U.S. patent application number 16/749870 was filed with the patent office on 2020-05-21 for glass dielectric capacitors and manufacturing processes for glass dielectric capacitors.
The applicant listed for this patent is GENERAL ATOMICS. Invention is credited to Esteban Balarezo Bagdy, Mark Aoraha Cacause, James Ross MacDonald, Mark Allen Schneider.
Application Number | 20200161054 16/749870 |
Document ID | / |
Family ID | 65024619 |
Filed Date | 2020-05-21 |
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United States Patent
Application |
20200161054 |
Kind Code |
A1 |
MacDonald; James Ross ; et
al. |
May 21, 2020 |
GLASS DIELECTRIC CAPACITORS AND MANUFACTURING PROCESSES FOR GLASS
DIELECTRIC CAPACITORS
Abstract
A method for making a glass dielectric capacitor may include
providing a plurality of foil sheets, cutting each of the plurality
of foil sheets with a laser beam by melting each of the plurality
of foil sheets, forming a respective smooth foil edge on each of
said plurality of foil sheets during the cutting, providing a
plurality of glass sheets, and stacking the plurality of foil
sheets in alternating layers with the plurality of glass
sheets.
Inventors: |
MacDonald; James Ross; (SAN
DIEGO, CA) ; Bagdy; Esteban Balarezo; (SAN DIEGO,
CA) ; Cacause; Mark Aoraha; (EL CAJON, CA) ;
Schneider; Mark Allen; (SAN DIEGO, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GENERAL ATOMICS |
San Diego |
CA |
US |
|
|
Family ID: |
65024619 |
Appl. No.: |
16/749870 |
Filed: |
January 22, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
15851658 |
Dec 21, 2017 |
10586654 |
|
|
16749870 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 2255/26 20130101;
H01G 4/105 20130101; B32B 2457/16 20130101; H01G 4/01 20130101;
H01G 4/30 20130101; B32B 17/06 20130101; H01J 37/32 20130101; B32B
38/0008 20130101; H01J 2237/335 20130101; B32B 2307/202 20130101;
B32B 37/12 20130101; H01G 13/006 20130101; H01G 4/232 20130101;
B32B 2309/105 20130101 |
International
Class: |
H01G 4/30 20060101
H01G004/30; H01G 13/00 20060101 H01G013/00; H01G 4/232 20060101
H01G004/232; B32B 38/00 20060101 B32B038/00; B32B 37/12 20060101
B32B037/12; B32B 17/06 20060101 B32B017/06 |
Claims
1. A system for making glass dielectric capacitors, wherein the
system includes mechanical components configured to: provide a
plurality of foil sheets of 4 micrometers to 25 micrometers
thickness; cut each of the plurality of foil sheets with a laser
beam by melting each of the plurality of foil sheets; form a
respective smooth foil edge on each of said plurality of foil
sheets during the cutting; provide a plurality of glass sheets; and
stack the plurality of foil sheets in alternating layers with the
plurality of glass sheets.
2. The system of claim 1, wherein: said stacking comprises stacking
two or more of said plurality of foil sheets between alternating
layers of the plurality of glass sheets.
3. The system of claim 1, wherein the system is further configured
to: deposit a metalized layer on both sides of each one of the
plurality of glass sheets prior to said stacking of said plurality
of foil sheets in alternating layers with said plurality of glass
sheets.
4. The system of claim 3, wherein: said depositing of said
metalized layer comprises depositing said metalized layer on an
area of each of said plurality of glass sheets that extends beyond
an area of each of said plurality of glass sheets juxtaposed
respectively to one of said plurality of foil sheets.
5. The system of claim 4, wherein: said stacking comprises stacking
said plurality of foil sheets in alternating layers with the
plurality of glass sheets with said plurality of foil sheets
extending out beyond a respective edge of each of said plurality of
glass sheets, wherein an extended portion of each of said plurality
of foil sheets allows for attachment of a terminal.
6. The system of claim 1, wherein: said stacking comprises stacking
said plurality of foil sheets in alternating layers with said
plurality of glass sheets with said plurality of glass sheets
offset from one another.
