CAPACITOR MODULE AND A METHOD OF MAKING THEREOF

A capacitor module is provided with a case with a bottom surface and an opening, a first capacitor group including first capacitors each having first and second electrodes, and a side surface connecting the first and second electrodes, a second capacitor group including second capacitors each having third and fourth electrodes, and a side surface connecting the third and fourth electrodes, a first bus bar having an electrode contact portion in contact with the first electrode, a second bus bar having an electrode contact portion in contact with the third electrode, a third bus bar having an electrode contact portion commonly in contact with the second electrode and the fourth electrode, a sealing resin filled in the case; and an insulating member provided between the electrode contact portion of the first bus bar and the electrode contact portion of the second bus bar and surrounded by the sealing resin.

TECHNICAL FIELD

The present disclosure is directed to a capacitor module.

BACKGROUND OF THE INVENTION

There is known a capacitor module in which one or a plurality of capacitors formed by winding or layering a dielectric film having a metal film on the surface are housed in a case, and bus bars are connected to electrodes at both ends of each capacitor.

For example, JP 2001-210548A (the “JP '548 Publication”) discloses a film capacitor in which a capacitor element and an electronic component are separately housed with a partition plate provided on a bottom surface of a case.

The film capacitor described in the JP '548 Publication still has room for improvement in terms of enhancement in insulation.

SUMMARY OF THE INVENTION

Therefore, an object of the present disclosure is to provide a capacitor module with improved insulation.

In an exemplary aspect, a capacitor module is provided that includes: a case with an opening provided at a position opposing a bottom surface; a first capacitor group disposed inside the case and including one or a plurality of first capacitors each having a first electrode, a second electrode, and a side surface connecting the first electrode and the second electrode; a second capacitor group disposed inside the case and including one or a plurality of second capacitors each having a third electrode, a fourth electrode, and a side surface connecting the third electrode and the fourth electrode; a first bus bar having a plate shape, the first bus bar being disposed on the opening side with respect to the first capacitor group inside the case and having an electrode contact portion in contact with the first electrode; a second bus bar having a plate shape, the second bus bar being disposed on the opening side with respect to the second capacitor group inside the case and having an electrode contact portion in contact with the third electrode; a third bus bar disposed on the bottom surface side with respect to the first capacitor group and the second capacitor group inside the case and having an electrode contact portion commonly in contact with the second electrode and the fourth electrode; a sealing resin with which the case is filled; and an insulating member provided between the electrode contact portion of the first bus bar and the electrode contact portion of the second bus bar and surrounded by the sealing resin.

Thus, according to the present disclosure, a capacitor module is provided with improved insulation.

DETAILED DESCRIPTION

A capacitor module having two or more capacitor groups having different functions is known in the art. For example, there is a capacitor module in which each capacitor group is housed in one case and the case is filled with an insulating resin. Each capacitor group includes one or more capacitors. Each capacitor group is insulated by the insulating resin filled in the case. However, in the case of such configuration, there is a problem that insulation quality is deteriorated due to bubbles generated in the insulating resin.

Aspects of the present disclosure is directed to improving insulation between capacitor groups in a capacitor module having two or more capacitor groups.

A capacitor module according to an exemplary aspect of the present disclosure includes a case with an opening provided at a position opposing a bottom surface; a first capacitor group disposed inside the case and including one or a plurality of first capacitors each having a first electrode, a second electrode, and a side surface connecting the first electrode and the second electrode; a second capacitor group disposed inside the case and including one or a plurality of second capacitors each having a third electrode, a fourth electrode disposed on the bottom surface side, and a side surface connecting the third electrode and the fourth electrode; a first bus bar having a plate shape, the first bus bar being disposed on the opening side with respect to the first capacitor group inside the case and having an electrode contact portion in contact with the first electrode; a second bus bar having a plate shape, the second bus bar being disposed on the opening side with respect to the second capacitor group inside the case and having an electrode contact portion in contact with the third electrode; a third bus bar disposed on the bottom surface side with respect to the first capacitor group and the second capacitor group inside the case and having an electrode contact portion commonly in contact with the second electrode and the fourth electrode; a sealing resin with which the case is filled; and an insulating member provided between the electrode contact portion of the first bus bar and the electrode contact portion of the second bus bar and surrounded by the sealing resin.

According to this configuration, a capacitor module is provided with improved insulation.

The insulating member may be disposed such that, in a direction from the opening toward the bottom surface, one end portion is positioned on the opening side relative to the electrode contact portion of the first bus bar and the electrode contact portion of the second bus bar, and another end portion is positioned on the bottom surface side relative to the first electrode and the third electrode.

According to this configuration, the insulation distance of each capacitor group can be secured while reducing the distance between the first capacitor group and the second capacitor group. Therefore, it is possible to achieve downsizing of the capacitor module while improving the insulation.

In an exemplary aspect, a recess that receives the insulating member in a direction from the opening toward the bottom surface may be provided on an inner side surface of the case.

According to this configuration, positional displacement of the insulating member in the case can be prevented.

In an exemplary aspect, the third bus bar may further have an extending portion extending to an outside of the case through the opening along a side surface of the case from the electrode contact portion of the third bus bar, and a through hole through which the insulating member passes may be provided in the extending portion.

According to this configuration, interference between the third bus bar and the insulating member can be prevented.

