Capacitor module

Abstract

A capacitor module 1 comprises: a capacitor element 20 having a first external electrode 22a and a second external electrode 22b; an exterior film 30 encapsulating the capacitor element 20; a capacitor 10 having a first extension terminal 40a that has one end side electrically connected to the first external electrode 22a and that has the other end side extended to the outside of the exterior film 30, and a second extension terminal 40b that has one end side electrically connected to the second external electrode 22b and that has the other end side extended to the outside of the exterior film 30; a first bus bar 100a provided to the outside of the exterior film 30 and electrically connected to the other end side of the first extension terminal 40a; and a second bus bar 100b provided to the outside of the exterior film 30 and electrically connected to the other end side of the second extension terminal 40b. The exterior film 30 has a body 30a covering the capacitor element 20, and the first bus bar 100a and the second bus bar 100b hold the capacitor element 20 via the body 30a of the exterior film 30.

Description

Capacitor Module

[0001] The present invention relates to a capacitor module.

[0002] Patent Document 1 discloses a surface-mounted capacitor that is characterized by having a capacitor element having lead-out leads wrapped in a laminate film, the laminate film attached to a fixing plate having external connection terminals, and the lead-out leads and the external connection terminals fixed to each other.

[0003] Patent Document 2 discloses a capacitor module comprising one or more capacitor elements covered with a laminate film and a support having a frame portion for fixing the laminate film, wherein the laminate film has a covering portion that covers the surface of the capacitor element and a flange portion extending from the outer edge of the covering portion, and the support holds the capacitor element by fixing the flange portion of the laminate film with the end face of the frame portion.

[0004] Patent Document 3 discloses a capacitor module including: a main body covered with a laminate film; one or more capacitor elements, each having a first terminal electrode and a second terminal electrode exposed from the main body; a case accommodating the one or more capacitor elements; a first bus bar integrally built into the case and electrically connected to the first terminal electrode; and a second bus bar integrally built into the case and electrically connected to the second terminal electrode, wherein the case is formed with one or more recesses for accommodating each of the one or more capacitor elements, the first bus bar having one or more first connection portions connected to each of the first terminal electrodes of the capacitor elements arranged in the recesses, and the second bus bar having one or more second connection portions connected to each of the second terminal electrodes of the capacitor elements arranged in the recesses.

[0005] JP 2005-093940 A International Publication No. 2023 / 140095 International Publication No. 2023 / 140104

[0006] Patent Document 1 describes a capacitor in which a capacitor element is covered (exterior) with a laminate film (also called an exterior film).

[0007] Patent Document 2 (see, for example, Figures 2 and 7) describes a technique for fixing a capacitor in which a capacitor element is covered with a laminate film by fixing a flange portion of the laminate film with a support. However, with the technique described in Patent Document 2, the support used to fix the capacitor increases the volume and weight of the entire capacitor module including the capacitor and the support. Furthermore, with the technique described in Patent Document 2, the cost (e.g., manufacturing cost) of the capacitor module also increases because of the support used to fix the capacitor.

[0008] Patent Document 3 (see, for example, Figures 2, 10, 18, etc.) describes a technique for fixing a capacitor in which the capacitor element is covered with a laminate film, by housing the laminate film-covered capacitor element in a case that has a built-in bus bar. However, with the technique described in Patent Document 3, the case used to fix the capacitor increases the volume and weight of the entire capacitor module including the capacitor and the case. Furthermore, with the technique described in Patent Document 3, the cost (e.g., manufacturing cost) associated with the capacitor module increases because a case is used to fix the capacitor.

[0009] The present invention has been made to solve the above problems, and aims to provide a capacitor module that can be made smaller, lighter, and less expensive to achieve a fixed state of the capacitor.

[0010] A capacitor module of the present invention comprises: a capacitor element having a first external electrode and a second external electrode; an exterior film enclosing the capacitor element; a first lead-out terminal having one end electrically connected to the first external electrode and the other end extended to the outside of the exterior film; and a second lead-out terminal having one end electrically connected to the second external electrode and the other end extended to the outside of the exterior film; a first bus bar provided outside the exterior film and electrically connected to the other end of the first lead-out terminal; and a second bus bar provided outside the exterior film and electrically connected to the other end of the second lead-out terminal, wherein the exterior film has a main body portion covering the capacitor element, and the first bus bar and the second bus bar sandwich the capacitor element via the main body portion of the exterior film.

[0011] According to the present invention, it is possible to provide a capacitor module that can be made smaller, lighter, and less expensive in order to achieve a fixed state of the capacitor.

[0012] FIG. 1 is a perspective view schematically illustrating an example of a capacitor module according to a first embodiment of the present invention, as viewed from the first bus bar side. FIG. 2 is a perspective view schematically illustrating the capacitor module shown in FIG. 1, as viewed from the second bus bar side. FIG. 3 is a perspective view schematically illustrating the capacitor module shown in FIG. 1 in an exploded state. FIG. 4 is a perspective view schematically illustrating one of the capacitors shown in FIGS. 1, 2, and 3. FIG. 5 is a cross-sectional view schematically illustrating an example of a cross section of the capacitor shown in FIG. 4, taken along line a1-a2. FIG. 6 is a cross-sectional view schematically illustrating an example of a cross section of the capacitor shown in FIG. 4, taken along line b1-b2. FIG. 7 is a perspective view schematically illustrating an example of a capacitor element shown in FIGS. 4, 5, and 6. FIG. 8 is a cross-sectional view schematically illustrating an example of a cross section of the capacitor element shown in FIG. 7, taken along line c1-c2. FIG. 9 is a perspective view schematically illustrating an example of a capacitor module according to a second embodiment of the present invention, as viewed from the first bus bar side. Fig. 10 is a perspective view schematically showing the capacitor module shown in Fig. 9 as viewed from the second bus bar side. Fig. 11 is a perspective view schematically showing the capacitor module shown in Fig. 9 in an exploded state.

[0013] A capacitor module of the present invention comprises: a capacitor element having a first external electrode and a second external electrode; an exterior film enclosing the capacitor element; a first lead-out terminal having one end electrically connected to the first external electrode and the other end extended to the outside of the exterior film; and a second lead-out terminal having one end electrically connected to the second external electrode and the other end extended to the outside of the exterior film; a first bus bar provided outside the exterior film and electrically connected to the other end of the first lead-out terminal; and a second bus bar provided outside the exterior film and electrically connected to the other end of the second lead-out terminal, wherein the exterior film has a main body portion covering the capacitor element, and the first bus bar and the second bus bar sandwich the capacitor element via the main body portion of the exterior film.

[0014] In the capacitor module of the present invention, the first bus bar and the second bus bar sandwich the capacitor element via the main body of the exterior film, thereby fixing the capacitor. In other words, in the capacitor module of the present invention, instead of using a dedicated component such as the support described in Patent Document 2 or the case described in Patent Document 3 to fix the capacitor, the first bus bar and the second bus bar, which are originally used to electrically connect the capacitor (capacitor element) to an external substrate, device, etc., are also used as components to fix the capacitor. In this way, the capacitor module of the present invention does not require a dedicated component such as the support described in Patent Document 2 or the case described in Patent Document 3 to fix the capacitor, which prevents increases in the overall volume and weight of the capacitor module and also prevents increases in costs (e.g., manufacturing costs) associated with the capacitor module. Therefore, the capacitor module of the present invention enables a compact, lightweight, and low-cost capacitor module to be fixed.

[0015] Furthermore, in the capacitor module of the present invention, the capacitor element is enclosed in an exterior film, so the capacitor element itself is easily cooled. In addition, in the capacitor module of the present invention, the capacitor element is sandwiched between the first bus bar and the second bus bar via the main body of the exterior film, and the first bus bar and the second bus bar are often made of a material with excellent thermal conductivity (e.g., a metal such as copper or aluminum). Therefore, heat generated in the capacitor element is easily released to the outside (e.g., into the air) through the first bus bar and the second bus bar. Therefore, in the capacitor module of the present invention, the capacitor, specifically the capacitor element, is easily cooled efficiently.

