JP6091979B2 - Metallized film capacitor and manufacturing method thereof - Google Patents

Description

  The present invention relates to a resin mold type metallized film capacitor and a method for manufacturing the same.

FIG. 7 is a perspective view showing a completed structure of a conventional metallized film capacitor, FIG. 8 is a plan view showing a process of manufacturing the metallized film capacitor, and FIG. 9 is a process of manufacturing the metallized film capacitor. It is a vertical side view which shows a mode. In these drawings, 10 is a capacitor element, 20 is an external lead terminal connected to the metal electrodes 11 at both ends in the axial direction of each capacitor element 10 in a laminated body 15 of a plurality of capacitor elements 10, and 30 is a plurality of capacitor elements 10. The capacitor unit is composed of the laminated body 15 and the external lead terminal 20. A plurality of capacitor elements 10 are stacked in the vertical direction, and are arranged in parallel in the horizontal direction to form a stacked body 15. The external lead terminal 20 includes a rectangular terminal plate 21 joined to the upper end surface of the laminate 15, a connection terminal portion 22 bent and connected in a hook shape from the terminal plate 21, and the terminal plate 21 and a plurality of capacitors. The connection plate 23 is soldered over the metal electrode 11 of the element 10.

  The capacitor unit 30 is entirely covered with an exterior resin 40 except for the connection terminal portion 22 of the external lead terminal 20, thereby forming a metallized film capacitor B.

Next, an outline of the manufacturing metallized film capacitor B will be described with reference to FIG. As a manufacturing means, a forming mold 50 and a fixing jig 60 are used.

A capacitor unit 30 formed by connecting an external lead terminal 20 to a plurality of capacitor elements 10 using a metallized film is accommodated in a cavity 51 of a molding frame 50. At this time, the bottom surface 31 of the capacitor unit 30 is in a state of being floated and separated from the inner bottom surface 53 of the molding frame 50 (see FIG. 9 ; however, in principle, there is no normal inclination of the capacitor unit 30). . Further, a predetermined interval is set between the outer peripheral surface 32 of the capacitor unit 30 and the inner peripheral surface 52 of the molding die 50. The fixing jig 60 is bridged on the upper surface portion of the forming mold 50. The fixing jig 60 has an elongated plate shape, and is slid in the length direction and passed through the lower surface of the hook-shaped connection terminal portion 22. The connection terminal portion 22 is fixed to the fixing jig 60 via a hanging tool 61 such as a bolt. By this fixing, the capacitor unit 30 with the external lead terminal 20 is held in a suspended state in the cavity 51 of the molding die 50. The fixing jig 60 is fixed to the upper end surface of the molding die 50 with bolts 90.

  Next, molten resin is filled into the cavity 51 which is a space between the outer peripheral surface 32 of the capacitor unit 30 and the inner peripheral surface 52 of the molding die 50 and is cured. When the molten resin is cured, it becomes the exterior resin 40, but the entire capacitor unit 30 is covered with the exterior resin 40 except for the connection terminal portion 22 of the external lead terminal 20.

  Next, the metallized film capacitor B in which the capacitor unit 30 is covered with the exterior resin 40 is released from the mold 50. At the time of this mold release, the fixing jig 60 and the fixing jig 60 are removed from the forming mold 50, and then the hanging tool 61 is removed to remove the fixing jig 60.

  As described above, the metalized film capacitor B obtained by covering the entire capacitor unit 30 with the exterior resin 40 except for the connection terminal portion 22 is obtained.

  Patent Document 1 discloses a basic configuration of a metallized film capacitor.

JP-A-9-260180 JP 2013-8709 A WO2010 / 004704

In the above conventional example, as shown in FIG. 9 , the capacitor unit 30 is tilted in the cavity 51 of the molding die 50 during the manufacturing process, or the corners and ridges of the capacitor unit 30 are formed on the molding die 50. There was a problem in that the thickness of the exterior resin 40 formed by curing of the filled molten resin contacted with the inner peripheral surface 52 was uneven. In extreme cases, the thickness of the exterior resin 40 may become zero (uncoated) or extremely thin. When the required thickness of the exterior resin 40 is not ensured, the function of preventing moisture penetration by the exterior resin 40 is impaired, and the function of the metallized film capacitor B is reduced and the life is shortened.