In an exemplary aspect, the insulating member may be positioned by being received by the third bus bar at one end on the bottom surface side of the through hole.

According to this configuration, it may not be necessary to provide a recess in the case, and therefore it is possible to reduce the manufacturing cost.

Moreover, the insulating member may include a first portion extending along between the electrode contact portion of the first bus bar and the electrode contact portion of the second bus bar, and a second portion extending so as to intersect with respect to the first portion and extending so as to be positioned on the bottom surface side of the case with respect to a surface on the first electrode side of the electrode contact portion of the first bus bar and a surface on the third electrode side of the electrode contact portion of the second bus bar.

According to this configuration, uplift due to buoyancy of the sealing resin of the insulating member can be prevented.

Moreover, the side surface of the first capacitor and the side surface of the second capacitor may each include a pair of flat portions opposing each other and a pair of curved portions connecting the pair of flat portions, and the second portion of the insulating member may be disposed between the adjacent curved portions of the adjacent first capacitors and between the adjacent curved portions of the adjacent second capacitors.

According to this configuration, the second portion can be disposed in an empty space between the capacitors, which contributes to downsizing of the capacitor module.

Furthermore, the second portion of the insulating member may have a protrusion, and the protrusion may be inserted into a hole provided in each of the first bus bar and the second bus bar.

According to this configuration, it is possible to easily position the insulating member.

In another exemplary aspect, the second portion of the insulating member may have a recess, and the capacitor module may further comprise a screw inserted into a hole provided in each of the first bus bar and the second bus bar and the recess.

According to this configuration, it is possible to easily position the insulating member.

Moreover, the bottom surface of the case may be flat.

According to this configuration, the filling property of the sealing resin can also be improved.

FIG.1is a perspective view schematically illustrating a capacitor module1according to exemplary aspects of the present disclosure.FIG.2is a plan view of the capacitor module1ofFIG.1.FIG.3Ais a perspective view illustrating a first capacitor20included in a first capacitor group12of the capacitor module1ofFIG.1.FIG.3Bis a perspective view illustrating a second capacitor30included in a second capacitor group13of the capacitor module1ofFIG.1.FIG.4is a perspective view illustrating a first bus bar14and a second bus bar15included in the capacitor module1ofFIG.1.FIG.5is a perspective view illustrating a third bus bar16included in the capacitor module1ofFIG.1.FIG.6is a perspective view illustrating an insulating member18included in the capacitor module1ofFIG.1.FIG.7is a cross-sectional view of the capacitor module1ofFIG.2taken along line A-A.FIG.8is an enlarged view of a part ofFIG.7.FIG.9is a cross-sectional view of the capacitor module1ofFIG.2taken along line B-B.FIG.10is a cross-sectional view of the capacitor module1ofFIG.2taken along line C-C.FIG.11Ais an enlarged perspective view of a part of the capacitor module1ofFIG.1.FIG.11Bis a perspective view of the capacitor module1ofFIG.11Awith the insulating member18omitted. Note that X, Y, and Z directions in the drawing respectively indicate a lateral direction, a height direction, and a longitudinal direction of the capacitor module1.

[Overall configuration] As illustrated inFIGS.1and2, the capacitor module1includes a case11, the first capacitor group12, the second capacitor group13, the first bus bar14, the second bus bar15, the third bus bar16, a sealing resin17, and the insulating member18. InFIG.2, the sealing resin17is not illustrated.

The case11has an opening11a(seeFIG.1) provided at a position opposing a bottom surface11b(seeFIG.7). The case11houses the first capacitor group12, the second capacitor group13, the first bus bar14, the second bus bar15, the third bus bar16, and the insulating member18, and the case11is filled with the sealing resin17.

In the capacitor module1, each of the first bus bar14, the second bus bar15, and the third bus bar16is provided to extend to the outside along the side surface of the case11. The first bus bar14, the second bus bar15, and the third bus bar16respectively have terminals14a,15a, and16athat connect an external element and circuit.

The first capacitor group12is an aggregate of capacitors including a plurality of the first capacitors20illustrated inFIG.3A. The second capacitor group13is an aggregate of capacitors including one or a plurality of the second capacitors30illustrated inFIG.3B. The first capacitor group12and the second capacitor group13have different functions (for example, capacitance), and therefore the capacitor module1has two functions. In an aspect of the disclosure, as illustrated inFIG.2, the first capacitor group12includes six first capacitors20, and the second capacitor group13includes two second capacitors30.

Each of the first capacitor20and the second capacitor30is a wound type film capacitor. As illustrated inFIG.3A, the first capacitor20has a first electrode21, a second electrode22, and a side surface23connecting the first electrode21and the second electrode22. As illustrated inFIG.3B, the second capacitor30has a third electrode31, a fourth electrode32, and a side surface33connecting the third electrode31and the fourth electrode32.

Returning toFIG.1, the first bus bar14and the second bus bar15are disposed on the opening side of the case11. The opening side of the case11indicates a side close to the opening11arelative to the bottom surface11bin the case11. The first bus bar14is connected to the first electrode21of each of the first capacitors20. The second bus bar15is connected to the third electrode31of each of the second capacitors30.