[0016] In recent years, the automotive industry has seen a trend toward electrification of automobiles, as seen in the development of electric vehicles, hybrid vehicles, fuel cell vehicles, and other electrically powered vehicles. As automobiles become more electrically powered, capacitors are increasingly being used in automobiles. Capacitors used in such automotive applications are required to be firmly fixed so that they are resistant to vibration, shock, and other factors. Meanwhile, from the perspectives of widespread adoption of electric vehicles and reducing their impact on the environment, there is a demand for smaller, lighter, and less costly electric vehicles. Accordingly, there is a demand for smaller, lighter, and less costly capacitors used in automotive applications. Furthermore, capacitors used in automotive applications are required to be efficiently cooled to ensure stable operation.

[0017] In contrast, the capacitor module of the present invention, as described above, can be made smaller, lighter, and less expensive when realizing a fixed state of the capacitor. Furthermore, as described above, the capacitor module of the present invention allows the capacitor, specifically the capacitor element, to be cooled efficiently. Therefore, the capacitor module of the present invention is useful for in-vehicle applications, such as inverters, chargers, and DC-DC converters mounted on electric vehicles.

[0018] The capacitor module of the present invention is applicable not only to in-vehicle applications but also to various fields such as power electronics.

[0019] The capacitor module of the present invention will be described in detail below. Note that the present invention is not limited to the following configurations and may be modified as appropriate without departing from the spirit of the present invention. Furthermore, a combination of multiple individual preferred configurations described below also constitutes the present invention.

[0020] In the following, a film capacitor will be shown as an example of a capacitor (capacitor element) of the capacitor module of the present invention, but the capacitor module of the present invention can also be applied to capacitors (capacitor elements) other than film capacitors.

[0021] The following embodiments are merely examples, and it goes without saying that partial substitution or combination of the configurations shown in different embodiments is possible. In the second and subsequent embodiments, descriptions of matters common to the first embodiment will be omitted, and differences will be mainly described.

[0022] In the following description, when no particular distinction is made between the embodiments, they will simply be referred to as "the capacitor module of the present invention."

[0023] The drawings shown below are schematic diagrams, and the dimensions, aspect ratio, scale, etc. may differ from those of the actual product.

[0024] In this specification, unless otherwise specified, terms indicating the relationship between elements (e.g., "parallel," "perpendicular," etc.) and terms indicating the shape of elements not only mean the literal strict form, but also mean a range that is substantially equivalent, for example, a range that includes a difference of about a few percent.

[0025] First Embodiment In a capacitor module according to a first embodiment of the present invention, a first bus bar and a second bus bar sandwich a capacitor element in one direction with the main body of the exterior film interposed therebetween.

[0026] Fig. 1 is a perspective view schematically showing an example of a capacitor module according to a first embodiment of the present invention as viewed from a first bus bar side. Fig. 2 is a perspective view schematically showing the capacitor module shown in Fig. 1 as viewed from a second bus bar side. Fig. 3 is a perspective view schematically showing the capacitor module shown in Fig. 1 in an exploded state.

[0027] The capacitor module 1 shown in FIGS. 1, 2, and 3 includes three capacitors 10, a first bus bar 100a, and a second bus bar 100b.

[0028] In FIG. 1 and other figures, the first direction D1, the second direction D2, and the third direction D3 are perpendicular to one another.

[0029] <Capacitor> Fig. 4 is a perspective view schematically showing one of the capacitors shown in Fig. 1, Fig. 2, and Fig. 3. Fig. 5 is a cross-sectional view schematically showing an example of a cross section along line a1-a2 of the capacitor shown in Fig. 4. Fig. 6 is a cross-sectional view schematically showing an example of a cross section along line b1-b2 of the capacitor shown in Fig. 4.

[0030] As shown in FIGS. 4, 5, and 6, the capacitor 10 includes a capacitor element 20, an exterior film 30, a first lead terminal 40a, and a second lead terminal 40b.

[0031] (Capacitor element) Fig. 7 is a perspective view schematically illustrating the capacitor element illustrated in Fig. 4, Fig. 5, and Fig. 6. Fig. 8 is a cross-sectional view schematically illustrating an example of a cross section taken along line c1-c2 of the capacitor element illustrated in Fig. 7.

[0032] As shown in FIGS. 7 and 8, the capacitor element 20 has an element body 21, a first external electrode 22a, and a second external electrode 22b.

[0033] Body 21 is a wound body in which first metallized film 23 a and second metallized film 23 b are wound in a stacked state in first direction D1. In other words, capacitor element 20 is a wound-type film capacitor in which metallized films are wound in a stacked state.

[0034] The capacitor element 20 may be a laminated film capacitor (for example, rectangular parallelepiped) in which metallized films are laminated.

[0035] The element body 21 has a first end face 21a and a second end face 21b facing each other in the second direction D2.

[0036] The element body 21 further has a side surface 21c extending in the second direction D2 so as to connect the peripheries of the first end surface 21a and the second end surface 21b.

[0037] From the viewpoint of reducing the height of capacitor element 20, it is preferable that element body 21 has a flat cross-sectional shape when viewed in a cross section perpendicular to the winding axis direction (second direction D2 in FIGS. 7 and 8 ) of element body 21. Specifically, it is preferable that element body 21 be pressed into a flat shape such as an ellipse or oval, and that the cross-sectional shape of element body 21 be a shape that is thinner than when the cross-sectional shape of element body 21 is a perfect circle.

[0038] Whether or not the element body has been pressed to have a flat cross-sectional shape can be confirmed, for example, by checking whether or not there are press marks on the element body.

[0039] Capacitor element 20 may have a cylindrical winding shaft that is disposed on the central axis of first metallized film 23 a and second metallized film 23 b in a wound state and serves as the winding shaft when winding first metallized film 23 a and second metallized film 23 b.

[0040] First metallized film 23a includes first dielectric film 24a and first metal layer 25a.

[0041] The first dielectric film 24a has a first main surface 24aa and a second main surface 24ab facing each other in the first direction D1.

[0042] The first metal layer 25a is provided on the first main surface 24aa of the first dielectric film 24a. Specifically, the first metal layer 25a is provided on the first main surface 24aa of the first dielectric film 24a so as to reach one side edge of the first dielectric film 24a in the second direction D2 but not reach the other side edge of the first dielectric film 24a.

[0043] Second metallized film 23b includes second dielectric film 24b and second metal layer 25b.

[0044] The second dielectric film 24b has a first main surface 24ba and a second main surface 24bb that face each other in the first direction D1.

[0045] The second metal layer 25b is provided on the first main surface 24ba of the second dielectric film 24b. Specifically, the second metal layer 25b is provided on the first main surface 24ba of the second dielectric film 24b so as not to reach one side edge of the second dielectric film 24b in the second direction D2 but to reach the other side edge of the second dielectric film 24b.

[0046] In element body 21, adjacent first metallized films 23a and second metallized films 23b are offset in second direction D2 so that the end of first metal layer 25a that reaches the side edge of first dielectric film 24a is exposed at first end face 21a of element body 21, and the end of second metal layer 25b that reaches the side edge of second dielectric film 24b is exposed at second end face 21b of element body 21. That is, in adjacent first metallized films 23a and second metallized films 23b, first metallized film 23a protrudes toward first external electrode 22a relative to second metallized film 23b. Also, in adjacent first metallized films 23a and second metallized films 23b, second metallized film 23b protrudes toward second external electrode 22b relative to first metallized film 23a. In this state, the first metal layer 25a is connected to the first external electrode 22a but is not connected to the second external electrode 22b, and the second metal layer 25b is connected to the second external electrode 22b but is not connected to the first external electrode 22a.

[0047] In element body 21, adjacent first metallized films 23a and second metallized films 23b are misaligned in second direction D2 as described above, so that, among adjacent first dielectric films 24a and second dielectric films 24b, the first dielectric film 24a having the first metal layer 25a provided on its first main surface 24aa protrudes toward first external electrode 22a relative to the second dielectric film 24b having no first metal layer 25a provided on its main surface. Also, among adjacent first dielectric films 24a and second dielectric films 24b, the second dielectric film 24b having the second metal layer 25b provided on its first main surface 24ba protrudes toward second external electrode 22b relative to the first dielectric film 24a having no second metal layer 25b provided on its main surface.

