阅读说明：本技术 薄膜电容器以及薄膜电容器用的外装壳体 (Film capacitor and outer case for film capacitor ) 是由 真岛亮 阪本拓也 城岸贤 于 2019-01-25 设计创作，主要内容包括：本发明的薄膜电容器具备：电容器元件,具备在树脂薄膜的表面设置了金属层的金属化薄膜；外装壳体,在内部收纳上述电容器元件；和填充树脂,填充在上述电容器元件与上述外装壳体之间,其中,上述外装壳体的填充上述填充树脂的一侧的内表面的表面自由能为44mN/m以下。(The film capacitor of the present invention comprises: a capacitor element including a metallized film having a metal layer provided on a surface of a resin film; an outer case that accommodates the capacitor element therein; and a filling resin filled between the capacitor element and the outer case, wherein a surface free energy of an inner surface of the outer case on a side where the filling resin is filled is 44mN/m or less.)

1. A film capacitor is provided with:

a capacitor element including a metallized film having a metal layer provided on a surface of a resin film;

an outer case that accommodates the capacitor element therein; and

a filling resin filled between the capacitor element and the outer case,

wherein a surface free energy of an inner surface of the outer case on a side filled with the filler resin is 44mN/m or less.

2. The film capacitor of claim 1,

the surface free energy is 34mN/m or less.

3. The film capacitor of claim 1 or 2,

the surface free energy is more than 25 mN/m.

4. A film capacitor as claimed in any one of claims 1 to 3,

the difference in linear expansion coefficient between the outer case and the filler resin is 11 ppm/DEG C or less.

5. The film capacitor of claim 4,

the difference in the linear expansion coefficients is greater than 0 ppm/DEG C.

6. The film capacitor as claimed in any one of claims 1 to 5,

the outer case is made of a resin composition.

7. The film capacitor of claim 6,

the resin composition comprises a liquid crystal polymer.

8. The film capacitor of claim 6,

the resin composition comprises polyphenylene sulfide.

9. The film capacitor of claim 7,

the resin composition further comprises an inorganic filler,

the content of the inorganic filler in the resin composition is 54 wt% or less.

10. The film capacitor of claim 8,

the resin composition further comprises an inorganic filler,

the content of the inorganic filler in the resin composition is 60 wt% or less.

11. The film capacitor of claim 9 or 10,

the content of the inorganic filler in the resin composition is 30 wt% or more.

12. The film capacitor of claim 11,

the inorganic filler material contains a glass filler as a main component.

13. The film capacitor as claimed in any one of claims 1 to 5,

the outer case is made of metal or alloy.

14. The film capacitor as claimed in any one of claims 1 to 13,

the filler resin comprises an epoxy resin.

15. The film capacitor as claimed in any one of claims 1 to 14,

the resin film contains, as a main component, a resin having at least one of a urethane bond and a urea bond.

16. The film capacitor as claimed in any one of claims 1 to 14,

the resin film contains a curable resin as a main component.

17. The film capacitor of claim 15 or 16,

the resin film contains at least one of an isocyanate group and a hydroxyl group.

18. An outer case for a film capacitor for housing therein a capacitor element including a metallized film having a metal layer provided on a surface of a resin film,

a filling resin is filled between the outer case and the capacitor element to fix the capacitor element when the capacitor element is housed inside,

the surface free energy of the inner surface on the side filled with the filler resin is 44mN/m or less.

19. The exterior case according to claim 18,

the surface free energy is 34mN/m or less.

20. The exterior case according to claim 18 or 19,

the surface free energy is more than 25 mN/m.

21. The exterior case according to any one of claims 18 to 20,

the outer case is made of a resin composition.

22. The exterior case according to claim 21,

the resin composition comprises a liquid crystal polymer.

23. The exterior case according to claim 21,

the resin composition comprises polyphenylene sulfide.

24. The exterior case according to claim 22,

the resin composition further comprises an inorganic filler,

the content of the inorganic filler in the resin composition is 54 wt% or less.

25. The exterior case according to claim 23,

the resin composition further comprises an inorganic filler,

the content of the inorganic filler in the resin composition is 60 wt% or less.

26. The exterior case according to claim 24 or 25,

the content of the inorganic filler in the resin composition is 30 wt% or more.

27. The exterior case according to claim 26,

the inorganic filler material contains a glass filler as a main component.

28. The exterior case according to any one of claims 18 to 20,

the outer case is made of metal or alloy.

Technical Field

The present invention relates to a film capacitor and an exterior case for a film capacitor.

Background

A metallized film capacitor is manufactured, for example, by housing a capacitor element in an outer case, the capacitor element being formed by winding or laminating a metallized film having a metal deposited film provided on a surface of a resin film, filling the case with a resin, and curing the resin.

Patent document 1 discloses a metallized film capacitor in which a case for housing a capacitor element is formed by mixing 50 to 85 wt% of glass fiber with polyphenylene sulfide resin, and the resin for filling the case is an epoxy resin in which 50 to 80 wt% of silica is mixed so that the glass transition temperature is 115 ℃ or higher and the viscosity at 60 ℃ is 1500 to 3000mPa · s.

