Method of making a capacitor

Claim 1

A method of making a capacitor comprising the steps of forming a plurality of thin dielectric sheets in the green state comprising a crystallizable glass frit in an organic binder, applying a film of a slurry of particulate metal to at least two of said green dielectric sheets in a predetermined position, disposing said green dielectric sheets with said films applied thereto in a stack such that each of said films is separated from adjacent films by one of said green dielectric sheets and such that the first two films of the stack partly overlap each other, alternate films being substantially in register with each other, said films comprising the capacitor electrodes, disposing a green dielectric film over the stack so formed as a cover therefor, subjecting the stack so formed to an elevated temperature to volatilize any organic constituents therein, applying pressure to said stack while at elevated temperature to compact and coalesce said glass and to seal adjacent members together thereby forming a substantially monolithic unit, heat treating said unit so as to crystallize the glass to form a glass-ceramic, removing the pressure and temperature, and thereafter removing edge portions of said unit as required so as to expose the nonoverlapping ends of said electrodes whereby electrical connection may be made to the capacitor.

Claim 2

A method of making a capacitor comprising the steps of forming a plurality of thin dielectric sheets in the green state comprising a crystallizable glass frit in an organic binder, applying a film of a slurry of particulate metal to at least two of said green dielectric sheets in a predetermined position, disposing said green dielectric sheets with said films applied thereto in a stack such that each of said films is separated from adjacent films by one of said green dielectric sheets and such that the first two films of the stack partly overlap each other, alternate films being substantially in register with each other, said films comprising the capacitor electrodes, disposing a green dielectric film over the stack so formed as a cover therefor, subjecting the stack so formed to an elevated temperature to volatilize any organic constituents therein, applying pressure to said stack while at elevated temperature to compact and coalesce said glass and to seal adjacent members together thereby forming a substantially monolithic unit, heat treating said unit so as to crystallize the glass to form a glass-ceramic, removing the pressure and temperature, and thereafter removing edge portions of said unit as required so as to expose the nonoverlapping ends of said electrodes whereby electrical connection may be made to the capacitor.

Claim 15

The method of making a capacitor comprising the steps of forming a plurality of thin dielectric sheets in the green state comprising a crystallizable glass frit in an organic binder, applying a first film of a slurry of particulate metal to a first of said green dielectric sheets in a predetermined position, disposing a second of said green dielectric sheets over said first film and first dielectric sheet substantially in register with said first dielectric sheet, applying a second film of said slurry to said second dielectric sheet in such manner as to partly overlap said first film, said first and second films comprising the capacitor electrodes, disposing a third of said green dielectric sheets over the stack so formed substantially in register with said first and second dielectric sheets, subjecting the assembly to an elevated temperature to volatilize any organic constituents therein, applying pressure to said assembly while at elevated temperature to compact and coalesce said glass and seal adjacent members together thereby forming a substantially monolithic unit, heat treating said unit so as to crystallize the glass to form a glass-ceramic, removing the pressure and temperature, and thereafter removing edge portions of said unit as required so as to expose the nonoverlapping ends of said electrodes,

Claim 16

The method of making a capacitor comprising the steps of forming a plurality of thin dielectric sheets in the green state comprising a crystallizable glass frit in an organic binder, applying a first film of a slurry of particulate metal to a first of said green dielectric sheets in a predetermined position, disposing a second of said green dielectric sheets over said first film and first dielectric sheet substantially in register with said first dielectric sheet, applying a second film of said slurry to said second dielectric sheet in such manner as to partly overlap said first film, said first and second films comprising the capacitor electrodes, disposing a third of said green dielectric sheets over the stack so formed substantially in register with said first and second dielectric sheets, subjecting the assembly to an elevated temperature to volatilize any organic constituents therein, applying pressure to said assembly while at elevated temperature to compact and coalesce said glass and seal adjacent members together thereby forming a substantially monolithic unit, heat treating said unit so as to crystallize the glass to form a glass-ceramic, removing the pressure and temperature, and thereafter removing edge portions of said unit as required so as to expose the nonoverlapping ends of said electrodes,