  Patent Document 2 mentions a slide member that engages with a capacitor unit as a measure for restricting the position of the capacitor unit within the cavity of the mold. This slide member slides laterally within the cavity of the molding mold, and engages with the bent portion of the base of the external lead terminal in the capacitor unit in the first half of the molten resin filling, and in the second half of the molten resin filling. Slide outward to disengage. The position regulation of the slide member and the capacitor unit in the latter half of the filling is based on the pressure of the molten resin to be filled. The slide member is attached to the mold, and is not embedded in the exterior resin in the metallized film capacitor after release.

  However, the slide member that temporarily supports (holds the position of) the capacitor unit is literally movable, and includes an engagement structure with the bent portion of the external lead terminal, a rail structure that guides the movement of the slide member, and the like. It is necessary and the structure of the mold is complicated. It is difficult to realize a mechanism for escaping outwards with the pressure of the molten resin. Since the filling of the molten resin is divided into the first half and the second half, the interface between the first half filling portion and the second half filling portion leaves the possibility of a moisture intrusion gap.

  Patent Document 3 mentions a support for regulating the position of a capacitor unit within a mold as a measure for regulating the position of the capacitor unit within the cavity of the mold. It uses a plurality of supports that are brought into contact with the boundary corners between the metal electrodes at both ends in the axial direction of the capacitor element and the bottom surface of the capacitor element. The contact here is presumed to mean fixing by adhesion or the like (see paragraph [0048]). A support is placed in the mold and a capacitor unit is placed on the support. A mold resin is filled with a molten resin (norbornene monomer) and cured to form an exterior resin (exterior body) (see paragraph [0023]). For positioning, it is considered that a recess for fitting the support is formed on the inner bottom surface of the mold, and the support is fitted in the recess (see paragraph [0035]).

  However, since the end portion of the support is exposed from the exterior resin, there is a possibility that external moisture may enter the inner capacitor element through the support. Although the support is in contact with the bottom surface portion of the capacitor element, the bottom surface portion is not preferable in terms of preventing moisture intrusion because it receives the strongest vibration during actual use.

  As another aspect, there is also disclosed one that regulates the position of a capacitor unit by bringing a support into contact with a connection plate (metal bus bar) in an external lead terminal (see paragraph [0044]).

  However, since the support is sandwiched and fixed by both of the support fixing portions provided on the inner surfaces of the mold clamping edge portions of the lower mold and the upper mold in the mold (see paragraph [0046]), the capacitor The structure for restricting the position of the unit is complicated. In addition, it is difficult to correctly hold the work.

  The present invention has been made in view of the above, and regarding the thickness of the exterior resin covering the outer periphery of the capacitor unit, the metallization that ensures a substantially uniform thickness on both the lateral side surface and the bottom surface of the capacitor unit. It is an object of the present invention to provide a film capacitor manufacturing method and a metallized film capacitor.

  The present invention takes the following means in order to solve the above problems.

  The manufacturing method of the metallized film capacitor according to the present invention includes a plurality of steps as follows.

(1) For a capacitor unit in which external lead terminals are connected to metal electrodes on both ends in the axial direction of a laminate of a plurality of capacitor elements using a metallized film, a portion other than the metal electrodes of the capacitor element laminate The support member is fastened in a state where the lateral side surface portion formed between the capacitor elements adjacent in the vertical direction in the multilayer body of the capacitor elements is fitted into the corrugated concave surface. In this case, the support member includes a triangular prism-shaped main body portion and a pair of projecting portions having a cross-sectional area smaller than that of the main body portion extending integrally from the both axial end portions of the main body portion in the axial direction. The triangular prism-shaped main body portion is fixed to the corrugated concave surface in a fitted state using a support member (capacitor unit with a support member). Here, it is important to the Installing stopper support member and fitting relative to the waveform concave surface of the lateral side portion of the capacitor unit (not the bottom portion). In addition, it is also important to use a support member including a triangular prism main body and a pair of projecting portions integrally extending in the axial direction from both ends thereof.

  (2) The free end portion of the support member in the capacitor unit with the support member is brought into contact with and close to the inner peripheral surface of the mold frame, and the capacitor unit is placed between the mold mold frame and the capacitor unit. The capacitor unit with the support member is accommodated in the cavity of the molding die in a state where the position is regulated at a predetermined interval.

  (3) In a state where the bottom surface of the capacitor unit with the support member housed in the cavity of the molding mold is lifted and separated from the inner bottom surface of the molding mold, the capacitor unit is placed on the upper surface of the molding mold. The suspended fixture is supported in a suspended state.

