Capacitors with sprayed electrode terminals

Claim 2

A capacitor comprising: at least two adjacent, spaced apart, first and second metal electrodes; at least one separating dielectric layer in contact with at least a portion of said electrodes; said layer having a first extension beyond a first edge of said first electrode to define, at the edge of said first extension, a first separator surface; said second electrode extending to said first separator surface, but having essentially no protrusion beyond said first separator surface, thereby defining a first electrode surface; a dielectric material covering said first edge of said first electrode and filling any void space between the first edge of said first electrode and said first separator; said separator layer having a second extension beyond a first edge of said second electrode to define at the edge of said second extension, a second separator surface; said first electrode extending to said second separator surface but having essentially no protrusion beyond said second separator surface, thereby defining a second electrode surface; a dielectric material covering said first edge of said second electrode and filling any void space between the first edge of said second electrode and said second separator surface; a first deposit of nickel-aluminum material consisting essentially of about 50 to 98 weight percent nickel, weldbonded to said first electrode surface to provide a terminal; and a second deposit of nickel-aluminum material consisting essentially of about 50 to 98 weight percent nickel, weldbonded to said second electrode surface to provide a terminal, the terminal to electrode bond strength being at least about 300 psi.

Claim 3

A capacitor comprising: at least two adjacent, spaced apart, first and second metal electrodes; at least one separating dielectric layer in contact with at least a portion of said electrodes; said layer having a first extension beyond a first edge of said first electrodE to define, at the edge of said first extension, a first separator surface; said second electrode extending to said first separator surface, but having essentially no protrusion beyond said first separator surface, thereby defining a first electrode surface; a dielectric material covering said first edge of said first electrode and filling any void space between the first edge of said edge of said first electrode and said first separator surface; said separator layer having a second extension beyond a first edge of said second electrode to define at the edge of said second extension, a second separator surface; said first electrode extending to said second separator surface but having essentially no protrusion beyond said second separator surface, thereby defining a second electrode surface; a dielectric material covering said first edge of said second electrode and filling any void space between the first edge of said second electrode and said second separator surface; a first deposit of nickel-aluminum material consisting essentially of about 50 to 98 weight percent nickel, weld-bonded to said first electrode surface; a second deposit of nickel-aluminum material consisting essentially of about 50 to 98 weight percent nickel, weld-bonded to said second electrode surface; and a layer of readily solderable material over at least one of said deposits of nickel-aluminum material, said solderable material having a melting point above about 775*C.

Claim 4

A capacitor comprising: at least two adjacent, spaced apart, first and second metal electrodes; at least one separating dielectric layer in contact with at least a portion of said electrodes; said layer having a first extension beyond a first edge of said first electrodE to define, at the edge of said first extension, a first separator surface; said second electrode extending to said first separator surface, but having essentially no protrusion beyond said first separator surface, thereby defining a first electrode surface; a dielectric material covering said first edge of said first electrode and filling any void space between the first edge of said edge of said first electrode and said first separator surface; said separator layer having a second extension beyond a first edge of said second electrode to define at the edge of said second extension, a second separator surface; said first electrode extending to said second separator surface but having essentially no protrusion beyond said second separator surface, thereby defining a second electrode surface; a dielectric material covering said first edge of said second electrode and filling any void space between the first edge of said second electrode and said second separator surface; a first deposit of nickel-aluminum material consisting essentially of about 50 to 98 weight percent nickel, weld-bonded to said first electrode surface; a second deposit of nickel-aluminum material consisting essentially of about 50 to 98 weight percent nickel, weld-bonded to said second electrode surface; and a layer of readily solderable material over at least one of said deposits of nickel-aluminum material, said solderable material having a melting point above about 775*C.

Claim 5

A capacitor according to claim 1 in which said nickel aluminum material is coated with a relatively high melting point readily solderable material and an electrode to terminal bond strength of at least about 500 psi is obtained.

Claim 6

A capacitor according to claim 1 in which said electrodes are made of tantalum, said nickel-aluminum material is coated with a relatively high melting point readily solderable material and an electrode to terminal bond strength of at least about 1,000 psi is obtained.

Claim 7

A capacitor according to claim 1 in which said electrodes are made of tantalum, said nickel-aluminum material is coated with a relatively high melting point readily solderable material and an electrode to terminal bond strength of at least about 2,000 psi is obtained.

Claim 8

The capacitor of claim 1, wherein the metal of said electrodes is selected from the group consisting of film-forming metals, noble metals and copper.

Claim 9

The capacitor of claim 6, wherein at least one of said electrodes is a film-forming metal selected from the group consisting of aluminum, tantalum, titanium, zirconium, hafnium and niobium.

Claim 10

The capacitor of claim 7, wherein said capacitor is an electrostatic capacitor having electrodes selected from the group consisting of aluminum and tantalum.

Claim 11

A capacitor according to claim 1, wherein said electrodes are swaged.

Claim 12

The capacitor of claim 1, wherein said electrostatic capacitor is convolutely wound.

Claim 13

The capacitor of claim 1, wherein said electrostatic capacitor includes substantially flat, stacked electrode plates.

Claim 14

A capacitor according to claim 1, wherein said electrodes do not project from the capacitor body.

Claim 15

A capacitor according to claim 12, wherein attachment is made to the edge portion only of said electrodes.

Claim 16

A capacitor according to claim 1, in which a lead is attached directly to said nickel-aluminum material.

Claim 17

A capacitor according to claim 14, in which said attachement is a welded joint.

Claim 18

A capacitor according to claim 14, in which said attachment is a solder joint.

Claim 19

A capacitor according to claim 1, in which said dielectric layer is at least in part a formed oxide on a film-forming metal.

Claim 20

A capacitor according to claim 1, in which said dielectric layer is at least in part on a polymeric film on a formed oxide.

Claim 21

A capacitor according to claim 10, having little increase in dissipation factor with increase in frequency.

Claim 22

A capaCitor according to claim 8, wherein the electrodes are made of aluminum.

Claim 23

A capacitor according to claim 8, wherein the electrodes are made of tantalum.

Claim 24

A capacitor according to claim 1, wherein a layer of readily solderable material overlies each of said deposits of nickel-aluminum material.

Claim 25

A capacitor according to claim 6, wherein said electrodes are made of a noble metal selected from the group consisting of platinum, silver, gold, and palladium and alloys thereof.

Claim 26

A capacitor according to claim 23, wherein said electrodes are platinum.