The third bus bar16having a plate shape is disposed on the bottom surface side of the case11. The bottom surface side of the case11indicates a side close to the bottom surface11brelative to the opening11ain the case11. Each of the first capacitors20and second capacitors30are disposed on the third bus bar16. The second electrode22of each of the first capacitors20and the fourth electrode32of each of the second capacitors30are connected to the third bus bar16. That is, each of the first capacitors20is disposed such that the first electrode21faces the opening side and the second electrode22faces the bottom surface side. Similarly, each of the second capacitors30is disposed such that the third electrode31faces the opening side and the fourth electrode32faces the bottom surface side.

As further shown, the insulating member18is disposed between the first bus bar14and the second bus bar15. The insulating member18insulates the first electrode21of the first capacitor20and the first bus bar14from the third electrode31of the second capacitor30and the second bus bar15.

Each component of the capacitor module1will be described below in detail.

Since the first capacitor20and the second capacitor30have the same configuration, only the first capacitor20will be described here. In an exemplary aspect, the first capacitor20is a wound type film capacitor. The first capacitor20is formed by winding a dielectric film having a metal evaporated film formed on the surface and pressing the wound body of the dielectric film into a flat shape. Therefore, as illustrated inFIG.3A, the side surface23of the first capacitor20has a pair of flat portions24opposing each other and a pair of curved portions25connecting the pair of flat portions24.

As the dielectric film of the first capacitor20, for example, a plastic film such as polyethylene terephthalate, polypropylene, polyphenylene sulfide, or polyethylene naphthalate can be used. As the metal evaporated film formed on the surface of the plastic film, Al, Zn, or the like can be used. The first electrode21and the second electrode22are formed by spraying Zn or the like, for example, onto the end portion of the wound dielectric film.

The first bus bar14is a conductive member connected to the first electrode21of each of the first capacitors20of the first capacitor group12. As illustrated inFIG.4, the first bus bar14has the terminal14aconnected to an element, a circuit, or the like outside the capacitor module1, and an electrode contact portion14bin contact with each of the first electrodes21.

The terminal14aand the electrode contact portion14bare formed (e.g., integrally) by bending one metal plate. The first bus bar14is formed of a conductive metal such as Al, Cu, or brass. The electrode contact portion14bis formed with a hole14cfor connecting each of the first electrodes21by solder. The terminal14ais formed by extending in the height direction (Y direction) from the electrode contact portion14band being bent in the longitudinal direction (Z direction) near the opening11aof the case11.

The second bus bar15is a conductive member connected to the third electrode31of each of the second capacitors30of the second capacitor group13. As illustrated inFIG.4, the second bus bar15has the terminal15aconnected to an element, a circuit, or the like outside the capacitor module1, and an electrode contact portion15bin contact with each of the third electrodes31.

The terminal15aand the electrode contact portion15bare formed (e.g., integrally) by bending one metal plate. The second bus bar15is formed of a conductive metal such as Al, Cu, or brass. The electrode contact portion15bis provided with a hole15cfor connecting each of the third electrodes31by solder. The terminal15ais formed by extending in the height direction (Y direction) from the electrode contact portion15band being bent in the longitudinal direction (Z direction) near the opening11aof the case11.

The first bus bar14and the second bus bar15are arranged at an interval d in the lateral direction (X direction) in order to be electrically insulated as illustrated inFIG.8described later.

The third bus bar16is connected to the second electrode22of each of the first capacitors20of the first capacitor group12and the fourth electrode32of each of the second capacitors30of the second capacitor group13. As illustrated inFIG.5, the third bus bar16has a terminal16a, an electrode contact portion16b, and an extending portion16c. The terminal16ais connected to an element or a circuit outside the capacitor module1. The electrode contact portion16bis commonly in contact with the second electrode22and the fourth electrode32. The extending portion16cextends outward from the electrode contact portion16balong the side surface of the case11.

The terminal16a, the electrode contact portion16b, and the extending portion16care formed (e.g., integrally) by bending one metal. The third bus bar16is formed of a conductive metal such as Al, Cu, or brass. The electrode contact portion16bis provided with a hole16dfor connecting each of the second electrodes22and fourth electrodes32by solder. The extending portion16cextends in the height direction (Y direction) from the electrode contact portion16b, and is bent in the longitudinal direction (Z direction) near the opening11aof the case11.

As illustrated inFIG.5, the extending portion16cof the third bus bar is provided with a through hole16e. The through hole16eis for inserting the insulating member18in the −Y direction.

As illustrated inFIGS.1and2, the insulating member18is a member that insulates between the first bus bar14and the first electrode21and the second bus bar15and the third electrode31. By disposing the insulating member18, the first bus bar14and the first electrode21and the second bus bar15and the third electrode31can be more reliably insulated.

As illustrated inFIG.6, the insulating member18has a first portion18ahaving a plate shape and a second portion18bextending so as to intersect along the first portion18a. The insulating member18is formed of an electrically insulating resin such as polyphenylene sulfide (PPS resin) or polybutylene terephthalate (PBT resin). The insulating member18is formed by injection molding, and therefore a resin suitable for injection molding is preferably used.

As illustrated inFIGS.1and2, the first portion18aof the insulating member18is disposed along between the electrode contact portion14bof the first bus bar14and the electrode contact portion15bof the second bus bar15. The first portion18ahas one end portion19apositioned on the opening side relative to the electrode contact portion14bof the first bus bar14and the electrode contact portion15bof the second bus bar15in the direction from the opening11atoward the bottom surface11b, that is, in the height direction (Y direction) as illustrated inFIGS.7and8. Another end portion19bof the second portion18bis positioned on the bottom surface side relative to the first electrode21and the third electrode31.