  (4) Fill and cure the molten resin in the space between the outer peripheral surface / bottom surface of the capacitor unit and the inner peripheral surface / inner bottom surface of the molding frame, the position of which is regulated by the support member (formation of exterior resin) . Thus, the entire capacitor unit is covered with the exterior resin except for the connection terminal portion of the external lead terminal.

  (5) The capacitor unit, which is entirely covered with the exterior resin in which the molten resin is cured, except for the connection terminal portion of the external lead terminal, is released from the mold frame.

The metallized film capacitor according to the present invention is preferably applied to the method for producing a metallized film capacitor described above, and includes a capacitor unit, an exterior resin, and a support member. That is, a capacitor unit in which external lead terminals are connected to metal electrodes on both ends in the axial direction of a laminate of a plurality of capacitor elements using a metallized film, and the capacitor unit except for the connection terminal portions of the external lead terminals. The corrugated concave surface of the lateral side surface portion formed between the exterior resin covering the whole and the capacitor elements adjacent to each other in the vertical direction in the capacitor element laminate, other than the metal electrodes of the capacitor element laminate And a support member embedded in the exterior resin and having a free end exposed on the surface of the exterior resin. The support member includes a triangular prism-shaped main body portion and a pair of projecting portions having a cross-sectional area smaller than the main body portion extending integrally in the axial direction from both axial end portions of the main body portion. .

According to the present invention, the capacitor unit with the support member fixed to the corrugated concave surface of the lateral side surface portion of the capacitor element laminate can be suspended and accommodated in the cavity of the molding mold. Realizes front / rear / right / left and top / bottom position restrictions while avoiding tilting of the unit and contact of the capacitor unit with the inner surface of the mold, and the thickness of the outer resin on the outer periphery of the capacitor unit due to filling and hardening of the molten resin It can be ensured in a state where both the lateral side surface portion and the bottom surface portion of the unit are substantially uniform. Ensuring this good exterior resin thickness is advantageous in preventing moisture from entering the capacitor element.

In addition, structurally, [1] the triangular prism-shaped main body of the support member is fastened in a state where it is fitted into the corrugated concave surface of the lateral side surface of the capacitor unit, and [2] the pair of overhanging portions of the support member is formed into a mold The capacitor unit is accommodated in the mold frame while being in contact with or close to the inner peripheral surface of the frame. [3] The capacitor unit is suspended and supported by a fixing jig spanned on the upper surface of the mold frame. The mold can be realized with a simpler structure as compared with the prior art.

In particular, as a support member, a support member composed of a triangular prism-shaped main body portion and a pair of projecting portions is used, and the triangular prism-shaped main body portion is fixed to the corrugated concave surface in a fitted state, and a pair of projecting portions. Since the capacitor unit is accommodated in the molding die in a state where the capacitor unit is brought into contact with and close to the inner peripheral surface of the molding die, the housing posture can be made stronger and more stable.

The perspective view which shows the structure of the completion state of the metallized film capacitor of Example 1 of this invention The perspective view which shows the state which remove | excluding exterior resin with the metallized film capacitor of Example 1 of this invention The perspective view of the support member in the metallized film capacitor of Example 1 of this invention, and the perspective view which shows the mode of fixation of the support member with respect to a capacitor | condenser unit The longitudinal front view which shows the mode of the manufacture process of the metallized film capacitor of Example 1 of this invention The top view which shows the mode of the manufacturing process of the metallized film capacitor of Example 1 of this invention. 1 is a longitudinal side view showing a state of a manufacturing process of a metalized film capacitor of Example 1 of the present invention. The perspective view which shows the structure of the completion state of the metallized film capacitor of a prior art example Plan view showing the state of the manufacturing process of the conventional metallized film capacitor Longitudinal side view showing the manufacturing process of a conventional metalized film capacitor

  Hereinafter, embodiments of the present invention will be described.

  The manufacturing method of the metallized film capacitor according to the present invention includes a plurality of steps as follows.

First, a capacitor unit comprising a plurality of capacitor elements using a metallized film and external lead terminals connected to metal electrodes at both ends in the axial direction of the capacitor elements is prepared. Then, the support member is fastened to the lateral side surface portion of the capacitor unit. This is a capacitor unit with a support member. The portion where the support member is fixed to the capacitor unit is the lateral side surface portion of the capacitor unit, not the bottom surface portion as in the conventional example.

