US6535105B2 — Electronic device and process of making electroni…

Claim 1

Independent Claim 141 words

An electronic device, comprising: a multi-sided body having an exterior surface and defined by a plurality of electrode plates arranged in a stack; at least two terminal structures affixed to said multi-sided body, said terminal structures each being electrically conductive with at least one of said plurality of electrode plates; wherein said multi-sided body and said terminal structures further comprise a metal-free polymer coating; the multi-sided body having said metal-free polymer coating on its exterior surface, said metal-free polymer coating being resistant to plating of metal onto the exterior surface of said multi-sided body; said terminal structures comprising a metal plating layer on said exterior surface of said terminal structures, said metal-free polymer coating being positioned between said metal plating layer and said electrode plates, wherein said metal plating layer is affixed to said metal-free polymer coating on said terminal structures.

Claim 2

Dependent Claim 141 words

An electronic device, comprising: a multi-sided body having an exterior surface and defined by a plurality of electrode plates arranged in a stack; at least two terminal structures affixed to said multi-sided body, said terminal structures each being electrically conductive with at least one of said plurality of electrode plates; wherein said multi-sided body and said terminal structures further comprise a metal-free polymer coating; the multi-sided body having said metal-free polymer coating on its exterior surface, said metal-free polymer coating being resistant to plating of metal onto the exterior surface of said multi-sided body; said terminal structures comprising a metal plating layer on said exterior surface of said terminal structures, said metal-free polymer coating being positioned between said metal plating layer and said electrode plates, wherein said metal plating layer is affixed to said metal-free polymer coating on said terminal structures.

Claim 3

Dependent Claim 18 words

The electronic device as set forth in claim 1 wherein the metal-free polymer coating comprises a resin coating.

Claim 4

Dependent Claim 23 words

The electronic device of claim 2 in which the device is selected from the group of electronic devices comprising: varistors, thermistors, and resistors.

Claim 5

Dependent Claim 19 words

The electronic device of claim 2 in which the metal-free polymer coating is capable of being cured by crosslinking.

Claim 6

Dependent Claim 16 words

The electronic device of claim 2 in which the metal-free polymer coating comprises a thermoset resin.

Claim 7

Dependent Claim 16 words

The electronic device of claim 2 in which the polymer coating comprises an aromatic cyclic compound.

Claim 8

Dependent Claim 14 words

The electronic device of claim 2 in which the electronic device is a varistor.

Claim 9

Dependent Claim 16 words

The electronic device of claim 1 in which the metal plating layer is comprised of nickel.

Claim 10

Dependent Claim 19 words

The electronic device of claim 1 in which the metal plating layer is comprised of an alloy containing tin.

Claim 11

Dependent Claim 136 words

An electronic conductive device, comprising: a multi-sided body defined by a plurality of electrode plates arranged in a stack; a plurality of terminal structures having exterior surfaces, said terminal structures electrically connected to said electrode plates in a predetermined manner, the terminal structures having interior and exterior layers, wherein the multi-sided body and the terminal structures are capable of receiving a nonmetallic resin coating, the nonmetallic resin coating comprising a thermoset resin; the multi-sided body having a nonmetallic resin coating on at least a portion of an exterior surface, the non-metallic resin coating preventing plating of metal onto the exterior surface of the multi-sided body; and the terminal structures comprising at least one metal plating layer on said exterior surfaces, wherein said metal plating layer upon said terminal structures is affixed to said nonmetallic resin coating.

Claim 12

Dependent Claim 136 words

An electronic conductive device, comprising: a multi-sided body defined by a plurality of electrode plates arranged in a stack; a plurality of terminal structures having exterior surfaces, said terminal structures electrically connected to said electrode plates in a predetermined manner, the terminal structures having interior and exterior layers, wherein the multi-sided body and the terminal structures are capable of receiving a nonmetallic resin coating, the nonmetallic resin coating comprising a thermoset resin; the multi-sided body having a nonmetallic resin coating on at least a portion of an exterior surface, the non-metallic resin coating preventing plating of metal onto the exterior surface of the multi-sided body; and the terminal structures comprising at least one metal plating layer on said exterior surfaces, wherein said metal plating layer upon said terminal structures is affixed to said nonmetallic resin coating.

Claim 13

Dependent Claim 14 words

The device of claim 10 in which the thermoset resin is a benzocyclobutene (BCB).

Claim 14

Dependent Claim 18 words

The device of claim 10 in which the terminal structures comprise at least two layers of metal plating.

Claim 15

Dependent Claim 13 words

The device of claim 12 in which one metal plating layer comprises nickel.