By disposing the first portion18aof the insulating member18in this manner, insulation distances i1 and i2 can be secured between the respective bus bars while reducing the distance between the first bus bar14and the second bus bar15as compared with the case of not disposing the insulating member18. In one aspect of the disclosure, arrows i1 and i2 illustrated inFIG.8indicate the insulation distances i1 and i2 between the first bus bar14and the first electrode21and the second bus bar15and the third electrode31.

In the case of not disposing the insulating member18, the interval d between the first bus bar14and the second bus bar15becomes the insulation distance, and thus the interval d may need to be increased, which makes it difficult to downsize the capacitor module1. In contrast, by disposing the insulating member18as in the present aspect, the insulation distance can be secured while reducing the interval d between the first bus bar14and the second bus bar15. Therefore, the first bus bar14and the first electrode21and the second bus bar15and the third electrode31can be more reliably insulated from each other.

The insulation distances i1 and i2 are preferably set to appropriate values in consideration of the maximum applied voltages of the capacitor groups12and13. It is possible to change the insulation distance by adjusting the positions in the height direction of the one end portion19aand the other end portion19bof the first portion18aof the insulating member18.

As illustrated inFIG.9, the second portion18bof the insulating member18is positioned on the bottom surface side of the case11with respect to a surface14don the first electrode21side of the electrode contact portion14bof the first bus bar14and a surface15don the third electrode31side of the electrode contact portion15bof the second bus bar15. That is, the second portion18bof the insulating member18is disposed on the lower side in the height direction of the first bus bar14and the second bus bar15. Since the second portion18bis disposed on the lower side of the first bus bar14and the second bus bar15, it is possible to prevent the insulating member18from uplifting due to the buoyancy of the sealing resin17.

Returning toFIG.2, the second portion18bof the insulating member18is disposed between the adjacent curved portions25of the adjacent first capacitors20and between the adjacent curved portions35of the adjacent second capacitors30. Since the first capacitor20has a shape having the curved portion25, a space is generated between the adjacent curved portions25of the adjacent first capacitors20. Similarly, in the case of the second capacitor30, a space is generated between the adjacent curved portions35. When the second portion18bof the insulating member18is disposed using this space, the second portion18bof the insulating member18can be disposed without enlarging the case11, and the uplift of the insulating member18can be prevented while effectively using the space.

In the present aspect, the first portion18aof the insulating member18is provided with a third portion18cthat prevents positional displacement in a horizontal direction including the lateral direction (e.g., the X direction) and the longitudinal direction (e.g., the Z direction). In order to create a space for disposing the third portion18c, the electrode contact portion14bof the first bus bar14and the electrode contact portion15bof the second bus bar15are provided with cutouts14eand15e, respectively. As illustrated inFIG.10, the third portion18cis disposed so as to be placed on a part of the first electrode21and a part of the third electrode31. The third portion18cof the insulating member18is disposed on the upper side in the height direction of the first capacitor20and the second capacitor30and is surrounded by the cutouts14eand15e, so that the insulating member18can be prevented from being displaced in the longitudinal direction (e.g., the Z direction) or the lateral direction (e.g., the Z direction).

As described above, in the insulating member18, the movement in the +Y direction can be restricted by the second portion18b, and the movement in the X direction and the Z direction can be restricted by the third portion18c.

The case11houses each component of the capacitor module1. In the present aspect, the case11has the opening11aprovided at a position opposing the bottom surface11b. In the present aspect, the case11has the opening11aand the bottom surface11bthat have a substantially square shape, and has a box shape. The shape of the case11is not limited to this, and can take various shapes depending on the arrangement of the capacitor group. The case11is formed of, for example, a synthetic resin such as polyphenylene sulfide (PPS resin) or polybutylene terephthalate (PBT resin).

As illustrated inFIGS.11A and11B, a protrusion11cfor positioning the insulating member18is provided in the case11. The protrusion11cis a protrusion provided inward from the inner side surface of the case11, and provides a recess11dthat receives the first portion18aof the insulating member18in a direction from the opening11atoward the bottom surface11b. The protrusion11crestricts the movement of the insulating member18in the lateral direction (e.g., the X direction) and the longitudinal direction (e.g., the Z direction). That is, the insulating member18is positioned in the X direction and the Z direction by the protrusion11c. The shape of the protrusion11cis not limited to that illustrated inFIGS.11A and11B, and may only be required to be a shape as long as it can hold the end portion of the insulating member18.

When the first portion18aof the insulating member18is disposed on the protrusion11c, the movement of the insulating member18in the X direction and the Z direction is restricted. Furthermore, the movement of the insulating member18in the −Y direction is also restricted. Since the periphery of the insulating member18is filled with the sealing resin17, the insulating member18is positioned by the protrusion11cof the case11and the sealing resin17.

As illustrated inFIGS.11A and11B, when the third bus bar16is disposed in the case11, the through hole16eof the third bus bar16overlaps the protrusion11cof the case11. By providing the through hole16eof the third bus bar16and the protrusion11cof the case11in such arrangement, it is possible to insert the insulating member18in the direction from the opening11atoward the bottom surface11b.