7. The system of claim 6, wherein the system is further configured
to: deposit metal on a side of the plurality of glass sheets having
been stacked.
8. The system of claim 6, wherein the system is further configured
to: deposit electrically conductive epoxy on a side of the
plurality of glass sheets having been stacked.
9. The system of claim 6, wherein the system is further configured
to: deposit a conductive layer on a side of the plurality of glass
sheets having been stacked.
10. The system of claim 9, wherein the system is further configured
to: couple a terminal to said conductive layer.
11. The system of claim 10, wherein the system is further
configured to: submerge the glass sheets having been stacked in an
electrical insulating liquid.
12. The system of claim 11, wherein: said submerging comprises
submerging under vacuum.
13. The system of claim 11, wherein: said submerging comprises
submerging said glass sheets having been stacked in a liquid
selected from the group of liquids comprising: silicone fluid,
mineral oil, synthetic ester, vegetable oil, rapeseed oil, aromatic
insulating fluid (such as biphenyls) and combinations thereof.
14. The system of claim 1, wherein the system is further configured
to: apply a voltage across separate ones of said plurality of foil
sheets.
15. The system of claim 14, wherein the system is further
configured to: apply said voltage across said separate ones of said
plurality of foil sheets by pulsing said voltage.
16. The system of claim 14, wherein the system is further
configured to: apply said voltage under vacuum.
17. The system of claim 1, wherein the system is further configured
to: coat each of said plurality of glass sheets with polymer
coating prior to said stacking.
18. The system of claim 1, wherein the system is further configured
to: coat each of said plurality of glass sheets with inorganic
ceramic coating prior to said stacking.
19. The system of claim 1, wherein the system is further configured
to: plasma cleaning the plurality of glass sheets and the plurality
of foil sheets having been stacked.
20. The system of claim 1, wherein the system is further configured
to: place into a vacuum furnace the plurality of glass sheets and
the plurality of foil sheets having been stacked.
21. The system of claim 1, wherein the system is further configured
to: clean the plurality of glass sheets prior to said stacking.
22. The system of claim 1, wherein the system is further configured
to: clean the plurality of foil sheets prior to said stacking.
23. An apparatus for making glass dielectric capacitors,
comprising: means for providing a plurality of foil sheets of 4
micrometers to 25 micrometers thickness; means for cutting each of
the plurality of foil sheets with a laser beam by melting each of
the plurality of foil sheets; means for forming a respective smooth
foil edge on each of said plurality of foil sheets during the
cutting; means for providing a plurality of glass sheets; and means
for stacking the plurality of foil sheets in alternating layers
with the plurality of glass sheets.
24. The apparatus of claim 23, wherein: said stacking comprises
stacking two or more of said plurality of foil sheets between
alternating layers of the plurality of glass sheets.
25. The apparatus of claim 23, further comprising: means for
depositing a metalized layer on both sides of each one of the
plurality of glass sheets prior to said stacking of said plurality
of foil sheets in alternating layers with said plurality of glass
sheets.
26. The apparatus of claim 25, wherein: said depositing of said
metalized layer comprises depositing said metalized layer on an
area of each of said plurality of glass sheets that extends beyond
an area of each of said plurality of glass sheets juxtaposed
respectively to one of said plurality of foil sheets.
27. The apparatus of claim 26, wherein: said stacking comprises
stacking said plurality of foil sheets in alternating layers with
the plurality of glass sheets with said plurality of foil sheets
extending out beyond a respective edge of each of said plurality of
glass sheets, wherein an extended portion of each of said plurality
of foil sheets allows for attachment of a terminal.
28. The apparatus of claim 23, wherein: said stacking comprises
stacking said plurality of foil sheets in alternating layers with
said plurality of glass sheets with said plurality of glass sheets
offset from one another.
29. The apparatus of claim 28, further comprising: means for
depositing metal on a side of the plurality of glass sheets having
been stacked.