[0048] Since element body 21 is formed by winding first metallized film 23a and second metallized film 23b in a stacked state in first direction D1, it can be said that element body 21 includes first dielectric film 24a, first metal layer 25a, second dielectric film 24b, and second metal layer 25b in this order in first direction D1. It can also be said that element body 21 is a wound body formed by winding first dielectric film 24a, first metal layer 25a, second dielectric film 24b, and second metal layer 25b in this order in first direction D1.

[0049] In element body 21, first main surface 24aa of first dielectric film 24a and second main surface 24bb of second dielectric film 24b face each other in first direction D1, and second main surface 24ab of first dielectric film 24a and first main surface 24ba of second dielectric film 24b face each other in first direction D1. Thus, in element body 21, first metalized film 23a and second metalized film 23b are wound in a stacked state in first direction D1. In other words, in element body 21, first metalized film 23a is on the inside of second metalized film 23b, specifically, first metal layer 25a is on the inside of first dielectric film 24a, and second metal layer 25b is on the inside of second dielectric film 24b. That is, in the element body 21, the first metal layer 25a and the second metal layer 25b face each other with the first dielectric film 24a or the second dielectric film 24b sandwiched therebetween.

[0050] The first metal layer 25a may be provided with a fuse portion. The fuse portion provided in the first metal layer 25a is, for example, a portion that connects a divided electrode portion formed by dividing a portion of the first metal layer 25a that faces the second metal layer 25b into multiple portions with an electrode portion that does not face the second metal layer 25b. Examples of electrode patterns of the first metal layer 25a provided with a fuse portion include the electrode patterns disclosed in Japanese Patent Laid-Open Nos. 2004-363431 and 5-251266.

[0051] The second metal layer 25b may also be provided with a fuse portion, similar to the first metal layer 25a.

[0052] The first dielectric film 24a may contain a curable resin as a main component.

[0053] In this specification, the term "major component" means the component with the highest weight percentage, preferably a component with a weight percentage greater than 50% by weight.

[0054] The curable resin may be a thermosetting resin or a photocurable resin.

[0055] In this specification, thermosetting resin means a resin that can be cured by heat, but the curing method is not limited thereto. Therefore, thermosetting resins also include resins that can be cured by methods other than heat (e.g., light, electron beam, etc.) as long as they are resins that can be cured by heat. Furthermore, depending on the material, a reaction may be initiated due to the reactivity of the material itself, and resins that proceed to cure without necessarily being subjected to external heat or the like are also considered thermosetting resins. The same applies to photocurable resins; as long as they are resins that can be cured by light, they also include resins that can be cured by methods other than light (e.g., heat, etc.).

[0056] The curable resin is preferably a cured product of a first organic material having a hydroxyl group (OH group) and a second organic material having an isocyanate group (NCO group). In this case, the curable resin is a cured product having a urethane bond obtained by reacting the hydroxyl group of the first organic material with the isocyanate group of the second organic material.

[0057] The presence of urethane bonds in the dielectric film can be confirmed by analysis with a Fourier transform infrared spectrophotometer (FT-IR).

[0058] When the curable resin is obtained by the above-described reaction, uncured portions of the starting material may remain in the first dielectric film 24a. For example, the first dielectric film 24a may contain at least one of a hydroxyl group and an isocyanate group. In this case, the first dielectric film 24a may contain either a hydroxyl group or an isocyanate group, or may contain both a hydroxyl group and an isocyanate group.

[0059] The presence of hydroxyl groups and / or isocyanate groups in the dielectric film can be confirmed by FT-IR analysis.

[0060] Examples of the first organic material include phenoxy resin, polyvinyl acetoacetal resin, and polyvinyl butyral resin.

[0061] As the first organic material, a plurality of types of organic materials may be used in combination.

[0062] Examples of the second organic material include aromatic polyisocyanates such as diphenylmethane diisocyanate (MDI) and tolylene diisocyanate (TDI), and aliphatic polyisocyanates such as hexamethylene diisocyanate (HDI). As the second organic material, at least one modified product of these polyisocyanates may be used, or a mixture of at least one modified product of these polyisocyanates may be used.

[0063] As the second organic material, a plurality of types of organic materials may be used in combination.

[0064] The first dielectric film 24a may contain a thermoplastic resin as a main component.

[0065] Examples of the thermoplastic resin include polypropylene resin, polyethersulfone resin, polyetherimide resin, and polyarylate resin.

[0066] The first dielectric film 24a may contain additives to impart various functions.

[0067] The additives include, for example, a leveling agent for imparting smoothness.

[0068] The additive preferably has a functional group that reacts with a hydroxyl group and / or an isocyanate group and forms part of the crosslinked structure of the cured product. Examples of such additives include resins having at least one functional group selected from the group consisting of a hydroxyl group, an epoxy group, a silanol group, and a carboxyl group.

[0069] Like the first dielectric film 24a, the second dielectric film 24b may contain a thermosetting resin as a main component, a photocurable resin as a main component, or a thermoplastic resin as a main component, and like the first dielectric film 24a, the second dielectric film 24b may also contain an additive.

[0070] The first dielectric film 24a and the second dielectric film 24b may have different compositions, but preferably have the same composition.

[0071] The thickness of the first dielectric film 24a and the second dielectric film 24b is preferably 1 μm or more and 10 μm or less, and more preferably 3 μm or more and 5 μm or less.

[0072] The thicknesses of the first dielectric film 24a and the second dielectric film 24b may be different from each other, but are preferably the same.

[0073] The thickness of the dielectric film is measured using an optical film thickness gauge.

[0074] The first dielectric film 24a and the second dielectric film 24b are each preferably produced by forming a resin solution containing the resin material as described above into a film and then curing it by heat treatment.

[0075] Examples of materials that can be used to form the first metal layer 25a and the second metal layer 25b include metals such as aluminum, zinc, titanium, magnesium, tin, and nickel.

[0076] The first metal layer 25a and the second metal layer 25b may have different compositions, but preferably have the same composition.

[0077] The thickness of the first metal layer 25a and the second metal layer 25b is preferably 5 nm or more and 40 nm or less.

[0078] The thickness of the first metal layer 25a and the second metal layer 25b may be different from each other, but it is preferable that they are the same.

[0079] The thickness of the metal layer is measured by observing a cross section of the metallized film along the first direction using a transmission electron microscope (TEM).

[0080] The first metal layer 25a and the second metal layer 25b are preferably formed by depositing the metals described above on the major surfaces of the first dielectric film 24a and the second dielectric film 24b, respectively.

[0081] Although the above describes an embodiment in which element body 21 includes two metallized films, element body 21 may also include a single metallized film. For example, element body 21 may include a metallized film having first dielectric film 24a with first metal layer 25a provided on first main surface 24aa and second metal layer 25b provided on second main surface 24ab, and a second dielectric film 24b with no metal layer. Alternatively, element body 21 may include a metallized film having second dielectric film 24b with first metal layer 25a provided on second main surface 24bb and second metal layer 25b provided on first main surface 24ba, and a first dielectric film 24a with no metal layer.

[0082] The first external electrode 22a is provided on the surface of the element body 21. In the example shown in Figures 7 and 8, the first external electrode 22a is provided on the first end surface 21a of the element body 21. The first external electrode 22a is connected to the first metal layer 25a by contacting the end of the first metal layer 25a exposed at the first end surface 21a of the element body 21. On the other hand, the first external electrode 22a is not connected to the second metal layer 25b.

[0083] The second external electrode 22b is provided at a position spaced apart from the first external electrode 22a on the surface of the element body 21. In the example shown in Figures 7 and 8, the second external electrode 22b is provided on the second end surface 21b of the element body 21. The second external electrode 22b is connected to the second metal layer 25b by contacting the end of the second metal layer 25b exposed at the second end surface 21b of the element body 21. On the other hand, the second external electrode 22b is not connected to the first metal layer 25a.

[0084] The first external electrode 22 a and the second external electrode 22 b have different polarities. For example, the first external electrode 22 a may be a positive electrode and the second external electrode 22 b may be a negative electrode, or the first external electrode 22 a may be a negative electrode and the second external electrode 22 b may be a positive electrode.

[0085] Examples of materials for the first external electrode 22a and the second external electrode 22b include metals such as zinc, aluminum, tin, and zinc-aluminum alloys.