  Next, the capacitor unit with the support member is accommodated in the cavity of the molding die. At this time, the free end portion of the support member is brought into contact / proximity with the inner peripheral surface of the molding frame. As a result, the position of the capacitor unit is regulated with respect to the molding die in a state where a predetermined interval is provided between the outer circumferential surface of the capacitor unit and the inner circumferential surface of the molding die. That is, the capacitor unit with the support member is accommodated in the cavity of the molding die in a position-regulated state with a predetermined interval.

  Next, the capacitor unit accommodated in the cavity of the molding die is supported in a suspended state with respect to a fixing jig laid over the upper surface of the molding die. At this time, the bottom surface of the capacitor unit with the support member housed in the cavity of the molding die is set in a state of being lifted and separated from the inner bottom surface of the molding die.

  Next, the molten resin is filled into the space between the outer peripheral surface / bottom surface of the capacitor unit and the inner peripheral surface / inner bottom surface of the mold frame, the position of which is regulated by the support member as described above. Is cured. The exterior resin is formed by curing the molten resin. That is, the entire capacitor unit is covered with the exterior resin except for the connection terminal portion of the external lead terminal.

  Finally, the capacitor unit covered with the exterior resin is released from the mold.

The metallized film capacitor according to the present invention is preferably applied to the method for producing a metallized film capacitor described above, and includes a capacitor unit, an exterior resin, and a support member. The capacitor unit includes a plurality of capacitor elements in which metal electrodes are formed on both ends in the axial direction after winding or laminating a metallized film, and external lead terminals connected to the metal electrodes of the capacitor elements. The exterior resin covers the entire capacitor unit except for the connection terminal portion of the external lead terminal. The support member is embedded in the exterior resin so as to be in contact with the lateral side surface portion of the capacitor unit, and its free end is exposed on the surface of the exterior resin. The exposed free end portion of the support member is a portion where the support member is in contact with or close to the inner peripheral surface of the molding frame during molding.

  In the present invention, the portion where the support member is fixed to the capacitor unit is the lateral side surface portion of the capacitor unit. That is, it is not for the bottom surface portion of the capacitor unit as in Patent Document 3. When the support member is fastened to the bottom surface of the capacitor unit, the position can not be regulated in the front-rear and left-right directions even if the position can be regulated in the vertical direction. When the position is restricted in the front-rear and left-right directions, an engaging portion such as a recess or a groove that engages with the support member must be formed on the inner bottom surface of the mold. Moreover, the process of aligning a support member with an engaging part, and the process of engaging both are required. In addition, forming the engaging portion such as the concave portion and the concave groove leads to a complicated structure of the forming mold. On the other hand, if the support member is fastened to the lateral side surface portion of the capacitor unit as in the present invention, the capacitor unit with the support member is simply housed in the cavity of the molding frame, and is Directional position regulation is realized. At the same time, since the capacitor unit is supported in a suspended state with respect to the fixing jig laid over the upper surface portion of the molding die, the vertical position restriction is realized. That is, in the cavity of the mold frame, the desired distance can be realized as the horizontal distance between the outer peripheral surface of the capacitor unit and the inner peripheral surface of the mold frame. It maintains a substantially constant interval from a low part to a high part. Further, in the cavity of the molding die, a desired spacing can be realized as the vertical spacing of the space between the bottom surface of the capacitor unit and the inner bottom surface of the molding die. It maintains a substantially constant spacing over the entire bottom surface. That is, it becomes possible to hold the capacitor unit with the external lead terminal in the expected correct posture in the cavity of the molding die. As a result, the inclination of the capacitor unit and the contact of the capacitor unit with the inner peripheral surface of the forming mold as in the conventional example are avoided.

  As a result of the above, the thickness of the exterior resin that covers the outer periphery of the capacitor unit, which is formed by filling and curing the molten resin in the cavity of the mold, is the bottom surface of the capacitor unit even at the lateral side surface of the capacitor unit. In this case, the thickness is substantially uniform. According to the present invention, it is possible to easily form an exterior resin having such a uniform thickness.

  In the manufactured metalized film capacitor, the exposure of the support member as in Patent Document 3 does not occur on the bottom surface portion of the exterior resin. The exposure of the support member to the bottom surface of the exterior resin that is susceptible to moisture during actual use and receives the strongest vibration is highly likely to cause external moisture to enter the inner capacitor element via the support member. In the case where the support member is not exposed to the bottom surface as described above, it is possible to reliably avoid the intrusion of moisture into the capacitor element. In this way, the function of preventing moisture intrusion can improve the performance of the metallized film capacitor and can be expected to extend its life.