Claim 16

Dependent Claim 14 words

The device of claim 12 which one metal plating layer comprises a tin alloy.

Claim 17

Dependent Claim 20 words

The device of claim 12 in which a nickel layer and a tin layer are applied to the terminal structures.

Claim 18

Dependent Claim 14 words

The device of claim 10 in which the thermoset resin is a siloxane-containing resin.

Claim 19

Dependent Claim 15 words

The device of claim 10 in which the resin additionally comprises mesitylene as a solvent.

Claim 20

Dependent Claim 27 words

The device of claim 10 in which the terminal structures include void spaces, further wherein said void spaces are substantially filled with thermoset resin prior to plating.

Claim 21

Dependent Claim 141 words

An electronic device, comprising: a multi-sided body defined by a plurality of electrode plates arranged in a stack; a plurality of dielectric layers between said electrode plates; a plurality of terminal structures electrically connected to said electrode plates in a predetermined manner, the terminal structures having interior and exterior layers; wherein the multi-sided body and the terminal structures are capable of receiving a BOB resin coating; the multi-sided body having a coating of BOB on at least a portion of an exterior surface, the BOB coating preventing plating of metal onto the surface of the body; the terminal structures comprising: a metal plating layer of a tin alloy applied on the exterior surface, and a metal plating layer comprising nickel applied to the BCB coating, the metal plating being affixed to the terminal structures, but not to the multi sided body.

Claim 22

Dependent Claim 141 words

An electronic device, comprising: a multi-sided body defined by a plurality of electrode plates arranged in a stack; a plurality of dielectric layers between said electrode plates; a plurality of terminal structures electrically connected to said electrode plates in a predetermined manner, the terminal structures having interior and exterior layers; wherein the multi-sided body and the terminal structures are capable of receiving a BOB resin coating; the multi-sided body having a coating of BOB on at least a portion of an exterior surface, the BOB coating preventing plating of metal onto the surface of the body; the terminal structures comprising: a metal plating layer of a tin alloy applied on the exterior surface, and a metal plating layer comprising nickel applied to the BCB coating, the metal plating being affixed to the terminal structures, but not to the multi sided body.

Claim 23

Dependent Claim 91 words

A process of making an electronic device, comprising: a) providing a multi-sided body having an interior defined by a plurality of electrode plates arranged in a stack; b) providing a pair of opposed terminals, each of said terminals being electrically conductive with at least one of said electrode plates, c) applying to said multi-sided body and said pair of opposed terminals a metal-free polymer coating; d) curing said metal-free polymer coating; and e) plating at least one metal plating layer upon said metal-free polymer coating at said pair of opposed terminals.

Claim 24

Dependent Claim 91 words

A process of making an electronic device, comprising: a) providing a multi-sided body having an interior defined by a plurality of electrode plates arranged in a stack; b) providing a pair of opposed terminals, each of said terminals being electrically conductive with at least one of said electrode plates, c) applying to said multi-sided body and said pair of opposed terminals a metal-free polymer coating; d) curing said metal-free polymer coating; and e) plating at least one metal plating layer upon said metal-free polymer coating at said pair of opposed terminals.

Claim 25

Dependent Claim 16 words

The process of claim 20 further comprising: plating multiple layers of dissimilar metals upon the terminals.

Claim 26

Dependent Claim 16 words

The process of claim 20 wherein the metal-free polymer coating is crosslinked during the curing step.

Claim 27

Dependent Claim 22 words

The process of claim 20 in which the step (c) comprises soaking the electronic device in a solution containing metal-free polymer coating.

Claim 28

Dependent Claim 24 words

The process of claim 20 in which the step (c) comprises removing excess metal-free polymer coating from the electronic devices by applying centrifugal force.

Claim 29

Dependent Claim 21 words

The process of claim 20 in which excess metal-free polymer coating is removed by placing the electronic devices in a centrifuge.

Claim 30

Dependent Claim 14 words

The process of claim 20 in which the metal-free polymer coating is a benzocyclobutene.

Claim 31

Dependent Claim 25 words

(Amended) The process of claim 20 wherein the step (c) additionally comprises filling void spaces on the terminals prior to plating metal upon the terminals.

Claim 32

Dependent Claim 11 words

An electronic device made by the process of claim 20 .

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2006-03-17	2006-09-16	2007-03-18	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2010-03-17	2010-09-16	2011-03-18	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2014-03-17	2014-09-16	2015-03-18	$7700.00	Window Closed / Lapsed

Electronic device and process of making electronic device

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