[0086] The first external electrode 22a and the second external electrode 22b may have different compositions, but preferably have the same composition.

[0087] The first external electrode 22a and the second external electrode 22b are preferably formed by spraying the above-mentioned metal onto the first end surface 21a and the second end surface 21b of the element body 21, respectively.

[0088] (Exterior Film) Exterior film 30 encloses capacitor element 20. Specifically, exterior film 30 has an internal space, and capacitor element 20 is housed in the internal space of exterior film 30.

[0089] The exterior film 30 has a main body portion 30 a that covers the capacitor element 20 .

[0090] The exterior film 30 may further have flange portions 30b that extend from the outer edges (four sides in FIGS. 4, 5, and 6) of the main body portion 30a and do not cover the capacitor element 20.

[0091] In the examples shown in FIGS. 4, 5, and 6, the exterior film 30 includes a first exterior film material 31a and a second exterior film material 31b.

[0092] The first exterior film material 31 a and the second exterior film material 31 b are formed, for example, into a cup shape to fit the outer shape of the capacitor element 20 .

[0093] When the exterior film 30 includes a first exterior film material 31a and a second exterior film material 31b, the main body 30a includes a portion of the first exterior film material 31a that covers the capacitor element 20 and a portion of the second exterior film material 31b that covers the capacitor element 20.

[0094] When the exterior film 30 includes a first exterior film material 31a and a second exterior film material 31b, the flange portion 30b includes a first flange portion 32a that the first exterior film material 31a has on its outer edge and a second flange portion 32b that the second exterior film material 31b has on its outer edge.

[0095] The first and second exterior film materials 31a and 31b may seal the capacitor element 20 by heat welding the first and second flange portions 32a and 32b.

[0096] Each of the exterior film 30, for example, the first exterior film material 31a and the second exterior film material 31b, is preferably a laminate film including a first resin layer (not shown), a metal layer (not shown), and a second resin layer (not shown), stacked in order from the capacitor element 20 side.

[0097] In the laminate film, the first resin layer functions as a layer for heat-sealing laminate films together, for example, a layer for heat-sealing the first flange portion 32a of the first exterior film material 31a and the second flange portion 32b of the second exterior film material 31b.

[0098] In the laminate film, the first resin layer is preferably made of a thermoplastic resin, and more preferably made of a polyolefin-based thermoplastic resin such as a polypropylene resin.

[0099] In the laminate film, the thickness of the first resin layer is preferably 20 μm or more and 150 μm or less.

[0100] In the laminate film, the metal layer functions as a layer for improving the barrier properties against moisture.

[0101] In the laminate film, the metal layer is preferably made of aluminum.

[0102] In the laminate film, the thickness of the metal layer is preferably 20 μm or more and 50 μm or less.

[0103] In the laminate film, the second resin layer functions as a layer for protecting the metal layer and further improving the barrier properties against moisture.

[0104] In the laminate film, the second resin layer is preferably made of a thermoplastic resin such as polyethylene terephthalate resin or nylon resin.

[0105] In the laminate film, the thickness of the second resin layer is preferably 10 μm or more and 40 μm or less.

[0106] In the laminate film, the first resin layer and the metal layer may be bonded with an adhesive or may be bonded by thermocompression.

[0107] In the laminate film, the second resin layer and the metal layer may be bonded with an adhesive or may be bonded by thermocompression.

[0108] The exterior film 30 may be composed of one layer or multiple layers. When the exterior film 30 is a laminate film composed of multiple layers, the number of layers is not particularly limited, and may be three layers as described above or may be other than three layers.

[0109] The thickness of each of the first exterior film material 31a and the second exterior film material 31b is preferably 80 μm or more and 200 μm or less, and more preferably 100 μm or more and 160 μm or less.

[0110] If the thickness of at least one of the first exterior film material 31a and the second exterior film material 31b is less than 80 μm, the strength of the exterior film 30 will be reduced, and the exterior film 30 may become more susceptible to breakage.

[0111] If the thickness of at least one of the first exterior film material 31a and the second exterior film material 31b is greater than 200 μm, the workability of the exterior film 30 may be reduced.

[0112] The exterior film 30 is preferably provided with a first outlet 33a for extracting a first extracted terminal 40a (described later) to the outside of the exterior film 30. Specifically, the exterior film 30 is preferably provided with the first outlet 33a for extracting the first extracted terminal 40a to the outside of the exterior film 30 between the first flange portion 32a and the second flange portion 32b.

[0113] The exterior film 30 is preferably provided with a second outlet 33b for extracting a second extracted terminal 40b (described later) to the outside of the exterior film 30. Specifically, the exterior film 30 is preferably provided with a second outlet 33b for extracting the second extracted terminal 40b to the outside of the exterior film 30 between the first flange portion 32a and the second flange portion 32b.

[0114] (First Lead-Out Terminal and Second Lead-Out Terminal) One end of the first lead-out terminal 40a is electrically connected to the first external electrode 22a.

[0115] One end of the first lead terminal 40a may be welded to the first external electrode 22a or may be connected via a joining member such as solder.

[0116] The other end of the first lead terminal 40 a is led out to the outside of the exterior film 30 .

[0117] One end of the second lead terminal 40b is electrically connected to the second external electrode 22b.

[0118] One end of the second lead terminal 40b may be welded to the second external electrode 22b, or may be connected via a joining member such as solder.

[0119] The other end of the second lead terminal 40 b is led out to the outside of the exterior film 30 .

[0120] The other end sides of the first lead-out terminal 40a and the second lead-out terminal 40b are preferably drawn out to the same side from the exterior film 30. In this case, it is easier to reduce the size of the capacitor 10 compared to, for example, a case in which the other end sides of the first lead-out terminal 40a and the second lead-out terminal 40b are drawn out to opposite sides from the exterior film 30.

[0121] The first lead terminal 40a and the second lead terminal 40b may each be, for example, plate-shaped or linear (rod-shaped).

[0122] The first lead-out terminal 40a and the second lead-out terminal 40b may or may not be bent.

[0123] Examples of materials for the first and second lead terminals 40a and 40b include metals such as copper, oxygen-free copper, aluminum, and alloys containing at least one of these. Among these, copper or oxygen-free copper is preferred as the material for the first and second lead terminals 40a and 40b. When the first and second lead terminals 40a and 40b are made of a copper-based material, oxygen-free copper (copper: 99.96% by weight or more), tough pitch copper (copper: 99.90% by weight or more), phosphorus-deoxidized copper (copper: 99.90% by weight or more, phosphorus: 0.015% by weight or more, 0.040% by weight or less), and the like can be used.

[0124] (First Insulator and Second Insulator) The capacitor 10 preferably further includes a first insulator 50a provided between the exterior film 30 and the first lead-out terminal 40a. Specifically, the first insulator 50a is preferably provided between the first flange portion 32a of the exterior film 30 and the first lead-out terminal 40a, and between the second flange portion 32b of the exterior film 30 and the first lead-out terminal 40a. In this case, the first lead-out terminal 40a is sealed and fixed by the first insulator 50a.

[0125] The first insulator 50 a preferably covers the entire first lead-out terminal 40 a at the first lead-out port 33 a of the exterior film 30 .

[0126] The first insulator 50 a is preferably adhered to the exterior film 30 .

[0127] The capacitor 10 preferably further includes a second insulator 50b provided between the exterior film 30 and the second lead-out terminal 40b. Specifically, the second insulator 50b is preferably provided between the first flange portion 32a of the exterior film 30 and the second lead-out terminal 40b, and between the second flange portion 32b of the exterior film 30 and the second lead-out terminal 40b. In this case, the second lead-out terminal 40b is sealed and fixed by the second insulator 50b.

[0128] The second insulator 50b preferably covers the entire second lead-out terminal 40b at the second lead-out port 33b of the exterior film 30.

[0129] The second insulator 50 b is preferably adhered to the exterior film 30 .

[0130] Examples of materials for the first insulator 50a and the second insulator 50b include resins. Among these, it is preferable that the first insulator 50a and the second insulator 50b are each made of a thermoplastic resin. It is particularly preferable that the first insulator 50a and the second insulator 50b are each made of a polyolefin-based thermoplastic resin such as polypropylene resin.

