POLYMERIC MONOLITHIC CAPACITOR

• US 20170213646A1
• Filed: 04/10/2017
• Published: 07/27/2017
• Est. Priority Date: 03/25/2015
• Status: Active Grant

• Current Assignee: PolyCharge America, Inc. (BorgWarner Incorporated)
• Original Assignee: Sigma Laboratories Of Arizona LLC
• Inventors: Yializis, Angelo
• Granted Patent: US 10,347,422 B2
• Time in Patent Office: Days
• CPC Class Codes: C08F 122/14 Esters having no free carboxylic acid groups
• CPC Class Codes: H01G 4/005 Electrodes
• CPC Class Codes: H01G 4/129 containing a glassy phase, e.g. glass ceramic
• CPC Class Codes: H01G 4/14 Organic dielectrics
• CPC Class Codes: H01G 4/232 electrically connecting two or more layers of a stacked or rolled capacitor
• CPC Class Codes: H01G 4/30 Stacked capacitors H01G4/33 takes precedence
• CPC Class Codes: H01G 4/304 obtained from a another capacitor

Abstract

Prismatic polymer monolithic capacitor structure operating at temperatures exceeding 140° C. and including multiple interleaving radiation-cured polymer dielectric layers and metal layers. Method for fabrication of same. The geometry of structure is judiciously chosen to increase sheet resistance of metal electrodes while reducing the capacitor'"'"'s equivalent series resistance. Metal electrode layers are provided with a thickened peripheral portion to increase strength of terminating connections and are passivated to increase corrosion resistance. Materials for polymer dielectric layers are devised to ensure that the capacitor'"'"'s dissipation factor remains substantially unchanged across the whole range of operating temperatures, to procure glass transition temperature that is no less than the desired operating temperature, and to optimize the absorption of ambient moisture by the polymeric layers.

Claims

1. A polymer monolithic capacitor formed in the vacuum, the capacitor comprising:

multiple polymer dielectric layers, and

multiple metallized electrode layers,

wherein at least one polymer dielectric layer comprises a chemical structure with a hydrogen-to-carbon ratio of at least 1.0 and an oxygen-to-carbon ratio of at least 0.1, and

wherein at least one polymer dielectric layer has a glass transition temperature greater than 100°

C.

2. The polymer monolithic capacitor of claim 1, wherein said at least one polymer dielectric layer has a chemical structure with a hydrogen-to-carbon ratio of at least 1.2.

3. The polymer monolithic capacitor of claim 1, wherein said at least one polymer dielectric layer has a glass transition temperature greater than 140°

C.

4. The polymer monolithic capacitor of claim 1, wherein a metallized electrode layer has a heavy edge.

5. The polymer monolithic capacitor of claim 1, wherein at least one metallized electrode layer has a passivated surface.

6. The polymer monolithic capacitor of claim 1, characterized by a dissipation factor of less than 0.02 at 140°

C.

7. The polymer monolithic capacitor of claim 1, characterized by a dissipation factor of less than 0.01 at 140°

C.

8. The polymer monolithic capacitor of claim 1, comprising two or more internal electrical connections configured in series.

9. The polymer monolithic capacitor of claim 1, wherein at least one metallized electrode layer is passivated and contains organometallic bonds between an adjacent polymer dielectric layer and a surface of the metallized electrode layer.

10. The polymer monolithic capacitor of claim 1, wherein said capacitor has a prismatic shape with transverse dimensions L, W, and H, wherein L represents a first extent of the capacitor along which the capacitor is equipped with an electrical termination, W represents a second extent of the capacitor, and l=1 represents a third extent of the capacitor in a direction in which said polymer dielectric layers and metallized electrode layers are stacked, and wherein the ratio of said first extent to said second extent is greater than 1.

11. The polymer monolithic capacitor of claim 10, wherein said ratio is greater than 2.

12. The polymeric monolithic capacitor of claim 1, wherein each polymer dielectric layer comprises a chemical structure with a hydrogen-to-carbon ratio of at least 1.0 and an oxygen-to-carbon ratio of at least 0.1, and wherein each polymer dielectric layer has a glass transition temperature greater than 100°

C.

13. An article of manufacture that includes the polymer monolithic capacitor of claim 1.

14. A polymer monolithic capacitor formed in the vacuum, the capacitor comprising:

multiple polymer dielectric layers, and

multiple metal electrode layers

wherein at least one polymer dielectric layer includes a chemical structure with a hydrogen-to-carbon ratio of at least 1.0 and an oxygen-to-carbon ratio of at least 0.1, and

wherein at least one metal electrode layer has a surface layer that is passivated.

15. The polymer monolithic capacitor according to claim 14, wherein at least one polymer dielectric layer includes a chemical structure with a hydrogen-to-carbon ratio of at least 1.0 and an oxygen-to-carbon ratio of at least 0.1, and wherein each metal electrode layer has a surface layer that is passivated.

16. The polymer monolithic capacitor of claim 14, wherein at least one polymer dielectric layer comprises a chemical structure with a hydrogen-to-carbon ratio of at least 1.2.

17. The polymer monolithic capacitor of claim 14, wherein at least one metal electrode layer has a heavy edge.

18. The polymer monolithic capacitor of claim 14, wherein at least one polymer dielectric layer has a glass transition temperature greater than 125°

C.

19. The polymer monolithic capacitor of claim 14, wherein at least one polymer dielectric layer has a glass transition temperature greater than 140°

C.

20. The polymer monolithic capacitor of claim 14, that has a dissipation factor of less than 0.02 at 140°

C.

21. The polymer monolithic capacitor of claim 14, which has a dissipation factor of less than 0.01 at 140°

C.

22. The polymer monolithic capacitor of claim 14, comprising two or more internal electrical connections configured in series.

23. The polymer monolithic capacitor of claim 14, wherein said capacitor has a prismatic shape with transverse dimensions L, W, and H,

wherein L represents a first extent of the capacitor along which the capacitor is equipped with an electrical termination, W represents a second extent of the capacitor, and H represents a third extent of the capacitor in a direction in which said polymer dielectric layers and metal electrode layers are stacked, and

wherein the ratio of said first extent to said second extent is greater than 1.

24. The polymer monolithic capacitor of claim 14, wherein said ratio is greater than 2.

25. An article of manufacture that includes the polymer monolithic capacitor of claim 14. *