High energy density capacitor

• US 5,731,948 A
• Filed: 04/04/1996
• Issued: 03/24/1998
• Est. Priority Date: 04/04/1996
• Status: Expired due to Term

• Current Assignee: Sigma Laboratories Of Arizona LLC
• Original Assignee: Sigma Labs, Inc.
• Inventors: Miller, Theodore A., Yializis, Angelo
• Primary Examiner(s): Picard, Leo P.
• Assistant Examiner(s): Dinkins, Anthony
• Application Number:
  US08/627,572
• Time in Patent Office: 719 Days
• Field of Search: 361/273, 361/279, 361/299.1, 361/272, 361/301.1, 361/305, 361/306.3, 361/311, 361/312, 361/313, 361/314, 361/315, 361/321.1, 361/321.2, 361/321.3 , 361/321.4, 361/321.5, 361/322, 361/323, 361/326, 361/328, 118/730, 118/718, 118/719, 118/720
• US Class Current: 361/313
• CPC Class Codes: H01G 4/18 of synthetic material, e.g. derivatives of cellulose H01G4/16 takes precedence
• CPC Class Codes: H01G 4/30 Stacked capacitors H01G4/33 takes precedence
• CPC Class Codes: Y10T 29/435 Solid dielectric type

Abstract

A high energy density, high power density capacitor having an energy density of at least about 0.5 J/cm³ is provided. The capacitor comprises a plurality of interleaved metal electrode layers separated by a polymer layer. The interleaved metal electrode layers terminate at opposite ends in a solder termination strip. The high energy density aspect of the capacitors of the invention is achieved by at least one of the following features: (a) the dielectric thickness between the interleaved metal electrode layers is a maximum of about 5 μm; (b) the polymer is designed with a high dielectric constant κ of at least about 3.5; (c) the metal electrode layers within the polymer layer are recessed along edges orthogonal to the solder termination strips to prevent arcing between the metal electrode layers at the edges; and (d) the resistivity of the metal electrode layers is within the range of about 10 to 500 ohms per square, or a corresponding thickness of about 200 to 30 Å.

Claims

1. A high energy density multilayer capacitor having an energy density of at least about 0.5 J/cm³, said capacitor comprising a plurality of interleaved, vacuum-deposited metal electrode layers, each layer separated by vacuum-deposited, radiation-cured polymer dielectric layers, thereby defining an active capacitor region, said interleaved metal electrode layers terminating at opposite ends in a multilayer sputtered, solder-coated termination strip, said metal electrode layers recessed into said polymer dielectric layers along edges orthogonal to said opposite ends, thus creating a non-conducting region, to protect against arcing and leakage current between said metal electrode layers along said orthogonal edges.

2. The high energy density capacitor of claim 1 wherein said non-conducting region between said polymer dielectric layers comprises a non-conducting oxide of said metal electrode layers.

3. The high energy density capacitor of claim 1 wherein each said polymer dielectric layer between said metal electrodes has a thickness that is less than about 10 μ

m.

4. The high energy density capacitor of claim 3 wherein said thickness ranges from about 0.05 μ

m to about 2.0 μ

m.

5. The high energy density capacitor of claim 1 wherein each said polymer dielectric layer comprises a polymer having a dielectric constant κ

greater than about 3.

6. The high energy density capacitor of claim 5 wherein said polymer has a dielectric constant κ

from about 3.5 to 15.

7. The high energy density capacitor of claim 6 wherein said polymer consists essentially of a radiation-cured polyfunctional acrylate.

8. The high energy density capacitor of claim 1 wherein said metal electrodes comprise a high conductivity, low melting point electrode material that allows said capacitor to self-heal when a breakdown occurs in any said polymer dielectric layer.

9. The high energy density capacitor of claim 8 wherein said metal electrodes are selected from the group consisting of aluminum, zinc, and zinc/aluminum alloys.

10. The high energy density capacitor of claim 9 wherein said metal electrode layers consist essentially of aluminum and have a thickness within the range of 30 to 200 Å

.

11. The high energy density capacitor of claim 1 wherein said metal electrode has a resistance in the range of about 1 to 500 ohms per square.

12. The high energy density capacitor of claim 11 wherein said resistance is about 1 ohm per square near said termination strip to allow for good electrical contact and low contact resistance and is in the range of about 10 to 500 ohm per square away from said termination strip and in said active capacitor region to facilitate self-healing if a breakdown occurs in any said polymer dielectric layer.