As illustrated inFIGS.7,9, and10, the bottom surface11bof the case11is flat. By making the bottom surface11bof the case11flat, the sealing resin17easily spreads over approximately the entire the bottom surface11bas compared with a case where the bottom surface11bis provided with a convex, and therefore the filling property of the sealing resin17can be improved.

The sealing resin17is filled in the case11to seal each component of the capacitor module1. The sealing resin17is a thermosetting resin, and for example, an epoxy resin can be used. Alternatively, it may be a urethane resin. As the material of the sealing resin17, a material having high fluidity and adhesiveness is preferably used.

A manufacturing method of the capacitor module1will be described with reference toFIGS.12A to12F.FIGS.12A to12Fare views illustrating the manufacturing process of the capacitor module1according to one exemplary aspect of the disclosure.

First, the third bus bar16is prepared. As illustrated inFIG.5, the third bus bar16can be formed by pressing a metal plate, for example. In order to insulate between the third bus bar16and the first electrode21of each of the first capacitors20and the third electrode31of each of the second capacitors30, an insulating paper41is attached to the extending portion16cof the third bus bar16.

Next, each of the first capacitors20and second capacitors30is disposed in the electrode contact portion16bof the third bus bar16. Specifically, as illustrated inFIG.12A, each of the first capacitors20and second capacitors30is disposed such that the second electrode22and the fourth electrode32face the electrode contact portion16b.

Next, the insulating member18is disposed. Specifically, as illustrated inFIG.12B, the first portion18aof the insulating member18is disposed between the first capacitor group12and the second capacitor group13. At this time, the second portion18bis positioned between the curved portions25of the first capacitors20and between the curved portions35of the second capacitors30. The third portion18cis placed on the first capacitor20and the second capacitor30. By disposing the insulating member18in this manner, the first portion18aof the insulating member18is disposed so as to be held between the first capacitor group12and the second capacitor group13, and the movement in the lateral direction is restricted. At this time, the end portion of the first portion18apasses through the through hole16eof the third bus bar, and therefore the first portion18aand the third bus bar16do not interfere with each other.

InFIG.12B, the insulating member18is not in a fixed state, and is disposed so that the end portion of the insulating member18can be fitted into the recess11din the process of inserting each component described later into the case11. At this time, the insulating member18becomes in a state of being movable in the Y direction by the second portion18bbeing positioned in the −Y direction relative to the first electrode21and the third electrode31, and therefore it is possible to easily perform fitting to the recess11d.

Next, the first bus bar14and the second bus bar15are disposed. Specifically, as illustrated inFIG.12C, the electrode contact portion14bof the first bus bar14is placed on the first electrode21of each of the first capacitors20of the first capacitor group12. The electrode contact portion15bof the second bus bar15is placed on the third electrode31of each of the second capacitors30of the second capacitor group13. At this time, the first bus bar14and the second bus bar15are disposed such that third portion18cof the insulating member18is positioned in the cutouts14eand15eof the first bus bar14and the second bus bar15, respectively.

Thereafter, in the hole14cof the electrode contact portion14bof the first bus bar14, the electrode contact portion14band each of the first electrodes21are connected by solder (not illustrated). In the hole15cof the electrode contact portion15bof the second bus bar15, the electrode contact portion15band each of the third electrodes31are connected by solder (not illustrated). By soldering, it is possible to electrically connect the first bus bar14and each of the first electrodes21, and the second bus bar15and each of the third electrodes31.

Next, the third bus bar16is connected to each of the second electrodes22and fourth electrodes32by solder (not illustrated). Specifically, as illustrated inFIG.12D, the third bus bar16is electrically connected to the second electrode22and the fourth electrode32by soldering in the hole16dprovided in the electrode contact portion16bof the third bus bar16.

Next, as illustrated inFIG.12E, each of the first capacitors20and second capacitors30, the first bus bar14, the second bus bar15, the third bus bar16, and the insulating member18that have been soldered are inserted into the case11. At this time, the end portion of the first portion18aof the insulating member18is inserted into recess11dof the protrusion11cof the case11(see, e.g.,FIG.11A). When the end portion of the first portion18ais inserted into the protrusion11c, the insulating member18is positioned in the X direction and the Z direction inside the case11.

After insertion into the case11, as illustrated inFIG.12F, the case11is filled with the sealing resin17, and the sealing resin17is cured to complete the capacitor module1. At this time, the movement of the second portion18bof the insulating member18in the +Y direction is restricted by the first bus bar14and the second bus bar15(see, e.g.,FIG.9). Therefore, it is possible to prevent uplift of the insulating member18when the sealing resin17is filled. Since the bottom surface11bof the case11is formed flat, the filling property of the sealing resin17is improved.

According to the capacitor module1according to one aspect of the disclosure, it is possible to achieve the following effects.