30. The apparatus of claim 28, further comprising: means for
depositing electrically conductive epoxy on a side of the plurality
of glass sheets having been stacked.
31. The apparatus of claim 28, further comprising: means for
depositing a conductive layer on a side of the plurality of glass
sheets having been stacked.
32. The apparatus of claim 31, further comprising: means for
coupling a terminal to said conductive layer.
33. The apparatus of claim 32, further comprising: means for
submerging the glass sheets having been stacked in an electrical
insulating liquid.
34. The apparatus of claim 33, wherein: said submerging comprises
submerging under vacuum.
35. The apparatus of claim 33, wherein: said submerging comprises
submerging said glass sheets having been stacked in a liquid
selected from the group of liquids comprising: silicone fluid,
mineral oil, synthetic ester, vegetable oil, rapeseed oil, aromatic
insulating fluid (such as biphenyls) and combinations thereof.
36. The apparatus of claim 23, further comprising: means for
applying a voltage across separate ones of said plurality of foil
sheets.
37. The apparatus of claim 36, further comprising: means for
applying said voltage across said separate ones of said plurality
of foil sheets by pulsing said voltage.
38. The apparatus of claim 36, further comprising: means for
applying said voltage under vacuum.
39. The apparatus of claim 23, further comprising: means for
coating each of said plurality of glass sheets with polymer coating
prior to said stacking.
40. The apparatus of claim 23, further comprising: means for
coating each of said plurality of glass sheets with inorganic
ceramic coating prior to said stacking.
41. The apparatus of claim 23, further comprising: means for plasma
cleaning the plurality of glass sheets and the plurality of foil
sheets having been stacked.
42. The apparatus of claim 23, further comprising: means for
placing into a vacuum furnace the plurality of glass sheets and the
plurality of foil sheets having been stacked.
43. The apparatus of claim 23, further comprising: means for
cleaning the plurality of glass sheets prior to said stacking.
44. The apparatus of claim 23, further comprising: means for
cleaning the plurality of foil sheets prior to said stacking.
Description
[0001] This application is a divisional of U.S. application Ser.
No. 15/851,658, filed Dec. 21, 2017, for GLASS DIELECTRIC
CAPACITORS AND MANUFACTURING PROCESSES FOR GLASS DIELECTRIC
CAPACITORS, which is incorporated in its entirety herein by
reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention relates generally to making dielectric
capacitors, and more specifically to making glass dielectric
capacitors using sheets of glass, foil, hybrid metalized glass, or
combinations thereof.
2. Discussion of the Related Art
[0003] Various systems and processes are known in the art for
making glass dielectric capacitors. A capacitor is an electrical
component that stores energy in an electric field. In some
examples, capacitors may contain two or more electrical conductors
mechanically separated by a dielectric to prevent the conductors
from contacting. These conductors may be in the form of metal
plates or sheets. As charge moves through a circuit containing a
capacitor and a voltage source, electrons accumulate on one of the
sheets. Capacitors may be used to store energy, to create a pulse
of energy, to smooth current, to couple or decouple signals, and
for other purposes.
[0004] Dielectric material may be used to separate the conductors
in a capacitor. Dielectric materials include glass, ceramic,
polymers, paper, mica, or oxides. The type of material used may
affect properties of the capacitor, including its capacity for
charge (capacitance), the amount of voltage that may be applied
before failing, and the operating temperature of the capacitor.
[0005] A capacitor may fail once it can no longer hold a charge,
which may happen when its dielectric becomes conductive (e.g., at a
certain temperature), or after degradation of the material.
Specifically, in some cases capacitors may generate high
temperatures under continuous operation. This may make them
unsuitable for some continuous high voltage operations.
SUMMARY
[0006] Methods for making glass dielectric capacitors are
described. In a first example of a stacked glass/foil capacitor,
individual foil sheets may alternate with glass sheets. The glass
sheets may have a thickness of from between 4 .mu.m and 100 .mu.m.