Prior art documents

Patent document

Patent document 1: japanese patent No. 4968788

Disclosure of Invention

Problems to be solved by the invention

According to patent document 1, in a metallized film capacitor using a case in which 50 to 85 wt% of glass fiber is mixed, since the adhesion between the resin and the case is improved, even if the temperature cycle test of-40 ℃ to +120 ℃ is repeated 2000 times, the interface between the case and the resin is not peeled.

However, a metallized film capacitor (hereinafter, also simply referred to as a film capacitor) is required to have heat resistance in a higher temperature range, and it is clear that merely controlling the amount of a filler such as glass fiber contained in an outer case may not suppress peeling at the interface between the outer case and a filler resin.

The above-described problems are not limited to the outer case made of polyphenylene sulfide resin, but are common to film capacitors having an outer case made of other resin, metal, or the like.

The present invention has been made to solve the above-described problems, and an object thereof is to provide a film capacitor capable of suppressing the peeling of the interface between the outer case and the filling resin even when repeatedly used in a high temperature region. It is another object of the present invention to provide an exterior case for a thin film capacitor.

Means for solving the problems

The film capacitor of the present invention comprises: a capacitor element including a metallized film having a metal layer provided on a surface of a resin film; an outer case that accommodates the capacitor element therein; and a filling resin filled between the capacitor element and the outer case, wherein a surface free energy of an inner surface of the outer case on a side where the filling resin is filled is 44mN/m or less.

An exterior case for a film capacitor according to the present invention is an exterior case for housing therein a capacitor element including a metallized film having a metal layer provided on a surface of a resin film, wherein a filler resin is filled between the exterior case and the capacitor element to fix the capacitor element when the capacitor element is housed therein, and a surface free energy of an inner surface on a side where the filler resin is filled is 44mN/m or less.

Effects of the invention

According to the present invention, it is possible to provide a film capacitor in which peeling at the interface between the outer case and the filling resin can be suppressed even when the film capacitor is repeatedly used in a high-temperature region.

Drawings

Fig. 1 (a) is a sectional view schematically showing a film capacitor according to an embodiment of the present invention, fig. 1 (b) is a sectional view taken along line Ib-Ib of the film capacitor shown in fig. 1 (a), and fig. 1 (c) is a sectional view taken along line Ic-Ic of the film capacitor shown in fig. 1 (a).

Fig. 2 (a) is a front view schematically showing an example of an outer case constituting the film capacitor shown in fig. 1 (a), and fig. 2 (b) is a side view of the outer case shown in fig. 2 (a).

Fig. 3 (a) is a perspective view schematically showing an example of a capacitor element constituting the film capacitor of the present invention, and fig. 3 (b) is a cross-sectional view taken along line IIIb-IIIb of the capacitor element shown in fig. 3 (a).

Fig. 4 is a perspective view schematically showing an example of a roll of metallized film constituting the capacitor element shown in fig. 3 (a) and 3 (b).

Fig. 5 is a perspective view schematically showing another example of a roll of metallized film constituting the capacitor element shown in fig. 3 (a) and 3 (b).

Fig. 6 (a) and 6 (b) are cross-sectional views showing the dimensions of the capacitor sample.

Fig. 7 (a) and 7 (b) are external views showing the dimensions of the capacitor sample.

Detailed Description

Hereinafter, the film capacitor of the present invention will be described.

However, the present invention is not limited to the following configuration, and can be applied with appropriate modifications within a scope not changing the gist of the present invention.

The present invention is also directed to a combination of two or more of the preferred structures of the present invention described below.

The outer case for a film capacitor described below is also one aspect of the present invention.

The film capacitor of the present invention comprises: the capacitor element includes a capacitor element having a metallized film, an outer case accommodating the capacitor element therein, and a filling resin filled between the capacitor element and the outer case.

In the film capacitor of the present invention, the surface free energy of the inner surface of the outer case on the side filled with the filling resin is 44mN/m or less. When the surface free energy of the inner surface of the outer case is 44mN/m or less, the adhesion between the outer case and the filling resin increases, and therefore, even when the film capacitor is repeatedly used in a high temperature region, peeling at the interface between the outer case and the filling resin can be suppressed.

The surface free energy of the inner surface of the outer case is preferably 34mN/m or less. When the surface free energy is 34mN/m or less, the peeling of the interface between the outer case and the filling resin can be further suppressed. The surface free energy of the inner surface of the outer case is preferably 25mN/m or more.

As a reagent for which the surface free energy of the liquid is known, three liquids, water, ethylene glycol, and diiodomethane, were used to measure the contact angle, and the surface free energy of the inner surface of the outer case can be calculated by utilizing the Kitazaki-Hata theory. The contact angle of each liquid means a contact angle immediately after dropping each liquid droplet in an environment of 25 ℃ and 50% RH by a contact angle meter (for example, DM-701 manufactured by Kyowa Kagaku K.K.).

In the film capacitor of the present invention, the difference in linear expansion coefficient between the outer case and the filling resin is preferably 11 ppm/DEG C or less. When the film capacitor is repeatedly used in a high-temperature region, the difference in linear expansion coefficient between the outer case and the filler resin is reduced, thereby suppressing the peeling of the interface between the outer case and the filler resin.

The difference in linear expansion coefficient between the outer case and the filler resin is more preferably 10 ppm/DEG C or less. The difference in linear expansion coefficient between the outer case and the filler resin is preferably greater than 0 ppm/DEG C, and more preferably 2 ppm/DEG C or more.