The capacitor module1includes the case11, the first capacitor group12, the second capacitor group13, the first bus bar14, the second bus bar15, the third bus bar16, the sealing resin17, and the insulating member18. The case11has the opening11aprovided at a position opposing the bottom surface lib. The first capacitor group12includes one or a plurality of the first capacitors20. The first capacitor20is disposed inside the case11and has the first electrode21, the second electrode22, and the side surface23connecting the first electrode21and the second electrode22. The second capacitor group13includes one or a plurality of the second capacitors30. The second capacitor30is disposed inside the case11, and includes the third electrode31, the fourth electrode32, and the side surface33connecting third electrode31and the fourth electrode32. The first bus bar14is disposed on the opening11aside with respect to the first capacitor group12inside the case11, and has a plate shape having the electrode contact portion14bin contact with the first electrode21. The second bus bar15is disposed on the opening11aside with respect to the second capacitor group13inside the case11, and has a plate shape having the electrode contact portion15bin contact with the third electrode31. The third bus bar16is disposed on the bottom surface11bside with respect to the first capacitor group12and the second capacitor group13inside the case11, and has the electrode contact portion16bcommonly in contact with the second electrode22and the fourth electrode32. The sealing resin17is filled in the case11. The insulating member18is provided between the electrode contact portion14bof the first bus bar14and the electrode contact portion15bof the second bus bar15, and is surrounded by the sealing resin17.

With such configuration, by providing the insulating member18, insulation between the first bus bar14and the first electrode21and the second bus bar15and the third electrode31can be improved as compared with a case where the insulating member18is not disposed and only the sealing resin17is provided. When the insulating member18is not disposed, insulation is provided by the sealing resin17, but there is a risk of insulation failure due to bubbles generated in the sealing resin17. By providing the insulating member18separately from the sealing resin17, it is possible to reliably insulate between the first bus bar14and the first electrode21and the second bus bar15and the third electrode31, and the insulation is improved.

By disposing the insulating member18, it is possible to secure the long insulation distances i1 and i2 while reducing the distance d between the first bus bar14and the first electrode21and the second bus bar15and the third electrode31. Therefore, the interval d between the first bus bar14and the first electrode21and the second bus bar15and the third electrode31can be reduced, thereby contributing to downsizing of the capacitor module1.

The one end portion19aof the insulating member18is positioned on the opening side of the case11relative to the electrode contact portion14bof the first bus bar14and the electrode contact portion15bof the second bus bar15in the direction from the opening11atoward the bottom surface11b. The other end portion19bof the insulating member18is positioned on the bottom surface side of the case11relative to the first electrode21and the third electrode31. Such configuration makes it possible to secure an appropriate insulation distance.

The insulation distance between the first bus bar14and the second bus bar15can be changed by the positions in the height direction (e.g., Y direction) of the end portions19aand19bof the insulating member18. Referring toFIG.8, if the position in the height direction of the one end portion19ais positioned upper (e.g., +Y direction) than that inFIG.8, the insulation distance i1 becomes longer. Similarly, if the position in the height direction of the other end portion19bof the insulating member18is positioned lower (e.g., −Y direction) than that inFIG.8, the insulation distance i2 becomes longer. Thus, the lengths of the insulation distances i1 and i2 are preferably set appropriately according to the capacitance of the capacitor module1or the like.

On the other hand, when the position in the height direction of the one end portion19aof the insulating member18is positioned lower (e.g., −Y direction) than the first bus bar14and the second bus bar15, the insulation distance is the distanced between the electrode contact portion14band the electrode contact portion15b. In this case, in order to secure an appropriate insulation distance, the distance d is increased, which makes it difficult to downsize the capacitor module1. Similarly, when the position in the height direction of the other end portion19bof the insulating member18is upper (e.g., +Y direction) than the first electrode21and the third electrode31, the insulation distance is the distance d between the first electrode21and the third electrode31. Also in this case, in order to secure an appropriate insulation distance, the distance d is increased. By disposing the insulating member18as in one aspect of the disclosure, it is possible to reduce the distance d while securing the insulation, thereby contributing to downsizing of the capacitor module1.

The inner side surface of the case11has the recess11dthat receives the insulating member18in the direction from the opening11atoward the bottom surface11b, and is provided with the protrusion11cthat positions the insulating member18. Such configuration prevents positional displacement of the insulating member18in the case11, and provide insulation more reliably.

The third bus bar16further has the extending portion16cextending to the outside of the case11through the opening11aalong the side surface of the case11from the electrode contact portion16bof the third bus bar16. The extending portion16cis provided with the through hole16ethrough which the insulating member18passes. Such configuration prevents interference between the third bus bar16and the insulating member18.

The insulating member18includes the first portion18aand the second portion18b. The first portion18aextends along between the electrode contact portion14bof the first bus bar14and the electrode contact portion15bof the second bus bar15. The second portion18bextends so as to intersect the first portion18a, and extends so as to be positioned on the bottom surface side of the case11with respect to the surface14don the first electrode21side of the electrode contact portion14bof the first bus bar14and the surface15don the third electrode31side of the electrode contact portion15bof the second bus bar15. Such configuration prevents uplift due to buoyancy of the sealing resin17of the insulating member18.

The side surface23of the first capacitor20has a pair of flat portions24opposing each other and a pair of curved portions25connecting the pair of flat portions24. The side surface33of the second capacitor30includes a pair of flat portions34and a pair of the curved portions35connecting the pair of flat portions34. The second portion18bof the insulating member18is disposed between the adjacent curved portions25of the adjacent first capacitors20and between the adjacent curved portions35of the adjacent second capacitors30. Such configuration makes it possible to dispose the second portion18bin a space provided between the adjacent curved portions25and between the adjacent curved portions35, thereby contributing to downsizing of the capacitor module1.

