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US 8,098,479 B1Granted
Capacitor having zinc coated common edge with welded aluminum terminal
AssigneeCornell Dubilier Marketing, Inc.
InventorsSamuel G. Parler, Jr., Herbert David Leigh, III
Life of this patent
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Abstract
A capacitor is provided having a capacitor element, with first and second metalized thermoplastic sheets, which are offset and wound together to create common edges at opposite ends, a zinc or zinc-rich conductive coating thermally sprayed on each of the common edges of the capacitor element, and aluminum or aluminum-rich terminals welded to each of the conductive coatings to form a metallurgical bond, having a pull strength of at least 5 pounds, without damaging the capacitor element.
Claims22
A capacitor, comprising:
- (a) a capacitor element having a first set of conductive plates and a second set of conductive plates, wherein the plates in the first set of plates and the plates in the second set of plates are arranged in alternating layers, separated by a dielectric, and wherein the first set of plates and the second set of plates are staggered relative to each other to create a first common edge for the first set of plates and a second common edge for the second set of plates;
- (b) a first metal coating applied to the first common edge of the capacitor element and a second metal coating applied to the second common edge of the capacitor element, wherein the first and second coatings are applied by thermal spraying, and wherein the first and second coatings are selected from the group consisting of zinc and zinc rich alloys;
- and
- (c) a first metal terminal welded to the first coating to form a metallurgical bond, wherein the first metal terminal is selected from the group consisting of aluminum and aluminum rich alloys, and a second metal terminal connected to the second coating.
1 more element
A capacitor, comprising:
- (a) a capacitor element comprising first and second thermoplastic polymer sheets having a metalized surface formed by vapor deposition, wherein the first and second sheets are arranged in multiple layers and staggered relative to each other to create a first common edge for the first sheet and a second common edge for the second sheet, wherein the capacitor element is capable of supporting a direct current potential, and thereby storing an electrical charge and energy;
- (b) a first metal coating applied to the first common edge of the capacitor element and a second metal coating applied to the second common edge of the capacitor element, wherein the first and second coatings are applied by thermal spraying, and wherein the first and second coatings are selected from the group consisting of zinc and zinc rich alloys;
- (c) a first metal terminal welded to the first coating to form a metallurgical bond, wherein the first metal terminal is selected from the group consisting of aluminum and aluminum rich alloys;
- and
- (d) a second metal terminal is welded to the second coating to form a metallurgical bond, and the second metal terminal is selected from the group consisting of aluminum and aluminum rich alloys.
2 more elements
An array of capacitors, comprising:
- (a) a plurality of capacitor elements, wherein each capacitor element has a first set of conductive plates and a second set of conductive plates, wherein the plates in the first set of plates and the plates in the second set of plates are arranged in alternating layers, separated by a dielectric, and wherein the first set of plates and the second set of plates are staggered relative to each other to create a first common edge for the first set of plates and a second common edge for the second set of plates;
- (b) a first metal coating applied to the first common edge of each of the capacitor elements and a second metal coating applied to the second common edge of each of the capacitor elements, wherein the first and second coatings are applied by thermal spraying, and wherein the first and second coatings are selected from the group consisting of zinc and zinc rich alloys;
- and
- (c) a first metal terminal sheet welded to the first coating of each of the capacitor elements to form a metallurgical bond, wherein the first metal terminal is selected from the group consisting of aluminum and aluminum rich alloys;
- and
- (d) a second metal terminal sheet welded to the second coating of each of the capacitor elements to form a metallurgical bond, and the second metal terminal is selected from the group consisting of aluminum and aluminum rich alloys.
3 more elements
Dependencies are inferred from the claim text.