The linear expansion coefficients of the outer case and the filler resin can be obtained by using catalog (catalog) values of the linear expansion coefficients of the respective materials. In addition, the linear expansion coefficient of the outer case is affected by the flow direction at the time of injection molding. Therefore, the linear expansion coefficients are obtained in the flow direction (MD direction) and the perpendicular direction (TD direction), and the average value calculated by (MD + TD)/2 is defined as the linear expansion coefficient of the outer case. As a method for actual measurement, for example, measurement can be performed by a thermomechanical analyzer (TMA) using a test piece of 10mm × 1mm × 5 mm. Specifically, it was determined by the following method, namely, based on the use of JISK 7197: 2012 method for testing linear expansion coefficient of thermo-mechanical analysis of plastic, the whole process of displacement of the test piece is recorded while the temperature is increased by applying a light load to the tip of the test piece at room temperature, and the result is compared with the result of the standard sample.

Fig. 1 (a) is a sectional view schematically showing a film capacitor according to an embodiment of the present invention, fig. 1 (b) is a sectional view taken along line Ib-Ib of the film capacitor shown in fig. 1 (a), and fig. 1 (c) is a sectional view taken along line Ic-Ic of the film capacitor shown in fig. 1 (a).

The film capacitor 1 shown in fig. 1 (a), 1 (b), and 1 (c) includes: capacitor element 10, outer case 20 in which capacitor element 10 is housed, and filling resin 30 filled between capacitor element 10 and outer case 20.

In the film capacitor 1 shown in fig. 1 (a), 1 (b), and 1 (c), a rectangular parallelepiped space is formed inside the outer case 20, and the capacitor element 10 is disposed at the center inside the outer case 20 apart from the inner surface of the outer case 20. In order to hold capacitor element 10, filling resin 30 such as epoxy resin is filled between the outer surface of capacitor element 10 and the inner surface of outer case 20. Outer case 20 has a bottomed cylindrical shape having an opening at one end, and filling resin 30 is filled into capacitor element 10 from the opening of outer case 20 in outer case 20. By heating and curing the epoxy resin, outer case 20 and capacitor element 10 can be integrally bonded and fixed.

In fig. 1 (a), the capacitor element 10 includes a roll 40 of a metallized film, and a 1 st external electrode 41 and a 2 nd external electrode 42 formed on both sides of the roll 40. A 1 st lead terminal 51 is electrically connected to the 1 st external electrode 41, and a 2 nd lead terminal 52 is electrically connected to the 2 nd external electrode 42. The 1 st lead terminal 51 and the 2 nd lead terminal 52 protrude outward from the inside of the external case 20.

In the film capacitor 1 shown in fig. 1 (a), 1 (b) and 1 (c), the 1 st rib (rib)60 and the 2 nd rib 70 are provided on the inner surface of the outer case 20. The 1 st rib 60 is a rib provided on the 1 st external electrode 41 side and/or the 2 nd external electrode 42 side. The 1 st rib 60 is formed in a plate shape extending from the bottom surface side of the outer case 20 toward the opening portion side, and the end surface on the opening portion side has a tapered shape such that the length thereof gradually decreases from the outer case 20 toward the capacitor element 10. The 1 st rib 60 is formed of a pair of plate-like members, one of which connects the bottom surface of the outer case 20 to the inner surface of the 3 rd side wall 23 shown in fig. 2 (a), and the other of which connects the bottom surface of the outer case 20 to the inner surface of the 4 th side wall 24 shown in fig. 2 (a). In fig. 1 (b), the 1 st rib 60 is located at the center in the width direction in the external case 20, and thus is located coaxially with the 1 st lead terminal 51. The 1 st rib 60 is located on the bottom side of the center of the outer case 20 in the direction from the bottom surface side toward the opening portion side. On the other hand, the 2 nd rib 70 is a rib provided on the bottom surface side of the outer case 20. The 2 nd rib 70 is formed in a plate shape extending from the bottom surface side of the outer case 20 toward the opening portion side. In fig. 1 (a), the 2 nd rib 70 is formed of a pair of plate-like portions separated from each other inside the outer case 20, and as shown in fig. 1 (c), the 2 nd rib 70 is formed of an outer surface shape along the inner surface shape of the outer case 20 and a U-shaped inner surface shape substantially along the inner surface of the capacitor element 10. In addition, one plate-shaped portion (left side of the paper surface in fig. 1 a) of the 2 nd rib 70 is divided into the 1 st portion and the 2 nd portion in the one plate-shaped portion on the left and right sides of the paper surface in fig. 1 c, the 1 st portion connects the bottom surface of the exterior case 20 to the inner surface of the 1 st side wall 21 shown in fig. 2 b, and the 2 nd portion connects the bottom surface of the exterior case 20 to the inner surface of the 2 nd side wall 22 shown in fig. 2 b. As shown in fig. 1 (a), one plate-like portion of the 2 nd rib 70 is located between the center of the capacitor element 10 and the 1 st external electrode 41, and the other plate-like portion of the 2 nd rib 70 is located between the center of the capacitor element 10 and the 2 nd external electrode 42. Further, as shown in fig. 1 (c), the 2 nd rib portion 70 is positioned to be elongated to be closer to the opening portion than the center of the capacitor element 10 and to be elongated to be closer to the opening portion side than the 2 nd lead terminal 52. By providing the rib portion on the inner surface of the outer case, the positional accuracy of the capacitor element can be improved at the time of resin molding.

