Extended foil capacitor with disc-like terminals centrally anchored thereto and a method of making the same

Claim 1

A CAPACITOR COMPRISING: A PAIR OF FOILS OF TIN ALLOY AND A PAIR OF THERMOPLASTIC DIELECTRIC WEBS CONVOLUTELY ARRANGED IN A ROLL WITH THE FOILS INTERLEAVED WITH AND SUPPORTED BY THE DIELECTRIC WEBS IN INSULATED, SUPERPOSED AND IN PARTIALLY OVERLAPPING RELATION TO ONE ANOTHER AND WITH A MARGINAL PORTION OF ONE OF THE FOILS EXTENDING BEYOND AND COMPRESSED AGAINST THE DIELECTRIC WEBS AT ONE END OF THE CAPACITOR ROLL, AND WITH A MARGINAL PORTION OF THE OTHER FOIL EXTENDING BEYOND AND COMPRESSED AGAINST THE DIELECTRIC WEBS AT THE OTHER END OF THE CAPACITOR ROLL, AND WITH THE LEADING END PORTIONS OF SAID DIELECTRIC WEBS EXTENDING BEYOND THE LEADING ENDS OF THE FOILS AND FORMING A TUBULAR CORE; AND TERMINALS FOR THE FOILS, EACH TERMINAL COMPRISING A FLAT DISC PORTION BONDED TO THE COMPRESSED MARGINAL PORTION OF THE FOIL ALONG THE ENTIRE LENGTH THEREOF AT ONE END OF THE CAPACITOR ROLL, AND A HUB PORTION WITH A REDUCED NECK AND AN ENLARGED END OF GREATER DIAMETER THAN THE BORE OF SAID TUBULAR CORE EXTENDING CENTRALLY FROM ONE SIDE OF SAID DISC PORTION AND EMBEDDED IN AND ANCHORED TO AN END PORTION OF SAID CORE.

Claim 3

A METHOD OF MAKING A CAPACITOR WHICH COMPRISES: FORMING A TUBULAR THERMOPLASTIC DIELECTRIC CORE; WINDING A PAIR OF DIELECTRIC WEBS HAVING A WIDTH COEXTENSIVE WITH THE CORE, AND A PAIR OF FOILS OF TIN ALLOY AROUND THE CORE TO FORM A CAPACITOR ROLL WITH THE FOILS SUPPORTED BY THE WEBS IN INSULATED, SUPERPOSED AND PARTIALLY OVERLAPPING RELATION TO EACH OTHER AND WITH A MARGINAL PORTION OF ONE OF THE FOILS EXTENDING BEYOND THE CORE AND THE WEBS AT ONE END OF THE CAPACITOR ROLL AND WITH THE MARGINAL PORTION OF THE OTHER FOIL EXTENDING BEYOND THE CORE AND THE WEBS AT OTHER END OF THE ROLL; FORMING A TERMINAL HAVING A FLAT DISC PORTION WITH A CENTRAL FLARED HUB EXTENDING FROM ONE SIDE THEREOF: HEATING A PAIR OF SUCH TERMINALS TO A TEMPERATURE SUFFICIENT TO MELT THE FOILS AND THE THERMOPLASTIC CORE; AND COMPRESSING THE EXTENDED PORTIONS OF THE FOILS AGAINST THE WEBS AT THE ENDS OF THE CAPACITOR ROLL WITH THE HEATED TERMINALS AND BONDING THE FLAT DISC PORTIONS OF THE TERMINALS TO THE MARGINAL PORTIONS OF THE FOILS ALONG THE ENTIRE LENGTH THEREOF, AND SIMULTANEOUSLY THEREWITH, EMBEDDING THE HUBS OF THE TERMINALS IN THE ENDS OF THE CORE.

Claim 4

A METHOD OF MAKING A CAPACITOR WHICH COMPRISES: FORMING A TUBULAR THERMOPLASTIC DIELECTRIC CORE; WINDING A PAIR OF DIELECTRIC WEBS HAVING A WIDTH COEXTENSIVE WITH THE CORE, AND A PAIR OF FOILS OF TIN ALLOY AROUND THE CORE TO FORM A CAPACITOR ROLL WITH THE FOILS SUPPORTED BY THE WEBS IN INSULATED, SUPERPOSED AND PARTIALLY OVERLAPPING RELATION TO EACH OTHER AND WITH A MARGINAL PORTION OF ONE OF THE FOILS EXTENDING BEYOND THE CORE AND THE WEBS AT ONE END OF THE CAPACITOR ROLL AND WITH THE MARGINAL PORTION OF THE OTHER FOIL EXTENDING BEYOND THE CORE AND THE WEBS AT OTHER END OF THE ROLL; FORMING A TERMINAL HAVING A FLAT DISC PORTION WITH A CENTRAL FLARED HUB EXTENDING FROM ONE SIDE THEREOF: HEATING A PAIR OF SUCH TERMINALS TO A TEMPERATURE SUFFICIENT TO MELT THE FOILS AND THE THERMOPLASTIC CORE; AND COMPRESSING THE EXTENDED PORTIONS OF THE FOILS AGAINST THE WEBS AT THE ENDS OF THE CAPACITOR ROLL WITH THE HEATED TERMINALS AND BONDING THE FLAT DISC PORTIONS OF THE TERMINALS TO THE MARGINAL PORTIONS OF THE FOILS ALONG THE ENTIRE LENGTH THEREOF, AND SIMULTANEOUSLY THEREWITH, EMBEDDING THE HUBS OF THE TERMINALS IN THE ENDS OF THE CORE.