  In addition, as for the structure of the forming mold, since a movable slide member is used as in Patent Document 2, an engagement structure with the bent portion of the external lead terminal and a rail structure for guiding the movement of the slide member are required. As compared with the above, it is possible to more reliably realize the thickness of the exterior resin and the prevention of moisture intrusion with a simpler structure.

  Further, as in another embodiment in Patent Document 3, compared to a structure in which the support is sandwiched and fixed by both of the support fixing portions provided on the inner surfaces of the mold clamping end edges of the lower mold and the upper mold in the molding mold. Thus, the thickness of the exterior resin and the prevention of moisture intrusion can be more reliably realized with a simpler structure.

  In the metallized film capacitor having the above configuration or the manufacturing method thereof, there are several preferred embodiments as follows.

  The fixing of the support member to the lateral side surface portion of the capacitor unit is performed to the lateral side surface portion other than the metal electrode of the capacitor element laminate in the capacitor unit. In this case, the fixing portion of the support member is not the metal electrode of the capacitor element, but the lateral side surface portion of the multilayer body of the capacitor element excluding the metal electrode. Even if a gap occurs at the interface between the support member and the exterior resin due to aging and moisture enters the inside through the gap, the moisture does not act on the metal electrode, and the capacitor element is well protected from moisture. Can do.

  The fixing of the support member to the lateral side surface portion of the capacitor unit is in a state of being fitted to the corrugated concave surface of the lateral side surface portion formed between the capacitor elements adjacent in the vertical direction in the multilayer body of the capacitor elements. Stop it. Many capacitor elements are formed by rolling a metallized film into a roll shape in the diameter direction to form a flat columnar body having an oval cross section. Further, in many cases, a capacitor element laminate is formed by laminating a plurality of capacitor elements having a flat columnar body. In the capacitor element laminate, the shape of the lateral side surface formed between the capacitor elements adjacent to each other in the vertical direction other than the metal electrode is a corrugated concave surface. If the support member is fixed to the corrugated concave surface in a fitted state, the fixing is strong and stable.

  Further, as the support member, a support composed of a triangular prism-shaped main body portion and a pair of projecting portions having a smaller cross-sectional area than the main body portion integrally extending in the axial direction from both axial end portions of the main body portion. Using a member, the triangular prism-shaped main body is fixed to the corrugated concave surface in a fitted state. Using a support member consisting of a triangular prism-shaped main body and a pair of triangular prism-shaped overhangs with a smaller cross-sectional area, if this is fixed to the corrugated concave surface, it will be stronger and more stable. Will be.

  Embodiments of the present invention will be described below with reference to the drawings.

  FIG. 1 is a perspective view showing a completed structure of a metalized film capacitor in Example 1 of the present invention, FIG. 2 is a perspective view showing a state in which an exterior resin is removed from the metalized film capacitor, and FIG. FIG. 3 (b) is a perspective view showing how the support member is fastened to the capacitor unit, FIG. 4 is a longitudinal front view showing the manufacturing process of the metallized film capacitor, and FIG. FIG. 6 is a vertical side view showing a state of the manufacturing process of the metallized film capacitor, and FIG.

  First, the components are listed. 1 to 6, A is a metallized film capacitor, 10 is a capacitor element, 20 is an external lead terminal, 30 is a capacitor unit, 40 is an exterior resin, 50 is a molding frame, 60 is a fixing jig, and 70 is a support. It is a member.