Further, the rib may not be provided on the inner surface of the outer case. When the ribs are provided on the inner surface of the outer case, the number of the ribs is not particularly limited. The shape of the rib is also not particularly limited, and for example, the thickness of the rib, the length of the rib, the projecting state of the rib, and the like may be appropriately changed.

(outer case)

The outer case constituting the film capacitor of the present invention is, for example, a bottomed cylinder having an opening at one end.

Fig. 2 (a) is a front view schematically showing an example of an outer case constituting the film capacitor shown in fig. 1 (a), and fig. 2 (b) is a side view of the outer case shown in fig. 2 (a).

The outer case 20 shown in fig. 2 (a) and 2 (b) has a bottomed rectangular tube shape including: the rectangular solid-state imaging device has a substantially rectangular opening at one end (see fig. 1 (a), 1 (b), and 1 (c)), a square tubular side portion including four flat plates extending from four sides of the opening toward the other end, and a bottom portion facing the opening and closing the other end of the square tubular side portion. The outer case 20 may be a cylindrical shape such as a bottomed cylindrical shape.

The side portion of the outer case 20 includes: the 1 st side wall 21; a 2 nd side wall 22 having substantially the same area as the 1 st side wall 21 and disposed apart from and facing the inner surface of the 1 st side wall 21; a 3 rd side wall 23 connecting one side edge of the 1 st side wall 21 and one side edge of the 2 nd side wall 22 and having an area smaller than that of the 1 st side wall 21; and a 4 th side wall 24 connecting the other side edge of the 1 st side wall 21 and the other side edge of the 2 nd side wall 22, having substantially the same area as the 3 rd side wall 23, and disposed apart from and facing the inner surface of the 3 rd side wall 23.

As shown in fig. 2 (a) and 2 (b), the side portion of the outer case 20 is preferably provided with recesses 25 on four sides of the opening portion. The recess 25 extends along four sides of the opening portion side from the opening portion side toward the bottom portion side. By providing the recess on the opening surface of the outer case, when the film capacitor is mounted on the substrate, the film capacitor and the substrate can be prevented from being sealed and the internal pressure can be prevented from increasing. Further, the recess may not be provided in the outer case.

As shown in fig. 2 (a) and 2 (b), a tapered portion 26 extending along the edge connecting the side walls is preferably provided on the side portion of the outer case 20. In fig. 2 (a) and 2 (b), a tapered portion 26 is provided at a bottom side corner of the 3 rd side wall 23 and the 4 th side wall 24. Therefore, a tapered portion is also provided at a side connecting the bottom side edge of the 1 st side wall 21 and the bottom, and a tapered portion is also provided at a side connecting the bottom side edge of the 2 nd side wall 22 and the bottom. Further, the side portion of the outer case may not be provided with a tapered portion.

In the film capacitor of the present invention, the outer case may be made of a resin composition, or may be made of a metal or an alloy.

In the film capacitor of the present invention, it is preferable to suppress heating of the capacitor element inside in order to suppress evaporation of moisture contained in the capacitor element inside. Therefore, the outer case is preferably opaque (e.g., black) even at a high temperature of 100 ℃. The term "opaque" as used herein means that the transmittance of visible light at a wavelength of 400nm to 700nm is 5% or less.

When the outer case is made of a resin composition, the resin composition preferably contains a Liquid Crystal Polymer (LCP).

As the LCP contained in the resin composition, in the examples described later, an LCP having a p-hydroxybenzoic acid group and a 6-hydroxy-2-naphthoic acid group in the skeleton was used. Furthermore, LCP's having polycondensates formed by using various components such as phenol, phthalic acid, and ethylene terephthalate in addition to p-hydroxybenzoic acid and 6-hydroxy-2-naphthoic acid can be used.

In the case of classifying LCP, although there are classification methods such as type I, type II, and type III, the material means the same material as LCP formed by the above-mentioned constituent elements.

The resin composition preferably contains an inorganic filler in addition to the LCP.

As the inorganic filler contained in the resin composition, a material having a higher strength than LCP can be used. The inorganic filler is preferably a material having a melting point higher than that of the LCP, and more preferably a material having a melting point of 680 ℃.

The form of the inorganic filler is not particularly limited, and examples thereof include a form having a longitudinal direction such as a fiber form or a plate form. These inorganic fillers may be used in combination of 2 or more. Therefore, the resin composition preferably contains a fibrous inorganic material and/or a plate-like inorganic material as the inorganic filler.

In the present specification, the term "fibrous" means that the relationship between the length of the filler in the longitudinal direction and the cross-sectional diameter of the filler in a cross-section perpendicular to the longitudinal direction is a state where the length in the longitudinal direction/the cross-sectional diameter is not less than 5 (i.e., the aspect ratio is not less than 5: 1). Here, the cross-sectional diameter is the longest distance between 2 points on the outer periphery of the cross-section. When the cross-sectional diameters are different in the longitudinal direction, the measurement is performed at a portion where the cross-sectional diameter becomes maximum.

The term "plate-like" means that the relationship between the cross-sectional diameter of the plane having the largest projected area and the maximum height in the direction perpendicular to the cross-sectional plane is a state where the cross-sectional diameter ÷ height ≧ 3.