Claim 33

The method of making capacitor comprising the steps of forming a plurality of thin dielectric sheets in the green state comprising a crystallizable glass frit in an organic binder, applying a plurality of films of a slurry of particulate metal to a first of said green dielectric sheets in a predetermined position, disposing a second of said green dielectric sheets over said first plurality of films and first sheet substantially in register with said first sheet, applying a plurality of films of said slurry to said second green dielectric sheet, each film on said second sheet overlapping a portion of at least one film on said first dielectric sheet while a portion thereof is nonoverlapping thereby forming a plurality of capacitor units, said first and second plurality of films comprising electrodes of said capacitor units, applying additional pluralities of films of said slurry of particulate metal to additional of said green dielectric sheets each of said additional green dielectric sheets being disposed over the previous plurality of films in register with the previous green dielectric sheets, each of said films being separated by a green dielectric sheet, alternate pluralities of films being in register with each other, said additional films comprising additional capacitor electrodes, said additional green dielectric sheets with films applied thereto being disposed until a stack of capacitor units having desired electrical properties are obtained, disposing a green dielectric sheet over the assembly so formed substantially in register with all other green dielectric sheets to provide a cover therefor, said films temporarily adhering adjacent green dielectric sheets, the nonoverlapping portions of alternate films extending in directions aT least about 90* from the remaining films, placing the assembly so formed on a pallet, disposing said pallet in a furnace at a temperature of less than 100* C., increasing the furnace temperature to about 250* C. and maintaining it for about 3 hours, then increasing the temperature to about 350* C. and maintaining it for about 7 hours, whereby any organic constituents of said assembly are volatilized, then increasing the temperature to a value ranging from about 725* C. to about 775* C. and subjecting the assembly to a pressure of about 200 pounds per square inch for a period ranging from about 45-60 minutes whereby the glass frit is coalesced and compacted and adjacent members sealed together thereby forming a substantially monolithic unit, then increasing the temperature to a value of ranging from about 775* to about 970* C. and decreasing said pressure to about 50 pounds per square inch for a period ranging from about 100 minutes to about 2 hours, cooling said assembly so as to crystallize the glass to form a glass-ceramic, said organic constituents being volatilized and the frit compacted and coalesced while in a glass state with the unit only thereafter being heat treated to crystallize the glass to form a glass-ceramic, the elevated temperature to which said assembly is subjected being less than the melting point of said particulate metal, separating the structure so formed into individual capacitors in a manner such that the nonoverlapping ends of said electrodes of the individual capacitors are simultaneously exposed while the capacitors are being separated, said capacitor units being separated after said glass is crystallized, metallizing the ends of said capacitors wherein said nonoverlapping ends of said electrodes are exposed, and thereafter attaching leads to said metallized ends of said capacitors.

Claim 34

The method of making capacitor comprising the steps of forming a plurality of thin dielectric sheets in the green state comprising a crystallizable glass frit in an organic binder, applying a plurality of films of a slurry of particulate metal to a first of said green dielectric sheets in a predetermined position, disposing a second of said green dielectric sheets over said first plurality of films and first sheet substantially in register with said first sheet, applying a plurality of films of said slurry to said second green dielectric sheet, each film on said second sheet overlapping a portion of at least one film on said first dielectric sheet while a portion thereof is nonoverlapping thereby forming a plurality of capacitor units, said first and second plurality of films comprising electrodes of said capacitor units, applying additional pluralities of films of said slurry of particulate metal to additional of said green dielectric sheets each of said additional green dielectric sheets being disposed over the previous plurality of films in register with the previous green dielectric sheets, each of said films being separated by a green dielectric sheet, alternate pluralities of films being in register with each other, said additional films comprising additional capacitor electrodes, said additional green dielectric sheets with films applied thereto being disposed until a stack of capacitor units having desired electrical properties are obtained, disposing a green dielectric sheet over the assembly so formed substantially in register with all other green dielectric sheets to provide a cover therefor, said films temporarily adhering adjacent green dielectric sheets, the nonoverlapping portions of alternate films extending in directions aT least about 90* from the remaining films, placing the assembly so formed on a pallet, disposing said pallet in a furnace at a temperature of less than 100* C., increasing the furnace temperature to about 250* C. and maintaining it for about 3 hours, then increasing the temperature to about 350* C. and maintaining it for about 7 hours, whereby any organic constituents of said assembly are volatilized, then increasing the temperature to a value ranging from about 725* C. to about 775* C. and subjecting the assembly to a pressure of about 200 pounds per square inch for a period ranging from about 45-60 minutes whereby the glass frit is coalesced and compacted and adjacent members sealed together thereby forming a substantially monolithic unit, then increasing the temperature to a value of ranging from about 775* to about 970* C. and decreasing said pressure to about 50 pounds per square inch for a period ranging from about 100 minutes to about 2 hours, cooling said assembly so as to crystallize the glass to form a glass-ceramic, said organic constituents being volatilized and the frit compacted and coalesced while in a glass state with the unit only thereafter being heat treated to crystallize the glass to form a glass-ceramic, the elevated temperature to which said assembly is subjected being less than the melting point of said particulate metal, separating the structure so formed into individual capacitors in a manner such that the nonoverlapping ends of said electrodes of the individual capacitors are simultaneously exposed while the capacitors are being separated, said capacitor units being separated after said glass is crystallized, metallizing the ends of said capacitors wherein said nonoverlapping ends of said electrodes are exposed, and thereafter attaching leads to said metallized ends of said capacitors.