  The capacitor element 10 generally has the following configuration. That is, a metal film formed by forming a metal vapor deposition electrode on at least one surface of a dielectric film is rolled or laminated in a diametric direction to form a flat columnar body having an oval cross section, and at both axial ends thereof Capacitor element 10 is formed by forming positive electrode / negative electrode metal electrodes 11 and 11 (preferably metal spray electrodes by spraying metal fine particles). Here, the odd-numbered metal vapor deposition electrodes are connected to the positive electrode metal electrode 11 on one axial end side, and the even-numbered metal vapor deposition electrodes are connected to the negative electrode metal electrode 11 on the other axial end side. A plurality of capacitor elements 10 are stacked in the vertical direction, and the stacked body 15 is arranged in parallel in the horizontal direction. Positive and negative terminal plates 21 and 21 are mounted on the upper surface of the laminated body 15 of the capacitor elements 10 arranged in parallel. The terminal plates 21 and 21 are electrically insulated from the capacitor element 10. The metal electrodes 11 of the plurality of stacked capacitor elements 10 are joined together by soldering or the like in the connection plate 23, and the terminal plate 21 on the upper surface of the laminate 15 is joined to the connection plate 23 by soldering or the like. . A hook-shaped connection terminal portion 22 for connecting an external power supply line is integrally formed at an end portion of the terminal plate 21. The terminal plate 21 with the connection terminal portion 22 and the connection plate 23 constitute the external lead terminal 20, and a pair of such external lead terminals 20 are provided for the positive electrode and the negative electrode. The capacitor unit 30 is formed by connecting the external lead terminals 20 and 20 to the metal electrodes 11 and 11 at both ends in the axial direction of the plurality of capacitor elements 10 as described above. The entire capacitor unit 30 is covered with the exterior resin 40 except for the bowl-shaped connection terminal portions 22 and 22 of the external lead terminals 20 and 20, thereby forming the metallized film capacitor A. The thickness of the exterior resin 40 covering the outer periphery of the capacitor unit 30 is substantially uniform in the lateral side surface, the bottom surface, and the top surface of the capacitor unit 30 by the action of the support member 70 described in detail below. It is thick.

  Support members 70, 70 on the end surface in the lateral direction of the capacitor unit 30, which is composed of the laminated body 15 of the plurality of capacitor elements 10 and the pair of external lead terminals 20, 20, are connected to the capacitor unit 30 when the metallized film capacitor A is formed. This will be described later in detail. Reference numeral 80 denotes a mounting nut member embedded in the exterior resin 40 in an exposed state. The nut member 80 is a portion into which a bolt member is screwed when the metallized film capacitor A is attached and fixed to a frame of an electric vehicle or industrial electric equipment.

  FIG. 3 shows the structure of the support member 70 and how it is fastened. As shown in FIG. 3, the support member 70 includes a triangular columnar main body 71 and triangular columnar projecting portions 72 and 72 extending integrally from both axial ends of the main body 71 in the axial direction. ing. In the cross-sectional area, the triangular prisms of the projecting portions 72 and 72 are formed smaller than the triangular prism of the main body portion 71, but one side surface of the projecting portions 72 and 72 is flush with one side surface of the main body portion 71. In addition, the shape of the projecting portion 72 may not be a triangular prism shape such as a cylindrical shape or a quadrangular prism shape. The shape of the main body portion 71 is preferably a triangular prism shape from the viewpoints of fastening properties to the laminate 15 shown below and miniaturization of members.

  The end face of the laminated body 15 of the capacitor element 10 has a wave shape with a change in unevenness, that is, a corrugated concave surface 16 in a form in which a semicircle is repeated in the vertical direction. The triangular prism-shaped main body 71 of the support member 70 is fitted and fixed to the corrugated concave surface 16 of the lateral side surface formed between the elements 10 and 10. The position where the support member 70 is fastened to the laminated body 15 of the capacitor element 10 is the bottom corrugated concave surface 16 in consideration of hanging the capacitor unit 30. This is because the suspended portion is the uppermost portion, and therefore it is preferable that the capacitor unit 30 be positioned as close to the lower end as possible in order to accommodate the capacitor unit 30 in the molding mold 50 in a stable position-regulated state.

  When fitting, it is assumed that the main body 71 and the overhanging portions 72, 72 are fitted in a state where the one surface side is located outward. The upper inclined surface of the main body portion 71 is in contact with the upper curved surface of the corrugated concave surface 16, and the lower inclined surface of the main body portion 71 is in contact with the lower curved surface of the corrugated concave surface 16. Is a wedge driven state. The main body 71 is fixed to the corrugated concave surface 16 using an adhesive (material), an adhesive (material), an adhesive tape, or the like. The length of the support member 70 is set to such a length that the outer end sides of the projecting portions 72, 72 are sufficient to protrude outward from both axial end surfaces of the capacitor element 10. Therefore, the projecting portions 72 and 72 literally project outward from the end face of the capacitor element 10. A pair of such support members 70 are fixed symmetrically on both end faces in the lateral width direction of the multilayer body 15 of the capacitor element 10.