Preferably, at least a part of the inorganic filler is dispersed in the outer case, and has a portion oriented from the case bottom side toward the opening and a portion oriented toward the adjacent side wall, in each of the side walls of the side portion of the outer case.

The inorganic filler preferably has at least a size of 5 μm or more in diameter and 50 μm or more in length. In particular, the inorganic filler is preferably dispersed throughout the outer case without aggregation.

As the inorganic filler, specifically, a fibrous glass filler, a plate-like talc, mica, or the like can be used. In particular, the inorganic filler material preferably contains a glass filler as a main component.

When the outer case is made of a resin composition containing LCP and an inorganic filler, the content of the inorganic filler in the resin composition is preferably 54 wt% or less, and more preferably 50 wt% or less, from the viewpoint of ensuring moldability of the outer case. The content of the inorganic filler in the resin composition is preferably 30 wt% or more, and more preferably 45 wt% or more.

The content of the inorganic filler in the resin composition can be calculated from the initial weight and the weight of the residual component by measuring the weight of the residual component as an inorganic component by ash measurement or thermogravimetric analysis using a test piece having a thickness of 20mm × 20mm × 0.5 mm.

Specifically, it is measured by a method of burning an organic material and heating the combustion residue thereof at a high temperature to become constant based on JIS K7250A method (direct ashing method).

When the outer case is made of a resin composition containing LCP and an inorganic filler, the content of LCP in the resin composition is preferably 46 wt% or more and 70 wt% or less, and more preferably 50 wt% or more and 55 wt% or less.

When the outer case is made of a resin composition, the resin composition may contain polyphenylene sulfide (PPS) instead of LCP.

The resin composition preferably contains an inorganic filler in addition to PPS.

As the inorganic filler contained in the resin composition, the same material as in the case of LCP can be used.

The resin composition preferably contains a fibrous inorganic material and/or a plate-like inorganic material as the inorganic filler. As the inorganic filler, specifically, a fibrous glass filler, a plate-like talc, mica, or the like can be used. In particular, the inorganic filler material preferably contains a glass filler as a main component.

When the outer case is made of a resin composition containing PPS and an inorganic filler, the content of the inorganic filler in the resin composition is preferably 60 wt% or less from the viewpoint of ensuring moldability of the outer case. The content of the inorganic filler in the resin composition is preferably 30 wt% or more, and more preferably 45 wt% or more.

When the outer case is made of a resin composition containing PPS and an inorganic filler, the content of PPS in the resin composition is preferably 40 wt% to 70 wt%, and more preferably 40 wt% to 55 wt%.

The outer case made of the resin composition can be manufactured by a method such as injection molding.

When the outer case is made of metal or alloy, aluminum, magnesium, iron, stainless steel, copper, or an alloy thereof can be used. Among them, aluminum or an aluminum alloy is preferable.

The outer case made of metal or alloy can be manufactured by, for example, impact molding.

(filled resin)

In the film capacitor of the present invention, the filling resin is filled between the capacitor element and the outer case.

As the filler resin, a resin corresponding to a required function can be appropriately selected.

The filling resin preferably comprises an epoxy resin. In examples described later, a bisphenol a type epoxy resin was used, and an acid anhydride curing agent was used as a curing agent for the epoxy resin. In addition, silica is used for the reinforcing agent.

As the filler resin, for example, an epoxy resin, a silicone resin, or the like can be used. As the curing agent for the epoxy resin, an amine curing agent or an imidazole curing agent may be used.

In addition, as the filler resin, only a resin may be used, but a reinforcing agent may be added for the purpose of improving the strength. As the reinforcing agent, silica, alumina, or the like can be used.

By filling the filling resin between the capacitor element and the outer case, the capacitor element can be blocked from the outside air. Therefore, it is preferable to appropriately select a resin having low moisture permeability and thicken the resin at the opening portion of the outer case.

The thickness of the resin in the opening of the outer case is preferably sufficient within a range in which the volume (physical constitution) of the entire capacitor is allowed, and specifically, is preferably 2mm or more, and more preferably 4mm or more. In particular, as shown in fig. 1 (a), 1 (b), and 1 (c), it is more preferable that the capacitor element 10 is disposed inside the outer case 20 so as to be located on the bottom surface side of the opening of the outer case 20, and thus the thickness of the resin on the opening side of the outer case 20 is made thicker than the thickness of the resin on the bottom surface side of the capacitor element 10.

In relation to the relationship between the height of the filling resin and the height of the outer case, the resin in the opening of the outer case may be as thick as possible, may be just full up to the position inside the outer case, or may slightly overflow due to surface tension.

Generally, a film capacitor is always subjected to vibration depending on the use environment. Therefore, the filling resin is required to have a predetermined hardness so that the capacitor element in the outer case does not move due to vibration. Further, since high-temperature heat resistance is required depending on the use environment of the film capacitor, the film capacitor in which the resin strength (viscosity) is reduced at high temperature cannot be used, and in this case, a predetermined hardness is required for the filler resin. On the other hand, the higher the hardness of the filling resin, the higher the stress generated when the capacitor element expands, and the easier the outer case deforms.

In the film capacitor of the present invention, when the outer case is made of a resin composition containing LCP and an inorganic filler, the deformation of the outer case can be suppressed even when the hardness of the filler resin is high (for example, durometer hardness of 85 or more; measurement method JISK 7215).

