US 11,791,100 B2Granted

Film capacitor with coated dielectric layer

AssigneeVishay Electronic GmbH

InventorGeert Stevens

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Abstract

A film capacitor preferably includes a single film capacitor layer wound around itself in adjacent layers to form a winding. The film capacitor layer preferably includes a dielectric film, a first metallization layer formed on the dielectric film, a dielectric coating formed on the first metallization layer, and a second metallization layer formed on the dielectric coating. A metallic contact layer is preferably formed on an outer edge of the winding. A terminal is preferably formed on an outer edge of the metallic contact layer. An insulating material preferably encapsulates the winding, the metallic contact layer, and a portion of the terminal. The capacitor as self-healing properties. Further, the border of the electrodes may be wave-cut. Further, an insulating gap may be added between the border and the upper electrode.

Claims20

Dependent claims

A film capacitor comprising:

a single film capacitor layer wound around itself in adjacent layers to form a winding, wherein the film capacitor layer comprises:
a single dielectric film having a first side and a second side opposite the first side,
a first metallization layer formed on the dielectric film,
a single dielectric coating formed on a side of the first metallization layer opposite the dielectric film, and
a second metallization layer formed on a side of the dielectric coating opposite the first metallization layer,
wherein the film capacitor layer has a first outer side comprising the dielectric film, the dielectric coating, and the second metallization layer, and a second outer side opposite the first outer side comprising the dielectric film,
the first outer side and the second outer side being cut in a wave cut such that the first outer side has first alternating areas extending laterally to a first outer edge of the film capacitor layer and second alternating areas curving away from the first outer edge of the film capacitor layer, and the second outer side has first alternating areas extending laterally to a second outer edge of the film capacitor layer and second alternating areas curving away from the second outer edge of the film capacitor layer,
the first alternating areas and the second alternating areas arranged such that alternating edges of the adjacent layers extend laterally to outer edges of the winding, and
wherein the wave cut at the first outer side extends through the second metallization layer, the dielectric coating, and the dielectric film of the film capacitor layer, and wherein the wave cut at the second outer side extends through the dielectric film of the film capacitor layer;
a first metallic contact layer formed on a first outer edge of the winding, and a second metallic contact layer formed on a second outer edge of the winding;
a first terminal formed on an outer edge of the first metallic contact layer, and a second terminal formed on an outer edge of the second metallic contact layer;
and
an insulating material encapsulating the winding, the first and second metallic contact layer, and a portion of the first and second terminals.

10 more elements

A method of forming a film capacitor, the method comprising:

forming a film capacitor layer comprising:
a single dielectric film,
a first metallization layer formed on the dielectric film,
a single dielectric coating formed on a side of the first metallization layer opposite the dielectric film, and
a second metallization layer formed on a side of the dielectric coating opposite the first metallization layer,
wherein a first outer side of the film capacitor layer comprises the dielectric film, the dielectric coating, and the second metallization layer, and wherein a second outer side of the film capacitor layer comprises the dielectric film;
forming a winding by rolling the film capacitor layer around itself in adjacent layers;
forming a wave cut in a first outer side and an opposite second outer side of the film capacitor layer, such that the first outer side has first alternating areas extending laterally to a first outer edge of the film capacitor layer and second alternating areas curving away from the first outer edge of the film capacitor layer, and the second outer side has first alternating areas extending laterally to a second outer edge of the film capacitor layer and second alternating areas curving away from the second outer edge of the film capacitor layer,
the first alternating areas and the second alternating areas arranged such that alternating edges of the adjacent layers extend laterally to outer edges of the winding, and
wherein the wave cut at the first outer side extends through the second metallization layer, the dielectric coating, and the dielectric film of the film capacitor layer, and wherein the wave cut at the second outer side extends through the dielectric film;
forming a first metallic contact layer on an outer edge of the winding;
forming a terminal on an outer edge of the first metallic contact layer;
and
encapsulating the winding, the first metallic contact layer, and a portion of the terminal with an insulating material.

11 more elements

Dependencies are inferred from the claim text.

Facts

Application: 17/282,321Filed 2 Oct 2019 · us provisional application
Priority: 3 Oct 2018
Published: US 2021/0383974 A19 Dec 2021
Granted: 17 Oct 2023
Term ends: Not estimatedThe source records don’t support an estimate.

Classification6 codes

H01G 4/232
Terminals: electrically connecting two or more layers of a stacked or rolled capacitor
H01G 4/018
Details: dielectrics
H01G 4/16
Organic dielectrics: of fibrous material, e.g. paper
H01G 4/206
Using combinations of dielectrics from more than one of groups H01G4/02 - H01G4/06: inorganic and synthetic material