The bottom surface11bof the case11is flat. Such configuration improves the filling property of the sealing resin17. When the bottom surface11bof the case11is flat, the fluidity of the resin is improved, and therefore it is possible to prevent the manufacturing cost from increasing due to time taken for filling of the resin due to blocking of the flow of the resin when filling the case with the resin. When the bottom surface11bof the case11is flat, manufacturing of the case11becomes easy, and therefore downsizing can be achieved, which contributes to downsizing of the capacitor module1.

In one exemplary aspect of the disclosure, an example in which the first capacitor group12includes the six first capacitors20and the second capacitor group13includes the two second capacitors30has been described, but the present disclosure is not limited to this. The numbers of capacitors included in the first capacitor group12and the second capacitor group13may be one or more.

In one exemplary aspect of the disclosure, an example in which the second portion18bof the insulating member18extends to both the first capacitor group12side and the second capacitor group13side has been described, but the present disclosure is not limited to this. The second portion18bmay extend to either the first capacitor group12side or the second capacitor group13side. Two or more second portions18bmay be provided in additional exemplary aspects.

In one exemplary aspect of the disclosure, an example in which the insulating member18is provided with the second portion18band the third portion18chas been described, but the second portion18band the third portion18cneed not be provided. When the insulating member18is not provided with the third portion18c, the respective cutouts14eand15eof the first bus bar14and the second bus bar15need not be provided.

While in one exemplary aspect of the disclosure, the insulating member18is positioned by the protrusion11cof the case11, the present disclosure is not limited to such a case, and the insulating member18may be positioned in the through hole of the third bus bar16as illustrated inFIGS.13A and13B.FIG.13Ais an enlarged perspective view of a part of a capacitor module1aaccording to a modification of one aspect of the disclosure of the present disclosure.FIG.13Bis a perspective view of the capacitor module1aofFIG.13Awith the insulating member18omitted. InFIGS.13A and13B, the sealing resin17is omitted.

As illustrated inFIGS.13A and13B, in the capacitor module1a, the case11is not provided with a protrusion, and the insulating member18is positioned by being received by the third bus bar16at one end on the bottom surface side of a through hole16fprovided in the extending portion16c. The through hole16fis provided with a portion whose width decreases from the opening side toward the bottom surface side and a portion having substantially the same constant width as that of the insulating member18. The insulating member18is positioned by the portion having the constant width. Therefore, when the insulating member18is inserted from the opening side to the bottom surface side, the insulating member18is positioned in the lateral direction (X direction).

According to such configuration, it is not necessary to provide a protrusion on the case11and it is only necessary to change the shape of the third bus bar16, and therefore the insulating member18can be positioned with a simple configuration and the manufacturing cost can be reduced. In the case of having the through hole16fas illustrated inFIGS.13A and13B, the insulating member18is already positioned in the state ofFIG.12B. Therefore, it is possible to prevent positional displacement of the insulating member18with respect to the bus bar or the capacitor when inserting the insulating member18into the case11as inFIG.12E. Therefore, the positioning accuracy of the insulating member18is improved, and the insulation can be improved.

A capacitor module1baccording to another exemplary aspect of the disclosure will be described.

In this exemplary aspect of the disclosure, points different from other aspects will be mainly described. In one aspect of the disclosure, the identical or equivalent configurations as those described above will be described with the same reference numerals given. In one aspect of the disclosure, description overlapping of aspects described above will be omitted.

FIG.14is a perspective view of the capacitor module1baccording to one aspect of the disclosure with a case and a sealing resin omitted.FIG.15is an enlarged view of the region R1 of the capacitor module1bofFIG.14.FIG.16is a view illustrating an insulating member58of the capacitor module1bofFIG.14.FIG.17is a view illustrating a first bus bar54and a second bus bar55of the capacitor module1bofFIG.14.

As illustrated inFIGS.14and15, aspects different from the aspects described above in a point that a second portion58bof the insulating member58has a protrusion58c, and the protrusion58cis inserted into holes54eand55e(seeFIG.17) provided in the first bus bar54and the second bus bar55, respectively.

As illustrated inFIG.16, the insulating member58has two second portions58bat each of both ends of a first portion58a. That is, four second portions58bare provided in the first portion58a. The protrusion58cis provided from each second portion58bof the insulating member58toward the +Y direction. The tip end of the protrusion58cis provided in a hook shape.

As illustrated inFIG.17, the first bus bar54and the second bus bar55are provided with the holes54eand55e, respectively. Since each protrusion58cof the second portion58bof the insulating member58is inserted into the hole54eof the first bus bar54or the hole55eof the second bus bar55, a hook of the protrusion58cis caught and fixed to the hole54eor55e. That is, each of the protrusion58cand the hole54eor55eis fitted by snap-fitting. In this manner, the insulating member58is joined to the first bus bar54and the second bus bar55.

In one aspect of the disclosure, the insulating member58is joined and positioned with the first bus bar54and the second bus bar55. Therefore, a protrusion or a through hole for positioning the insulating member58is not provided in the case11and the third bus bar16. Since the insulating member18is fitted to the first bus bar54and the second bus bar55by snap-fitting, the insulating member58is not provided with a portion that prevents uplift (the second portion18bof the one aspect), and has a configuration simpler than that of aspects described above.