  Next, the outer peripheral portion of the capacitor unit 30 with the support members 70 obtained as described above is coated with the exterior resin 40 by molding. That is, as shown in FIGS. 4, 5, and 6, the capacitor unit 30 with the external lead terminals 20 and 20 and the support members 70 and 70 is accommodated in the cavity 51 of the molding frame 50. At this time, the free ends of the support members 70, 70 in the capacitor unit 30 are brought into contact with and close to the inner peripheral surface 52 of the molding die 50, so that the capacitor unit 30 is located between the molding die 50 and both. The position is regulated at a predetermined interval. As shown in FIGS. 5 and 6, the outer end surfaces of the projecting portions 72, 72... Of the support members 70, 70 are in contact with (or slidably contact with) the inner peripheral surfaces 52, 52 facing the molding frame 50. State The nut members 80 are previously fastened to predetermined locations on the inner peripheral surface 52 of the molding die 50. The fastening is performed using an adhesive (material), an adhesive (material), an adhesive tape, or the like.

  Further, the capacitor unit 30 accommodated in the molding die 50 is supported in a suspended state with respect to the molding die 50 using an elongated plate-shaped fixing jig 60. The elongate plate-shaped fixing jig 60 is bridged on the upper surface of the molding frame 50 in a state where it passes through the lower surface of the positive and negative hook-shaped connection terminal portions 22 and 22. The fixing jig 60 is fixed to the upper surface of the molding frame 50 with bolts 90, and the positive and negative hook-shaped connection terminal portions 22 and 22 are attached to the fixing jig 60 with a hanging tool such as a bolt. Suspend at 61. Thus, the capacitor unit 30 is placed in the molding mold 50 in a state where the bottom surface 31 of the capacitor unit 30 with the support member 70 housed in the cavity 51 of the molding mold 50 is lifted and separated from the inner bottom surface 53 of the molding mold 50. It is made to support in the suspended state with respect to the fixing jig 60 laid over the upper surface part.

  As described above, as is apparent from FIG. 5, in the vicinity of the four corners on the front, rear, left and right sides of the capacitor unit 30, the support member projecting portions 72, 72. Therefore, in the cavity 51 of the molding die 50, the space in the horizontal direction between the outer peripheral surface 32 of the capacitor unit 30 and the inner peripheral surface 52 of the molding die 50 extends from a low part to a high part. The space between the bottom surface 31 of the capacitor unit 30 and the inner bottom surface 53 of the molding die 50 can be kept substantially constant over the entire bottom surface. That is, the capacitor unit 30 with the external lead terminals 20, 20 can be held in the correct posture as expected in the cavity 51 of the molding die 50. As a result, the inclination of the capacitor unit 30 and the contact of the capacitor unit 30 with the inner peripheral surface 52 of the molding frame 50 as in the conventional example are avoided.

  Next, the outer space is filled with a molten resin and cured by filling the space between the outer peripheral surface / bottom surface of the capacitor unit 30 and the inner peripheral surface / inner bottom surface of the molding die 50, which are position-regulated in the vertical and horizontal directions as described above. The entire capacitor unit 30 is covered and protected by the exterior resin 40 except for the resin 40, except for the bowl-shaped connection terminal portions 22 and 22 of the external lead terminals 20 and 20. The exterior resin 40 is for preventing external moisture from entering the capacitor element 10 and degrading the characteristics of the capacitor.

  Next, the capacitor unit 30, which is entirely covered by the outer resin 40 with the molten resin cured, except for the bowl-shaped connection terminal portions 22, 22 of the external lead terminals 20, 20, is released from the mold 50. That is, the bolt 90 is loosened and removed together with the fixing jig 60 from the forming mold 50, and then the hanging tool 61 is removed to remove the fixing jig 60.

  As described above, the metalized film capacitor A is obtained in which the capacitor unit 30 is entirely covered with the exterior resin 40 except for the connection terminal portions 22 and 22.

  In the metallized film capacitor A, the pair of support members 70 and 70 are embedded in the exterior resin 40. The outer end surfaces of the overhang portions 72, 72 on both sides of the support member 70 are exposed on the surface of the exterior resin 40. Only the outer end surface is exposed.

  As described above, according to the first embodiment, the thickness of the exterior resin 40 by filling and curing the molten resin is ensured to be sufficiently uniform in a state where the lateral side surface portion and the bottom surface portion of the capacitor unit 30 are substantially uniform. Therefore, the function of preventing moisture from entering the capacitor element 10 can be enhanced. In addition, the structure for that purpose is simply a structure in which the support member 70 is fastened to the lateral side surface portion of the capacitor unit 30 and is housed in a suspended state in the molding frame 50. 50, position restriction in the front-rear, left-right direction and up-down direction can be realized while avoiding contact with the inner peripheral surface 52.

