 is formed on the portion of the second bus bar 700 facing the rear side surface 203.

[0096] Furthermore, in the above embodiment, the capacitor element unit 100 includes three capacitor elements 500. However, the number of capacitor elements 500 can be changed as appropriate, including the case where it is one.

[0097] Furthermore, in the above embodiment, capacitor element 500 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 element 500 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.

[0098] 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.

[0099] 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.

[0100] In the description of the above embodiment, terms indicating directions such as "upward" and "downward" 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]

[0101] 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]

[0102] 1. Film capacitor (capacitor) 200 cases 200a opening 201 Bottom part (first side part) 202 Front side part (second side part) 203 Rear side part (second side part) 220 First Rib (Rib) 221 Tip 222 Upper end (end) 230 Second Rib (Rib) 231 Tip 232 Upper end face (end face) 300 Filled Resin 500 capacitor elements 510 1st electrode (electrode) 520 2nd electrode (electrode) 600 1st bus bar (bus bar) 610 1st electrode terminal part (opposing part) 615 1st protrusion (contact part, protrusion) 615a Tip 615b Peripheral surface (side surface) 700 Second bus bar (bus bar) 710 2nd electrode terminal part (opposing part) 715 2nd protrusion (contact part, protrusion) 715a tip 715b Peripheral surface (side surface)

Claims

1. A plurality of capacitor elements; a bus bar connected to electrodes of the plurality of capacitor elements; a case having an opening and accommodating the plurality of capacitor elements; a filling resin filled in the case, the case includes a bottom surface portion facing the opening and a side surface portion surrounding the bottom surface portion, the side surface portion includes a front side surface portion and a rear side surface portion opposed to each other, and a right side surface portion and a left side surface portion opposed to each other, the front side portion and the rear side portion are wider than the right side portion and the left side portion; the front side surface portion or the rear side surface portion has a flat surface extending along a first direction in which the opening portion and the bottom surface portion are aligned, the plurality of capacitor elements are arranged in a second direction in which the right side surface portion and the left side surface portion are aligned, the bus bar is located between the plurality of capacitor elements and the front side surface portion or the rear side surface portion, and has a flat plate-shaped opposing portion that faces the front side surface portion or the rear side surface portion, the facing portion has a plurality of protrusions that are aligned in the second direction, protrude toward the front side surface portion or the rear side surface portion, and abut against the flat surface, the plurality of protrusions are located within a range in which the capacitor element is present in the first direction; A capacitor characterized by:

2. 2. The capacitor according to claim 1, the protrusion does not abut on the flat surface in the first direction, but abuts on the flat surface in a direction perpendicular to the first direction; A capacitor characterized by:

3. 3. The capacitor according to claim 1, The flat surface is formed at a tip of a rib that protrudes from the front side surface portion or the rear side surface portion toward the protrusion portion. A capacitor characterized by:

4. 4. The capacitor according to claim 3, In the first direction, the dimension of the rib is longer than the dimension of the protrusion. A capacitor characterized by:

5. 5. The capacitor according to claim 3, The tip of the protrusion is formed on a flat surface. A capacitor characterized by:

6. The capacitor according to any one of claims 1 to 5, The bottom surface side of the protrusion is inclined so as to move away from the opening as it goes toward the inside of the case. A capacitor characterized by:

7. The capacitor according to any one of claims 1 to 6, The position of the protrusion is closer to the opening than the bottom surface. A capacitor characterized by:

8. a plurality of capacitor elements; a bus bar connected to electrodes of the plurality of capacitor elements; a case having an opening and accommodating the plurality of capacitor elements; a filling resin filled in the case, the case includes a bottom surface portion facing the opening and a side surface portion surrounding the bottom surface portion, the side surface portion includes a front side surface portion and a rear side surface portion opposed to each other, and a right side surface portion and a left side surface portion opposed to each other, the front side portion and the rear side portion are wider than the right side portion and the left side portion; the plurality of capacitor elements are arranged in a second direction in which the right side surface portion and the left side surface portion are aligned, the bus bar is located between the plurality of capacitor elements and the front side surface portion or the rear side surface portion, and has a flat plate-shaped opposing portion that faces the front side surface portion or the rear side surface portion, the facing portion has a plurality of protrusions that are aligned in the second direction, protrude toward the front side surface portion or the rear side surface portion, and abut against the front side surface portion or the rear side surface portion, the plurality of protrusions are located within a range in which the capacitor element is present in a first direction in which the opening and the bottom surface are aligned; A capacitor characterized by:

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