A manufacturing method of the capacitor module1bwill be described with reference toFIGS.18A to18F.FIGS.18A to18Fare views illustrating the manufacturing process of the capacitor module1baccording to one aspect of the disclosure.

First, the first bus bar54and the second bus bar55are prepared as illustrated inFIG.18A. The first bus bar54is provided with an electrode contact portion54b, a terminal54a, a hole54cfor soldering, and the hole54efor joining with the insulating member58. Similarly, the second bus bar55is provided with an electrode contact portion55b, a terminal55a, a hole55cfor soldering, and the hole55efor joining with the insulating member58.

Next, as illustrated inFIG.18B, the protrusion58cof the insulating member58is inserted into the hole54eof the first bus bar54and the hole55eof the second bus bar55. Each protrusion58cof the insulating member58is inserted in the direction (Y direction) from the bottom surface11bof the case11toward the opening11a. Since the insulating member58is joined to the first bus bar54and the second bus bar55by snap-fitting, the insulating member58can be firmly fixed to the first bus bar54and the second bus bar55. When joining the insulating member18to the first bus bar54and the second bus bar55in this manner, it is possible to fix the electrode contact portion54bof the first bus bar54and the electrode contact portion55bof the second bus bar55while keeping them in a substantially identical plane.

Next, as illustrated inFIG.18C, each of the first capacitors20and second capacitors30is disposed in the electrode contact portion16bof the third bus bar16. Next, as illustrated inFIG.18D, the first bus bar54and the second bus bar55joined to the insulating member58inFIG.18Bare disposed in the first capacitor20and the second capacitor30. At this time, unlike exemplary aspects described above, it is not required to dispose the insulating member58in the through hole of the third bus bar16, and it is possible to easily dispose the first bus bar54and the second bus bar55because they are kept in the substantially identical plane.

After the first bus bar54and the second bus bar55are disposed, the first bus bar54and the first electrode21of each of the first capacitors20, and the second bus bar55and the third electrode31of each of the second capacitors30are connected by solder (not illustrated). The first bus bar54and each of the first electrodes21are electrically connected by soldering in the hole54cprovided in the electrode contact portion54bof the first bus bar54. Similarly, the second bus bar55and the third electrode31are also soldered in the hole55cprovided in the electrode contact portion55bof the second bus bar55, whereby the second bus bar55and the third electrode31are electrically connected.

Next, as illustrated inFIG.18E, the third bus bar16is connected to each of the second electrodes22and fourth electrodes32by solder (not illustrated). The third bus bar16is electrically connected to the second electrode22and the fourth electrode32by soldering in the hole16dprovided in the electrode contact portion16bof the third bus bar16.

As illustrated inFIG.18F, each of the first capacitors20and second capacitors30, the first bus bar54, the second bus bar55, the third bus bar16, and the insulating member58that have been soldered are inserted into the case11. At this time, no protrusion is provided on the case11, and alignment between the insulating member58and the case11is unnecessary, and therefore arrangement is easy.

After insertion into the case11, as illustrated inFIG.18G, the case11is filled with the sealing resin17, and the sealing resin17is cured to complete the capacitor module1b. At this time, the protrusion58cof the insulating member58is inserted into each of the holes54eand55e. Therefore, it is possible to prevent the insulating member58from uplifting due to the buoyancy of the sealing resin17without separately providing an uplift prevention structure (e.g., the second portion18bof the exemplary aspects described above) of the insulating member58.

According to the capacitor module1baccording to one aspect of the disclosure, it is possible to achieve the following effects.

The second portion58bof the insulating member58of the capacitor module1bhas the protrusion58c, and is inserted into the holes54eand55eprovided in first bus bar54and the second bus bar55, respectively.

Such configuration makes it easy to position the insulating member58.

Moreover, a capacitor module1caccording to a modification of aspects will be described with reference toFIGS.19to21.

FIG.19is a perspective view of the capacitor module1caccording to a modification of exemplary aspects with the case and the sealing resin omitted.FIG.20is an enlarged view of the region R2 of the capacitor module1cofFIG.19.FIG.21is a view illustrating a first bus bar64, a second bus bar65, and an insulating member68of the capacitor module1cofFIG.19.

While in the capacitor module1bof one exemplary aspect of the disclosure, the insulating member58is joined to the first bus bar54and the second bus bar55by the snap-fit structure, they are joined by screws in the capacitor module1c.

As illustrated inFIGS.19and20, the insulating member68is joined to the first bus bar64and the second bus bar65by four screws69.

More specifically, as illustrated inFIG.21, a second portion68bof the insulating member68has a recess68c. The first bus bar64and the second bus bar65are provided with circular holes64eand65e, respectively. The capacitor module1cfurther has the screws69inserted into the holes64eand65eprovided in the first bus bar64and the second bus bar65and the recesses68crespectively.

Such configuration makes it possible to more firmly fix the insulating member68, the first bus bar64, and the second bus bar65as compared with the snap-fitting. It is possible to improve the positioning accuracy of the insulating member68.

The present disclosure is useful for capacitors used in various electronic equipment, electric equipment, industrial equipment, vehicle devices, and the like.

In general, the description of the aspects disclosed should be considered as being illustrative in all respects and not being restrictive. The scope of the present disclosure is shown by the claims rather than by the above description, and is intended to include meanings equivalent to the claims and all changes in the scope. While preferred aspects of the disclosure have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the disclosure.