[0131] In this specification, the insulator includes forms such as insulating paper, insulating plate, insulating sheet, and insulating film.

[0132] 1, 2, and 3, the three capacitors 10 are aligned in the second direction D2 such that the main bodies 30a of adjacent exterior films 30 (see FIG. 4, etc.) are spaced apart in the second direction D2. Specifically, the three capacitors 10 are aligned in the second direction D2 such that the first end face 21a and the second end face 21b of each element body 21 (see FIG. 7, etc.) face each other in the second direction D2, the side face 21c of each element body 21 extends in the second direction D2, and further such that the first end face 21a of one element body 21 and the second end face 21b of the other element body 21 face each other in the second direction D2 with a gap therebetween. Since the capacitor 10 (element body 21) is often shorter in the first direction D1 than in the second direction D2 and the third direction D3, when three capacitors 10 are arranged in the manner described above, the capacitor module 1 is likely to be miniaturized, particularly in the first direction D1.

[0133] 1, 2, and 3, the three capacitors 10 are aligned in the second direction D2 such that portions of adjacent exterior films 30 (see FIG. 4, etc.) overlap in the first direction D1. Specifically, the three capacitors 10 are aligned in the second direction D2 such that portions of the flange portions 30b of adjacent exterior films 30 overlap in the first direction D1. When the three capacitors 10 are aligned in the above-described manner, the capacitor module 1 is more likely to be miniaturized, particularly in the second direction D2.

[0134] <First Bus Bar and Second Bus Bar> As shown in FIG. 1 , the first bus bar 100 a is provided outside the exterior film 30 .

[0135] The first bus bar 100a is electrically connected to the other end side (the side drawn out to the outside of the exterior film 30) of the first drawn-out terminal 40a.

[0136] The first bus bar 100a may be welded to the other end of the first lead terminal 40a, or may be connected via a joining member such as solder.

[0137] As shown in FIG. 2 , the second bus bar 100 b is provided outside the exterior film 30 .

[0138] The second bus bar 100b is electrically connected to the other end side (the side drawn out to the outside of the exterior film 30) of the second lead terminal 40b.

[0139] The second bus bar 100b may be welded to the other end of the second lead terminal 40b, or may be connected via a joining member such as solder.

[0140] As described above, the first bus bar 100a and the second bus bar 100b are electrically connected to the first lead-out terminal 40a and the second lead-out terminal 40b, respectively, and are thereby electrically connected to the capacitor 10. Specifically, the first bus bar 100a is electrically connected to the first external electrode 22a of the capacitor element 20 of the capacitor 10 via the first lead-out terminal 40a. Furthermore, the second bus bar 100b is electrically connected to the second external electrode 22b of the capacitor element 20 of the capacitor 10 via the second lead-out terminal 40b.

[0141] As described above, the first bus bar 100a and the second bus bar 100b are electrically connected to external electrodes having different polarities, and therefore have different polarities. For example, if the first external electrode 22a is a positive electrode and the second external electrode 22b is a negative electrode, the first bus bar 100a is a bus bar for the positive electrode and the second bus bar 100b is a bus bar for the negative electrode. Alternatively, if the first external electrode 22a is a negative electrode and the second external electrode 22b is a positive electrode, the first bus bar 100a is a bus bar for the negative electrode and the second bus bar 100b is a bus bar for the positive electrode.

[0142] It is preferable that the first busbar 100a has a first frame-shaped portion 101a that is frame-shaped when viewed from the first direction D1, and a first protruding portion 102a that protrudes from the first frame-shaped portion 101a in the first direction D1.

[0143] 1, 2, and 3, the first protrusion 102a of the first bus bar 100a protrudes from the first frame-shaped portion 101a in the first direction D1 and then extends in the third direction D3. Specifically, the first protrusion 102a of the first bus bar 100a extends from one end on the first frame-shaped portion 101a side toward the other end opposite the first frame-shaped portion 101a along the side surface 21c of the element body 21 (see FIG. 7, etc.).

[0144] In the examples shown in FIGS. 1, 2, and 3, the first protrusion 102a of the first bus bar 100a is curved.

[0145] It is preferable that the second busbar 100b has a second frame-shaped portion 101b that is frame-shaped when viewed from the first direction D1, and a second protruding portion 102b that protrudes from the second frame-shaped portion 101b in the first direction D1.

[0146] 1, 2, and 3, the second protrusion 102b of the second bus bar 100b protrudes from the second frame-shaped portion 101b in the first direction D1 and then extends in the third direction D3. Specifically, the second protrusion 102b of the second bus bar 100b extends from one end on the second frame-shaped portion 101b side toward the other end opposite the second frame-shaped portion 101b along the side surface 21c of the element body 21 (see FIG. 7, etc.).

[0147] In the examples shown in FIGS. 1, 2, and 3, the second protrusion 102b of the second bus bar 100b is curved.

[0148] Examples of materials for the first bus bar 100a and the second bus bar 100b include metals such as copper, oxygen-free copper, aluminum, and alloys containing at least one of these. Among these, copper or oxygen-free copper is preferred as the material for the first bus bar 100a and the second bus bar 100b. When the material for the first bus bar 100a and the second bus bar 100b is a copper-based material, examples of usable materials include oxygen-free copper (copper: 99.96% by weight or more), tough pitch copper (copper: 99.90% by weight or more), and phosphorus-deoxidized copper (copper: 99.90% by weight or more, phosphorus: 0.015% by weight or more, 0.040% by weight or less).

[0149] The constituent materials of the first bus bar 100a and the second bus bar 100b may be the same as or different from each other.

[0150] The thickness of the first bus bar 100a and the second bus bar 100b may be the same as or different from each other.

[0151] In the capacitor module 1, the first bus bar 100a and the second bus bar 100b sandwich the capacitor element 20 via the main body 30a of the exterior film 30.

[0152] 1, 2, and 3, the first protrusion 102a of the first bus bar 100a and the second protrusion 102b of the second bus bar 100b sandwich the capacitor element 20 (see FIG. 7, etc.) in the first direction D1 via the main body 30a of the exterior film 30 (see FIG. 4, etc.). Specifically, the portions of the first protrusion 102a of the first bus bar 100a and the second protrusion 102b of the second bus bar 100b that face each other in the first direction D1 sandwich the capacitor element 20 from the side surface 21c of the element body 21 in the first direction D1 via the main body 30a of the exterior film 30.

[0153] As described above, in the capacitor module 1, the first bus bar 100a and the second bus bar 100b sandwich the capacitor element 20 via the main body portion 30a of the exterior film 30 in one direction, here the first direction D1.

[0154] In the capacitor module 1, the first bus bar 100a and the second bus bar 100b sandwich the capacitor element 20 via the main body 30a of the exterior film 30, thereby allowing the capacitor 10 to be fixed by the first bus bar 100a and the second bus bar 100b. In other words, in the capacitor module 1, instead of using a dedicated component such as the support described in Patent Document 2 or the case described in Patent Document 3 to fix the capacitor 10, the first bus bar 100a and the second bus bar 100b, which are originally used to electrically connect the capacitor 10 (capacitor element 20) to an external substrate, device, etc., are also used as components for fixing the capacitor 10. In this way, the capacitor module 1 does not require a dedicated component such as the support described in Patent Document 2 or the case described in Patent Document 3 to fix the capacitor 10. This prevents an increase in the overall volume and weight of the capacitor module 1 and also prevents an increase in costs (e.g., manufacturing costs) associated with the capacitor module 1. Therefore, the capacitor module 1 enables a compact, lightweight, and low-cost capacitor module to be fixed.

[0155] Furthermore, in the capacitor module 1, the capacitor element 20 is enclosed in the exterior film 30, so the capacitor element 20 itself is easily cooled. In addition, in the capacitor module 1, the capacitor element 20 is sandwiched between the first bus bar 100a and the second bus bar 100b via the main body 30a of the exterior film 30, and the first bus bar 100a and the second bus bar 100b are often made of a material with excellent thermal conductivity (e.g., a metal such as copper or aluminum). Therefore, heat generated in the capacitor element 20 is easily released to the outside (e.g., into the air) through the first bus bar 100a and the second bus bar 100b. Therefore, in the capacitor module 1, the capacitor 10, specifically the capacitor element 20, is easily cooled efficiently.