(capacitor element)

In the film capacitor of the present invention, the capacitor element is, for example, a columnar element having a long circular cross section, and external electrodes formed by, for example, metal plating (metalikon) are provided at both ends in the central axis direction.

Fig. 3 (a) is a perspective view schematically showing an example of a capacitor element constituting the film capacitor of the present invention, and fig. 3 (b) is a cross-sectional view taken along line IIIb-IIIb of the capacitor element shown in fig. 3 (a).

The capacitor element 10 shown in fig. 3 (a) and 3 (b) includes: a roll 40 of metallized films in which the 1 st metallized film 11 and the 2 nd metallized film 12 are wound in a laminated state, and a 1 st external electrode 41 and a 2 nd external electrode 42 connected to both end portions of the roll 40. As shown in fig. 3 (b), the 1 st metalized film 11 includes a 1 st resin film 13 and a 1 st metal layer (counter electrode) 15 provided on the surface of the 1 st resin film 13, and the 2 nd metalized film 12 includes a 2 nd resin film 14 and a 2 nd metal layer (counter electrode) 16 provided on the surface of the 2 nd resin film 14.

As shown in fig. 3 (b), the 1 st metal layer 15 and the 2 nd metal layer 16 face each other with the 1 st resin film 13 or the 2 nd resin film 14 interposed therebetween. Further, the 1 st metal layer 15 is electrically connected to the 1 st external electrode 41, and the 2 nd metal layer 16 is electrically connected to the 2 nd external electrode 42.

The 1 st resin film 13 and the 2 nd resin film 14 may have different structures, but preferably have the same structure.

The 1 st metal layer 15 is formed on one surface of the 1 st resin film 13 so as to reach one side edge but not the other side edge. On the other hand, the 2 nd metal layer 16 is formed on one surface of the 2 nd resin film 14 so as to reach not one side edge but the other side edge. The 1 st metal layer 15 and the 2 nd metal layer 16 are made of, for example, aluminum layers.

Fig. 4 is a perspective view schematically showing an example of a roll of metallized film constituting the capacitor element shown in fig. 3 (a) and 3 (b).

As shown in fig. 3 (b) and 4, the 1 st resin film 13 and the 2 nd resin film 14 are laminated while being shifted from each other in the width direction (in the left-right direction in fig. 3 (b)), so that the end portion of the 1 st metal layer 15 on the side reaching the side edge of the 1 st resin film 13 and the end portion of the 2 nd metal layer 16 on the side reaching the side edge of the 2 nd resin film 14 are exposed from the laminated films. As shown in fig. 4, the 1 st resin film 13 and the 2 nd resin film 14 are wound in a laminated state to form a wound body 40, and the 1 st metal layer 15 and the 2 nd metal layer 16 are stacked while being exposed at the end portions.

In fig. 3 (b) and 4, the winding is: the 2 nd resin film 14 is located outside the 1 st resin film 13, and the 1 st metal layer 15 and the 2 nd metal layer 16 face inward with respect to the 1 st resin film 13 and the 2 nd resin film 14, respectively.

The 1 st external electrode 41 and the 2 nd external electrode 42 are formed by thermal spraying, for example, zinc on each end surface of the roll 40 of the metalized film obtained as described above. The 1 st external electrode 41 is in contact with the exposed end portion of the 1 st metal layer 15, thereby being electrically connected to the 1 st metal layer 15. On the other hand, the 2 nd external electrode 42 is in contact with the exposed end portion of the 2 nd metal layer 16, and thereby electrically connected to the 2 nd metal layer 16.

In the film capacitor of the present invention, the resin film constituting the capacitor element preferably has heat resistance of 125 ℃.

In this case, the film capacitor can be used in a high-temperature environment of 125 ℃. On the other hand, when the film capacitor is used at 125 ℃ or higher, moisture evaporates between the resin films to expand the capacitor element, and the outer case is easily deformed.

In the film capacitor of the present invention, when the outer case is made of a resin composition containing LCP and an inorganic filler, the deformation of the outer case can be suppressed even when the film capacitor is used in a high-temperature environment (for example, 125 ℃.

In the film capacitor of the present invention, the resin film constituting the capacitor element preferably contains a resin having at least one of a urethane bond and a urea bond as a main component. Examples of such a resin include a urethane resin having a urethane bond, a urea resin having a urea bond, and the like. Further, the resin may have both urethane bond and urea bond. Specifically, the curable resin, the vapor-deposited polymer film, and the like described below can be exemplified.

The presence of urethane bonds and/or urea bonds can be confirmed using a fourier transform infrared spectrophotometer (FT-IR).

In the present specification, the term "main component of the resin film" means a component having the largest proportion (wt%), preferably more than 50 wt%. Therefore, the resin film may contain, for example, an additive such as a silicone resin, and uncured portions of starting materials such as the 1 st organic material and the 2 nd organic material described later as components other than the main components.

In the film capacitor of the present invention, the resin film constituting the capacitor element may contain a curable resin as a main component. The curable resin may be a thermosetting resin or a photocurable resin. The curable resin may or may not have at least one of a urethane bond and a urea bond.