  In the metallized film capacitor A thus manufactured, the support member 70 is not exposed on the bottom surface portion that is most susceptible to the vibration of moisture in the exterior resin 40, and has high moisture infiltration prevention performance. Therefore, high performance as a capacitor can be demonstrated, and the life can be extended.

  Further, since the support member 70 is fastened to the lateral side surface portion of the capacitor unit 30 and is secured to the lateral side surface portion other than the metal electrode 11 of the capacitor element 10, the support member 70 and the exterior resin 40 are separated by aging. Even if a gap occurs at the interface and moisture enters the inside through the gap, the moisture does not act on the metal electrode 11, and the capacitor element 10 can be protected from moisture.

  Further, since the support member 70 is fitted and fixed to the corrugated concave surface 16 of the lateral side surface portion of the capacitor element laminate 15, the support member 70 is firmly and stably fixed. In addition, since the support member 70 composed of the triangular pillar-shaped main body 71 and the pair of projecting portions 72, 72 having a smaller cross-sectional area is used, the fastening becomes stronger and more stable.

In the first embodiment, the material of the support member 70 may be the same as or different from the constituent material of the exterior resin 40.

  The present invention relates to a case-less resin mold type metallized film capacitor such as an industrial machine capacitor and a vehicle capacitor, and the bottom surface portion of the outer side surface of the capacitor unit. Is also useful as a technique for ensuring a substantially uniform thickness.

A Metallized film capacitor 10 Capacitor element 11 Metal electrode 15 Laminated body 16 Waveform concave surface 20 External lead terminal 21 Terminal plate 22 Connection terminal portion 23 Connection plate 30 Capacitor unit 40 Exterior resin 50 Molding mold 51 Cavity 60 Fixing jig 70 support member 71 triangular body portion 72 projecting portion

Claims (2)

The capacitor unit formed by connecting the external lead terminal to the metal electrodes of the axial ends of the stack of multiple capacitor elements with metallized film, a part of non-metallic electrodes of the laminate of the capacitor element The support member is fastened in a state of being fitted to the corrugated concave surface of the lateral side surface portion formed between the capacitor elements adjacent in the vertical direction in the multilayer body of capacitor elements, and the support member has a triangular prism shape The triangular prism-shaped main body using a support member composed of a main body and a pair of projecting portions having a smaller cross-sectional area than the main body extending in the axial direction integrally from both axial ends of the main body And a step of fastening in a state of fitting to the corrugated concave surface ,
In the capacitor unit with the support member, the free end portion of the support member is brought into contact with and close to the inner peripheral surface of the molding die, and the capacitor unit is spaced from the molding die by a predetermined distance therebetween. A step of accommodating the capacitor unit with the support member in a cavity of the molding frame in a state in which the position is regulated with a gap therebetween,
In the state where the bottom surface of the capacitor unit with the support member housed in the cavity of the molding die is floated away from the inner bottom surface of the molding die, the capacitor unit is bridged over the top surface of the molding die. A process of supporting the fixing jig in a suspended state;
Filling and curing a molten resin in a space between the outer peripheral surface / bottom surface of the capacitor unit, the position of which is regulated by the support member, and the inner peripheral surface / inner bottom surface of the mold frame; and
And a step of releasing the capacitor unit, which is entirely covered except for the connection terminal portion of the external lead terminal, from the molding frame with an exterior resin in which the molten resin is cured. A capacitor unit in which external lead terminals are connected to metal electrodes on both ends in the axial direction of a laminate of a plurality of capacitor elements using a metallized film;
An exterior resin that covers the entire capacitor unit except for the connection terminal portion of the external lead terminal;
The capacitor element laminate is a portion other than the metal electrode, and is fastened in a fitted state to the corrugated concave surface of the lateral side surface portion formed between the capacitor elements adjacent in the vertical direction in the capacitor element laminate. And a support member embedded in the exterior resin and having a free end exposed on the surface of the exterior resin,
The support member is composed of a triangular pillar-shaped main body portion and a pair of projecting portions having a smaller cross-sectional area than the main body portion extending integrally from the both axial end portions of the main body portion in the axial direction. Film capacitor.

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