[0156] In the examples shown in Figures 1, 2, and 3, when the first bus bar 100a and the second bus bar 100b sandwich the capacitor element 20 via the main body portion 30a of the exterior film 30, the main body portion 30a of the exterior film 30 and the first bus bar 100a (e.g., the first protrusion 102a) are in direct contact with each other, and further, the main body portion 30a of the exterior film 30 and the second bus bar 100b (e.g., the second protrusion 102b) are in direct contact with each other.

[0157] The main body 30a of the exterior film 30 and the first bus bar 100a (e.g., the first protruding portion 102a) may be bonded together with, for example, an adhesive. The main body 30a of the exterior film 30 and the second bus bar 100b (e.g., the second protruding portion 102b) may be bonded together with, for example, an adhesive.

[0158] <Elastic member> It is preferable that the capacitor module 1 further includes an elastic member 200 sandwiched at least one between the main body portion 30a of the exterior film 30 and the first bus bar 100a, and between the main body portion 30a of the exterior film 30 and the second bus bar 100b.

[0159] If the capacitor module 1 has the elastic member 200, when the capacitor 10 is fixed by the first bus bar 100a and the second bus bar 100b, the elastic member 200 can apply pressure (biasing force) to the capacitor 10 while absorbing dimensional variations (e.g., variations in thickness) of the capacitor 10, the first bus bar 100a, and the second bus bar 100b through its elastic deformation. Therefore, when the capacitor 10 is fixed by the first bus bar 100a and the second bus bar 100b, the capacitor 10 can be fixed even more firmly by using the elastic member 200.

[0160] Furthermore, when the capacitor module 1 includes the elastic member 200, heat generated in the capacitor 10 is more easily conducted to at least one of the first bus bar 100a and the second bus bar 100b through the elastic member 200. At this time, as described above, the elastic member 200 applies pressure (biasing force) to the capacitor 10, which tends to reduce the contact thermal resistance between the capacitor 10 (exterior film 30) and the elastic member 200, and therefore heat generated in the capacitor 10 is more easily conducted to at least one of the first bus bar 100a and the second bus bar 100b through the elastic member 200. In particular, when the elastic member 200 is made of a material with excellent thermal conductivity (e.g., metal paste), heat generated in the capacitor 10 is significantly more easily conducted to at least one of the first bus bar 100a and the second bus bar 100b through the elastic member 200. Furthermore, heat transferred to at least one of the first bus bar 100a and the second bus bar 100b is likely to be released to the outside (e.g., into the air) because the first bus bar 100a and the second bus bar 100b are often made of a material with excellent thermal conductivity (e.g., a metal such as copper or aluminum). Therefore, using the elastic member 200 to secure the capacitor 10 with the first bus bar 100a and the second bus bar 100b makes it easier to cool the capacitor 10, specifically, the capacitor element 20, more efficiently. When the capacitor 10 is more easily cooled in this manner, it becomes easier to accommodate cases where cooling of the capacitor 10 is required to ensure stable operation, such as when the ripple current flowing through the capacitor 10 is increased or when the capacitor 10 is used in a wide range of temperature environments, particularly high-temperature environments.

[0161] As described above, the elastic member 200 functions as a member for strengthening the fixed state of the capacitor 10 and promoting the conduction of heat generated in the capacitor 10 .

[0162] In the example shown in FIGS. 1, 2, and 3, the elastic member 200 includes a first elastic member 200a and a second elastic member 200b.

[0163] The first elastic member 200a is sandwiched between the main body 30a of the exterior film 30 and the first bus bar 100a. Specifically, the first elastic member 200a is sandwiched between the main body 30a of the exterior film 30 and the first protrusion 102a of the first bus bar 100a.

[0164] The first elastic member 200a has a shape that follows the first protruding portion 102a of the first bus bar 100a, for example, and here is curved.

[0165] The second elastic member 200b is sandwiched between the main body 30a of the exterior film 30 and the second bus bar 100b. Specifically, the second elastic member 200b is sandwiched between the main body 30a of the exterior film 30 and the second protrusion 102b of the second bus bar 100b.

[0166] The second elastic member 200b has a shape that conforms to the second protruding portion 102b of the second bus bar 100b, for example, and is curved in this example.

[0167] The constituent material of the elastic member 200, here the first elastic member 200a and the second elastic member 200b, is not particularly limited as long as it is a material that has elasticity, and may be, for example, a conductive material or an insulating material.

[0168] When the elastic member 200 is made of a conductive material, examples of the conductive material include a metal paste containing a metal filler and a resin, and a silver paste containing a silver filler and a resin.

[0169] When the elastic member 200 is made of metal paste, the elastic member 200 has excellent thermal conductivity, so that the heat generated in the capacitor 10 is easily transferred to the first bus bar 100a and the second bus bar 100b through the elastic member 200, and as a result, is easily released to the outside (e.g., into the air).

[0170] When the elastic member 200 is made of metal paste, the elastic member 200 functions as an adhesive that bonds the main body portion 30a of the exterior film 30 and the first bus bar 100a (e.g., the first protrusion portion 102a), and can also function as an adhesive that bonds the main body portion 30a of the exterior film 30 and the second bus bar 100b (e.g., the second protrusion portion 102b).

[0171] When the elastic member 200 is made of a conductive material, in order to prevent a short circuit between the first bus bar 100a (e.g., the first protrusion 102a) and the second bus bar 100b (e.g., the second protrusion 102b) through the elastic member 200, it is preferable that the elastic member 200 provided for one capacitor 10 is divided into multiple parts, such as the first elastic member 200a and the second elastic member 200b.

[0172] When the elastic member 200 is made of an insulating material, examples of the insulating material include resin, rubber, etc. Examples of rubber include silicone rubber, etc.

[0173] When the elastic member 200 is made of an insulating material, the elastic member 200 provided for one capacitor 10 may be a single member rather than being divided into multiple members, as long as there is no risk of a short circuit between the first bus bar 100a (e.g., the first protruding portion 102a) and the second bus bar 100b (e.g., the second protruding portion 102b) via the elastic member 200. Note that even when the elastic member 200 is made of an insulating material, the elastic member 200 provided for one capacitor 10 may be divided into multiple members, such as the first elastic member 200a and the second elastic member 200b.

[0174] In this specification, the elastic member includes forms such as an elastic plate, an elastic sheet, and an elastic film.

[0175] 1, 2, and 3 show an embodiment in which the elastic member 200 (the first elastic member 200a and the second elastic member 200b) is sandwiched both between the main body portion 30a of the exterior film 30 and the first bus bar 100a, and between the main body portion 30a of the exterior film 30 and the second bus bar 100b. However, the elastic member 200 (the first elastic member 200a or the second elastic member 200b) may be sandwiched either between the main body portion 30a of the exterior film 30 and the first bus bar 100a, or between the main body portion 30a of the exterior film 30 and the second bus bar 100b.

[0176] It is not necessary for the elastic member 200 to be sandwiched between both the main body portion 30a of the exterior film 30 and the first bus bar 100a and between the main body portion 30a of the exterior film 30 and the second bus bar 100b. Even in this case, for example, by increasing the curvature (reducing the radius of curvature) of the first protruding portion 102a of the first bus bar 100a and the second protruding portion 102b of the second bus bar 100b, the degree of bending between them can be made tighter, thereby increasing the pressure (urging force) applied to the capacitor 10 from the first bus bar 100a and the second bus bar 100b, and therefore the capacitor 10 can be fixed more firmly by the first bus bar 100a and the second bus bar 100b.

[0177] <Insulating Member> The capacitor module 1 preferably further includes an insulating member 300 sandwiched between the first bus bar 100a and the second bus bar 100b. In other words, when the first bus bar 100a and the second bus bar 100b partially overlap each other in the capacitor module 1, the capacitor module 1 preferably further includes an insulating member 300 sandwiched between the first bus bar 100a and the second bus bar 100b in the region where the first bus bar 100a and the second bus bar 100b partially overlap each other. In other words, the capacitor module 1 preferably further includes the insulating member 300 that forms a laminated structure together with the first bus bar 100a and the second bus bar 100b. In this way, in the capacitor module 1, the first bus bar 100a, the insulating member 300, and the second bus bar 100b preferably form a laminated structure by being stacked in this order.