In the present specification, the thermosetting resin means a resin that can be cured by heat, and is not limited to a curing method. Therefore, as long as the resin is curable by heat, a resin that is curable by a method other than heat (for example, light, electron beam, or the like) is also included in the thermosetting resin. Further, depending on the material, the reaction may be initiated by the reactivity of the material itself, and a material which does not necessarily promote curing by external heat or light is also used as the thermosetting resin. The same applies to the photocurable resin, and the curing method is not limited.

In the film capacitor of the present invention, the resin film constituting the capacitor element may contain a vapor-deposited polymer film as a main component. The vapor-deposited polymer film may or may not have at least one of a urethane bond and a urea bond.

The vapor-deposited polymer film is a polymer film formed by a vapor deposition polymerization method, and is basically contained in a curable resin.

In the film capacitor of the present invention, the resin film constituting the capacitor element is preferably formed of a cured product of the 1 st organic material and the 2 nd organic material. For example, a cured product obtained by reacting a hydroxyl group (OH group) of the 1 st organic material with an isocyanate group (NCO group) of the 2 nd organic material may be mentioned.

In the case where a cured product is obtained by the above reaction, uncured portions of the starting material may remain in the film. For example, the resin film may contain at least one of an isocyanate group (NCO group) and a hydroxyl group (OH group). In this case, the resin film may contain either one of an isocyanate group and a hydroxyl group, or both of an isocyanate group and a hydroxyl group.

The presence of isocyanate groups and/or hydroxyl groups can be confirmed by a fourier transform infrared spectrophotometer (FT-IR).

The 1 st organic material is preferably a polyol having a plurality of hydroxyl groups (OH groups) in the molecule. Examples of the polyol include polyether polyol, polyester polyol, and polyvinyl acetal. As the 1 st organic material, 2 or more kinds of organic materials may be used in combination. Among the 1 st organic materials, phenoxy resins belonging to polyether polyols are preferred.

The 2 nd organic material is preferably an isocyanate compound, an epoxy resin or a melamine resin having a plurality of functional groups in the molecule. As the 2 nd organic material, 2 or more kinds of organic materials may be used in combination.

Examples of the isocyanate compound include aromatic polyisocyanates such as diphenylmethane diisocyanate (MDI) and Toluene Diisocyanate (TDI), and aliphatic polyisocyanates such as Hexamethylene Diisocyanate (HDI). These polyisocyanates may be modified, for example, with carbodiimide or urethane. Among them, aromatic polyisocyanates are preferable, and MDI is more preferable.

The epoxy resin is not particularly limited as long as it is a resin having an epoxy ring, and examples thereof include bisphenol a type epoxy resins, biphenyl skeleton epoxy resins, cyclopentadiene skeleton epoxy resins, naphthalene skeleton epoxy resins, and the like.

The melamine resin is not particularly limited as long as it is an organic nitrogen compound having a triazine ring at the center of the structure and three amino groups at the periphery thereof, and examples thereof include alkylated melamine resins. Besides, a modified form of melamine is also possible.

In the film capacitor of the present invention, the resin film constituting the capacitor element is preferably obtained by molding a resin solution containing the 1 st organic material and the 2 nd organic material into a film shape, and then performing heat treatment to cure the film.

In the film capacitor of the present invention, the resin film constituting the capacitor element may contain a thermoplastic resin as a main component. Examples of the thermoplastic resin include highly crystalline polypropylene, polyether sulfone, polyether imide, and polyallylate.

In the film capacitor of the present invention, the resin film constituting the capacitor element may contain an additive for adding another function. Smoothness can be imparted, for example, by adding a leveler. The additive is more preferably a material having a functional group that reacts with a hydroxyl group and/or an isocyanate group and forms a part of the crosslinked structure of the cured product. Examples of such a material include a resin having at least one functional group selected from the group consisting of an epoxy group, a silanol group, and a carboxyl group.

In the film capacitor of the present invention, the thickness of the resin film constituting the capacitor element is not particularly limited, but is preferably 5 μm or less, more preferably less than 3.5 μm, and still more preferably 3.4 μm or less. The thickness of the resin film is preferably 0.5 μm or more.

The thickness of the resin thin film can be measured using an optical film thickness meter.

For example, a case is considered in which a resin film constituting a capacitor element is thinned and the winding length of the resin film is not changed. In this case, the resin film becomes thin, so that the volume of the capacitor element becomes small, and the outer case also becomes small in accordance with the volume of the capacitor element. However, since the winding length of the resin films is not changed, the amount of the gap between the resin films is not changed. That is, the amount of clearance with respect to the volume of the capacitor element is large when the resin film is thin. Therefore, when moisture contained between the resin films of the capacitor element evaporates and the capacitor element expands, the thinner the resin film is, the larger the volume change amount of the capacitor element itself becomes.

In the film capacitor of the present invention, when the outer case is made of a resin composition containing LCP and an inorganic filler, the deformation of the outer case can be suppressed even when the resin film is thin (for example, 3.4 μm or less).

In the thin film capacitor of the present invention, the kind of metal included in the metal layer constituting the capacitor element is not particularly limited, but the metal layer preferably includes any one selected from the group consisting of aluminum (Al), titanium (Ti), zinc (Zn), magnesium (Mg), tin (Sn), and nickel (Ni).