[0178] When the capacitor module 1 has the insulating member 300, the insulating member 300 ensures a creepage distance between the first bus bar 100a and the second bus bar 100b, thereby ensuring insulation between the first bus bar 100a and the second bus bar 100b.

[0179] Examples of the constituent material of the insulating member 300 include resin.

[0180] In this specification, the insulating member includes forms such as insulating paper, insulating plate, insulating sheet, and insulating film.

[0181] In the capacitor module 1, as described above, when the exterior film 30 has a flange portion 30b that extends from the outer edge of the main body portion 30a and does not cover the capacitor element 20, it is preferable that the first bus bar 100a and the second bus bar 100b sandwich the flange portion 30b of the exterior film 30.

[0182] In the examples shown in Figures 1, 2, and 3, the first frame-shaped portion 101a of the first bus bar 100a and the second frame-shaped portion 101b of the second bus bar 100b partially sandwich the flange portion 30b of the exterior film 30 in the first direction D1. Specifically, the first frame-shaped portion 101a of the first busbar 100a partially contacts the first flange portion 32a of the first exterior film material 31a in the first direction D1, and the second frame-shaped portion 101b of the second busbar 100b partially contacts the second flange portion 32b of the second exterior film material 31b in the first direction D1, so that the first frame-shaped portion 101a of the first busbar 100a and the second frame-shaped portion 101b of the second busbar 100b partially sandwich the first flange portion 32a of the first exterior film material 31a and the second flange portion 32b of the second exterior film material 31b in the first direction D1.

[0183] In the capacitor module 1, when the first bus bar 100a and the second bus bar 100b sandwich the capacitor element 20 via the main body portion 30a of the exterior film 30, and also sandwich the flange portion 30b of the exterior film 30, the capacitor 10 is more firmly fixed by the first bus bar 100a and the second bus bar 100b, and the capacitor 10, specifically the capacitor element 20, is more easily cooled efficiently through the first bus bar 100a and the second bus bar 100b.

[0184] It should be noted that the flange portion 30b of the exterior film 30 does not necessarily have to be sandwiched between the first bus bar 100a and the second bus bar 100b.

[0185] When the capacitor module 1 has an insulating member 300 and the first bus bar 100a and the second bus bar 100b sandwich the flange portion 30b of the exterior film 30, it is preferable that in the capacitor module 1, the insulating member 300 is not sandwiched between the portions of the first bus bar 100a and the second bus bar 100b that sandwich the flange portion 30b of the exterior film 30.

[0186] 1, 2, and 3, the insulating member 300 is not sandwiched between the first frame-shaped portion 101a of the first bus bar 100a and the second frame-shaped portion 101b of the second bus bar 100b, which are portions that sandwich the flange portions 30b located between the main bodies 30a of adjacent exterior films 30 (see FIG. 4, etc.). Specifically, the insulating member 300 is not sandwiched between the first flange portion 32a of the first exterior film material 31a located between the main bodies 30a of adjacent exterior films 30 and the first frame-shaped portion 101a of the first bus bar 100a. Furthermore, the insulating member 300 is not sandwiched between the second flange portion 32b of the second exterior film material 31b located between the main bodies 30a of adjacent exterior films 30 and the second frame-shaped portion 101b of the second bus bar 100b.

[0187] When the first bus bar 100a and the second bus bar 100b sandwich the flange portion 30b of the exterior film 30, the creepage distance between the portions of the first bus bar 100a and the second bus bar 100b that sandwich the flange portion 30b of the exterior film 30 is ensured by the flange portion 30b of the exterior film 30, thereby ensuring insulation between these portions of the first bus bar 100a and the second bus bar 100b. Therefore, in order to ensure insulation between the portions of the first bus bar 100a and the second bus bar 100b that sandwich the flange portion 30b of the exterior film 30, it is not necessary to further sandwich the insulating member 300 in addition to the flange portion 30b of the exterior film 30. In this way, the amount of insulating member 300 used can be reduced between the portions of the first bus bar 100a and the second bus bar 100b that sandwich the flange portion 30b of the exterior film 30, thereby reducing the cost associated with the insulating member 300 (e.g., manufacturing cost).

[0188] The insulating member 300 may be sandwiched between the portions of the first bus bar 100a and the second bus bar 100b that sandwich the flange portion 30b of the exterior film 30.

[0189] Second Embodiment In a capacitor module according to a second embodiment of the present invention, a first bus bar and a second bus bar sandwich a capacitor element in a plurality of directions with the main body of the exterior film interposed therebetween.

[0190] Fig. 9 is a perspective view schematically showing an example of a capacitor module according to embodiment 2 of the present invention as viewed from the first bus bar side. Fig. 10 is a perspective view schematically showing the capacitor module shown in Fig. 9 as viewed from the second bus bar side. Fig. 11 is a perspective view schematically showing the capacitor module shown in Fig. 9 in an exploded state.

[0191] In the capacitor module 2 shown in Figures 9, 10, and 11, the first bus bar 100a and the second bus bar 100b sandwich the capacitor element 20 (see Figure 7, etc.) via the main body 30a of the exterior film 30 (see Figure 4, etc.).

[0192] 9, 10, and 11, the first protrusion 102a of the first bus bar 100a protrudes from the first frame-shaped portion 101a in the first direction D1 and then extends in the second direction D2. Specifically, the first protrusion 102a of the first bus bar 100a extends from one end side on the first frame-shaped portion 101a side toward the other end side opposite the first frame-shaped portion 101a, along the second end surface 21b of the element body 21 (see FIG. 7, etc.) and the side surface 21c of the element body 21 in that order.

[0193] In the examples shown in Figures 9, 10, and 11, the first protrusion 102a of the first busbar 100a has a shape in which a flat portion extending in the first direction D1 and a flat portion extending in the second direction D2 are connected, and in this case, it has a bent shape (e.g., an L-shape) when viewed from the third direction D3.

[0194] 9, 10, and 11, the second protrusion 102b of the second bus bar 100b protrudes from the second frame-shaped portion 101b in the first direction D1 and then extends in the second direction D2. Specifically, the second protrusion 102b of the second bus bar 100b extends from one end side on the second frame-shaped portion 101b side toward the other end side opposite the second frame-shaped portion 101b, sequentially along the first end surface 21a of the element body 21 (see FIG. 7, etc.) and the side surface 21c of the element body 21.

[0195] In the examples shown in Figures 9, 10, and 11, the second protrusion 102b of the second busbar 100b has a shape in which a flat portion extending in the first direction D1 and a flat portion extending in the second direction D2 are connected, and in this case, it has a bent shape (e.g., an L-shape) when viewed from the third direction D3.

[0196] 9, 10, and 11, the first protrusion 102a of the first bus bar 100a and the second protrusion 102b of the second bus bar 100b sandwich the capacitor element 20 in the first direction D1 and the second direction D2, via the main body 30a of the exterior film 30. Specifically, the portions of the first protrusion 102a of the first bus bar 100a and the second protrusion 102b of the second bus bar 100b that extend in the first direction D1 sandwich the capacitor element 20 in the second direction D2 from the first end surface 21a side of the element body 21 (the first external electrode 22a side) and the second end surface 21b side of the element body 21 (the second external electrode 22b side), via the main body 30a of the exterior film 30. Furthermore, the portions of the first protrusion 102a of the first bus bar 100a and the second protrusion 102b of the second bus bar 100b that extend in the second direction D2 sandwich the capacitor element 20 from the side surface 21c of the base body 21 in the first direction D1, via the main body portion 30a of the exterior film 30.

[0197] As described above, in capacitor module 2, first bus bar 100a and second bus bar 100b sandwich capacitor element 20 in two directions, here, first direction D1 and second direction D2, via main body 30a of exterior film 30. As a result, in capacitor module 2, capacitor 10 can be fixed more firmly by first bus bar 100a and second bus bar 100b than in capacitor module 1.

[0198] In capacitor module 2, similar to capacitor module 1, first elastic member 200a is sandwiched between main body 30a of exterior film 30 and first protrusion 102a of first bus bar 100a. In the examples shown in Figures 9, 10, and 11, first elastic member 200a has a shape that follows first protrusion 102a of first bus bar 100a, for example, and here has a bent shape (for example, an L-shape) when viewed from third direction D3.

[0199] In capacitor module 2, similar to capacitor module 1, second elastic member 200b is sandwiched between main body 30a of exterior film 30 and second protrusion 102b of second bus bar 100b. In the examples shown in Figures 9, 10, and 11, second elastic member 200b has a shape that follows second protrusion 102b of second bus bar 100b, for example, and here has a bent shape (for example, an L-shape) when viewed from third direction D3.

[0200] 9 , 10 , and 11 show an embodiment in which the first bus bar 100a and the second bus bar 100b sandwich the capacitor element 20 in two directions via the main body portion 30a of the exterior film 30, but the first bus bar 100a and the second bus bar 100b may sandwich the capacitor element 20 in three or more directions via the main body portion 30a of the exterior film 30. For example, the first bus bar 100a and the second bus bar 100b may sandwich the capacitor element 20 in the first direction D1, the second direction D2, and the third direction D3 via the main body portion 30a of the exterior film 30. As described above, the first bus bar 100a and the second bus bar 100b may sandwich the capacitor element 20 in a plurality of directions via the main body portion 30a of the exterior film 30.

[0201] In the first embodiment, when the first protrusion 102a of the first bus bar 100a and the second protrusion 102b of the second bus bar 100b sandwich the capacitor element 20 in the first direction D1 via the main body 30a of the exterior film 30, the first protrusion 102a of the first bus bar 100a and the second protrusion 102b of the second bus bar 100b face each other in the first direction D1. On the other hand, in the second embodiment, when the first protrusion 102a of the first bus bar 100a and the second protrusion 102b of the second bus bar 100b sandwich the capacitor element 20 in the first direction D1 and the second direction D2 via the main body 30a of the exterior film 30, the first protrusion 102a of the first bus bar 100a and the second protrusion 102b of the second bus bar 100b do not face each other in the first direction D1 and the second direction D2. In this way, if it can be said that the first protrusion 102a of the first bus bar 100a and the second protrusion 102b of the second bus bar 100b are sandwiching the capacitor element 20 in at least one direction via the main body 30a of the exterior film 30, the first protrusion 102a of the first bus bar 100a and the second protrusion 102b of the second bus bar 100b may or may not be facing each other in the direction in which the capacitor element 20 is sandwiched.

[0202] The capacitor module of the present invention is not limited to the above-described embodiment, and various applications and modifications can be made within the scope of the present invention with respect to the configuration of the capacitor module, manufacturing conditions, etc.

[0203] The number of capacitors in the capacitor module of the present invention is not particularly limited. The capacitor module of the present invention may have one capacitor or multiple capacitors (three in FIG. 1 and other figures).

[0204] When the capacitor module of the present invention has a plurality of capacitors, the configurations of the plurality of capacitors may be the same as each other, may be different from each other, or may be partially different from each other.

[0205] When the capacitor module of the present invention has a plurality of capacitors, the plurality of capacitors may be arranged in a single row or in multiple rows. When the capacitor module of the present invention has a plurality of capacitors arranged in multiple rows, the plurality of capacitors may be arranged in multiple rows in one direction or in multiple directions.

[0206] The present specification discloses the following:

[0207] <1> A capacitor module comprising: a capacitor element having a first external electrode and a second external electrode; an exterior film enclosing the capacitor element; a first lead-out terminal having one end electrically connected to the first external electrode and the other end drawn out to the exterior of the exterior film; and a second lead-out terminal having one end electrically connected to the second external electrode and the other end drawn out to the exterior of the exterior film; a first bus bar provided outside the exterior film and electrically connected to the other end of the first lead-out terminal; and a second bus bar provided outside the exterior film and electrically connected to the other end of the second lead-out terminal, wherein the exterior film has a main body portion that covers the capacitor element, and the first bus bar and the second bus bar sandwich the capacitor element via the main body portion of the exterior film.

[0208] <2> The capacitor module according to <1>, wherein the first bus bar and the second bus bar sandwich the capacitor element in one direction via the main body portion of the exterior film.

[0209] <3> The capacitor module according to <1>, wherein the first bus bar and the second bus bar sandwich the capacitor element in a plurality of directions via the main body portion of the exterior film.

[0210] <4> The capacitor module according to any one of <1> to <3>, further comprising an elastic member sandwiched at least one between the main body of the exterior film and the first bus bar and between the main body of the exterior film and the second bus bar.

[0211] <5> The capacitor module according to any one of <1> to <4>, further comprising an insulating member sandwiched between the first bus bar and the second bus bar.

[0212] <6> The capacitor module according to any one of <1> to <5>, wherein the exterior film further has a flange portion that extends from an outer edge of the main body portion and does not cover the capacitor element, and the first bus bar and the second bus bar sandwich the flange portion of the exterior film.

[0213] <7> The capacitor module according to <6>, further comprising an insulating member sandwiched between the first bus bar and the second bus bar, wherein the insulating member is not sandwiched between portions of the first bus bar and the second bus bar that sandwich the flange portion of the exterior film.

[0214] <8> The capacitor module according to any one of <1> to <7>, wherein the capacitor element is a film capacitor.

[0215] REFERENCE SIGNS 1, 2 Capacitor module 10 Capacitor 20 Capacitor element 21 Element body 21a First end face of element body 21b Second end face of element body 21c Side face of element body 22a First external electrode 22b Second external electrode 23a First metallized film 23b Second metallized film 24a First dielectric film 24aa First main surface of first dielectric film 24ab Second main surface of first dielectric film 24b Second dielectric film 24ba First main surface of second dielectric film 24bb Second main surface of second dielectric film 25a First metal layer 25b Second metal layer 30 Exterior film 30a Main body portion 30b Flange portion 31a First exterior film material 31b Second exterior film material 32a First flange portion 32b Second flange portion 33a First outlet 33b Second outlet 40a First lead-out terminal 40b Second lead-out terminal 50a First insulator 50b Second insulator 100a First bus bar 100b Second bus bar 101a First frame-shaped portion 101b Second frame-shaped portion 102a First protrusion 102b Second protrusion 200 Elastic member 200a First elastic member 200b Second elastic member 300 Insulating member D1 First direction D2 Second direction D3 Third direction

Claims

1. A capacitor module comprising: a capacitor element having a first external electrode and a second external electrode; an exterior film encapsulating the capacitor element; a first lead-out terminal having one end electrically connected to the first external electrode and the other end drawn out to the outside of the exterior film; and a second lead-out terminal having one end electrically connected to the second external electrode and the other end drawn out to the outside of the exterior film; a first bus bar provided outside the exterior film and electrically connected to the other end side of the first lead-out terminal; and a second bus bar provided outside the exterior film and electrically connected to the other end side of the second lead-out terminal, wherein the exterior film has a main body portion covering the capacitor element, and the first bus bar and the second bus bar sandwich the capacitor element via the main body portion of the exterior film.

2. The capacitor module according to claim 1, wherein the first bus bar and the second bus bar sandwich the capacitor element via the main body portion of the exterior film in one direction.

3. The capacitor module according to claim 1, wherein the first bus bar and the second bus bar sandwich the capacitor element via the main body portion of the exterior film in a plurality of directions.

4. The capacitor module according to any one of claims 1 to 3, further comprising an elastic member sandwiched between at least one of the space between the main body portion of the exterior film and the first bus bar and the space between the main body portion of the exterior film and the second bus bar.

5. The capacitor module according to any one of claims 1 to 4, further comprising an insulating member sandwiched between the first bus bar and the second bus bar.

6. The capacitor module according to any one of claims 1 to 5, wherein the exterior film further has a flange portion extending from the outer edge of the main body portion and not covering the capacitor element, and the first bus bar and the second bus bar sandwich the flange portion of the exterior film.

7. The capacitor module according to claim 6, further comprising an insulating member sandwiched between the first bus bar and the second bus bar, wherein the insulating member is not sandwiched between the portions of the first bus bar and the second bus bar that sandwich the flange portion of the exterior film.

8. The capacitor module according to any one of claims 1 to 7, wherein the capacitor element is a film capacitor.

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