In the film capacitor of the present invention, the thickness of the metal layer constituting the capacitor element is not particularly limited, but the thickness of the metal layer is preferably 5nm or more and 40nm or less from the viewpoint of suppressing breakage of the metal layer.

The thickness of the metal layer can be determined by observing a cross section of the metalized film cut in the thickness direction with an electron microscope such as a field emission scanning electron microscope (FE-SEM).

Fig. 5 is a perspective view schematically showing another example of a roll of metallized film constituting the capacitor element shown in fig. 3 (a) and 3 (b).

In the film capacitor of the present invention, when the capacitor element is formed of a roll of a metallized film, it is preferable that the capacitor element is pressed into a flat shape having an oval or oblong cross-sectional shape, as in the roll of a metallized film 40a shown in fig. 5, and the capacitor element is formed into a more compact shape.

In this case, the outer case can be made smaller by reducing the dead space inside the outer case, and therefore the entire film capacitor can be made smaller.

When moisture contained between resin films of a capacitor element evaporates and the capacitor element swells, if a roll of a metallized film has a cylindrical shape as shown in fig. 4, the roll expands radially from the center of the circle in the cross section, and thus the expansion direction is not biased. On the other hand, if the roll of the metallized film has a flat shape as shown in fig. 5, the roll does not expand radially from the center of the cross section. In particular, since the roll body is pressed, a part of the resin film is not plastically deformed, and a biasing force (elasticity) for restoring the shape in the outward direction is applied. Therefore, as the capacitor element expands, a biasing force is applied to a part of the capacitor element that is not plastically deformed, and therefore the outer case is more easily deformed than a case where the roll of the metallized film is cylindrical.

In the film capacitor of the present invention, when the outer case is made of a resin composition containing LCP and an inorganic filler, even when the roll of the metallized film is in a flat shape, deformation of the outer case can be suppressed.

In the film capacitor of the present invention, when the capacitor element is formed of a roll of a metallized film, the capacitor element may have a cylindrical roll axis. The winding shaft is disposed on the central axis of the metallized film in a wound state, and serves as a winding shaft for winding the metallized film.

In the film capacitor of the present invention, since the size and shape of the capacitor element are determined according to the capacitor capacitance, capacitor elements of various sizes can be used.

For example, if the capacitor capacitance is 1 μ F or more and 150 μ F or less, it is preferable that the capacitor element has a cross-sectional oblong shape in which the length in the oblong direction is 15mm or more and 65mm or less, the length in the short circle direction is 2mm or more and 50mm or less, and the length in the longitudinal direction (the depth front-rear direction of the cross section and including the external electrode) is 10mm or more and 50mm or less.

In this case, it is preferable that the outer shape of the outer case has a long side of the bottom portion of 16mm to 73mm, a short side of the bottom portion of 3mm to 58mm, and a height of 10.5mm to 50.5 mm. The thickness of the outer case is preferably 0.5mm to 3mm, and more preferably 0.5mm to 2 mm.

In the film capacitor of the present invention, the volume of the capacitor element is preferably 30% or more and 85% or less with respect to the internal volume of the outer case. If the volume of the capacitor element exceeds 85% of the internal volume of the outer case, it becomes difficult to fix the outer case and the capacitor element by filling resin. On the other hand, if the volume of the capacitor element is less than 30% of the internal volume of the outer case, the outer case becomes too large for the capacitor element, and the film capacitor becomes large.

In the film capacitor of the present invention, the separation distance between the inner surface of the outer case and the outer surface of the capacitor element is preferably 1mm or more and 5mm or less, and more preferably 1mm or more and 2mm or less.

As the size of the outer case is closer to the size of the capacitor element, the film capacitor can be made smaller, but on the other hand, when moisture contained between resin films of the capacitor element evaporates and the capacitor element expands, the outer case is easily deformed.

In the film capacitor of the present invention, when the outer case is made of a resin composition containing LCP and an inorganic filler, the deformation of the outer case can be suppressed even when the size of the outer case is made to be close to the size of the capacitor element.

(lead terminal)

In the film capacitor of the present invention, the lead terminals protrude outward from the filling resin filled in the outer case.

Since the portions of the lead terminals electrically connected to the external electrodes of the capacitor element are provided in a small area of the external electrodes, the lead terminals may be separated from the external electrodes when a load is applied to the lead terminals. Therefore, the filling resin is positioned outside the external electrodes of the capacitor element and the lead terminals in the outer case, and the two are fixed in close contact with each other. Thus, even if a load is applied to the protruding portions of the lead terminals, the connection between the lead terminals and the external electrodes can be enhanced by the filling resin, and separation of the lead terminals and the external electrodes can be suppressed.

The connection position between the external electrode and the lead terminal may be the central portion of the external electrode, or may be an electrode end portion near the opening as shown in fig. 1 of japanese patent No. 4733566.

(other embodiments)

Although fig. 1 (a), 1 (b) and 1 (c) show an example in which a single capacitor element is housed in a single outer case, a plurality of capacitor elements may be housed in a single outer case, as described in, for example, japanese patent laid-open No. 2012-69810.

In addition, although the winding type film capacitor in which the 1 st metalized film and the 2 nd metalized film are wound in a laminated state has been described above, a laminated type film capacitor in which the 1 st metalized film and the 2 nd metalized film are laminated may be used. The above-described operation and effect of the present invention can be obtained even in a film capacitor such as a laminated film capacitor.