In a second example of a stacked glass/foil capacitor, glass sheets
may alternate with two foil sheets. In a stacked glass/foil
capacitor, a voltage may be applied to the capacitor to permanently
adhere the foil sheets to each glass sheet. In a stacked metalized
glass capacitor, a metal layer (e.g., gold or gallium) may be
deposited on both sides of a glass sheet to form a hybrid metalized
glass sheet. In a stacked hybrid electrode capacitor, hybrid
metalized glass sheets may be alternated with one or more foil
sheets to form the capacitor.
[0007] In one embodiment, a method may include providing a
plurality of foil sheets of 4 micrometers to 25 micrometers
thickness, cutting each of the plurality of foil sheets with a
laser beam by melting each of the plurality of foil sheets, forming
a respective smooth foil edge on each of said plurality of foil
sheets during the cutting, providing a plurality of glass sheets,
and stacking the plurality of foil sheets in alternating layers
with the plurality of glass sheets. Alternatively, or in addition,
the foil electrodes may be cut, for example, by die cutting or
blade cutting (such as cutting with the razor blade). The foil
sheets may, for example, include aluminum, copper, gold, silver or
combinations thereof.
[0008] In one embodiment, a non-transitory computer-readable medium
may include instructions operable to cause a processor to provide a
plurality of foil sheets of 4 micrometers to 25 micrometers
thickness, cut each of the plurality of foil sheets with a laser
beam by melting each of the plurality of foil sheets, form a
respective smooth foil edge on each of said plurality of foil
sheets during the cutting, provide a plurality of glass sheets, and
stack the plurality of foil sheets in alternating layers with the
plurality of glass sheets.
[0009] In one embodiment, a system may include one or more
components configured to provide a plurality of foil sheets of 4
micrometers to 25 micrometers thickness, cut each of the plurality
of foil sheets with a laser beam by melting each of the plurality
of foil sheets, form a respective smooth foil edge on each of said
plurality of foil sheets during the cutting, provide a plurality of
glass sheets, and stack the plurality of foil sheets in alternating
layers with the plurality of glass sheets.
[0010] In one embodiment, an apparatus may include means for
providing a plurality of foil sheets of 4 micrometers to 25
micrometers thickness, means for cutting each of the plurality of
foil sheets with a laser beam by melting each of the plurality of
foil sheets, means for forming a respective smooth foil edge on
each of said plurality of foil sheets during the cutting, means for
providing a plurality of glass sheets, and means for stacking the
plurality of foil sheets in alternating layers with the plurality
of glass sheets.
[0011] In some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above,
said stacking comprises stacking two or more of said plurality of
foil sheets between alternating layers of the plurality of glass
sheets.
[0012] Some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above may
further include processes, features, means, or instructions for
depositing a metalized layer on both sides of each one of the
plurality of glass sheets prior to said stacking of said plurality
of foil sheets in alternating layers with said plurality of glass
sheets. In some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above,
said depositing of said metalized layer comprises depositing said
metalized layer on an area of each of said plurality of glass
sheets that extends beyond an area of each of said plurality of
glass sheets juxtaposed respectively to one of said plurality of
foil sheets.
[0013] In some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above,
said stacking comprises stacking said plurality of foil sheets in
alternating layers with the plurality of glass sheets with said
plurality of foil sheets extending out beyond a respective edge of
each of said plurality of glass sheets, wherein an extended portion
of each of said plurality of foil sheets allows for attachment of a
terminal.
[0014] In some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above,
said stacking comprises stacking said plurality of foil sheets in
alternating layers with said plurality of glass sheets offset from
one another.
[0015] Some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above may
further include processes, features, means, or instructions for
depositing metal on a side of the plurality of glass sheets.
[0016] Some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above may
further include processes, features, means, or instructions for
depositing electrically conductive epoxy on a side of the plurality
of glass sheets.
[0017] Some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above may
further include processes, features, means, or instructions for
depositing a conductive layer on a side of the plurality of glass
sheets. For example, the electrically conductive layer may be a
conductive metal deposited onto the sides of the glass sheets using
an arc spray or cold spray procedure.
[0018] Some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above may
further include processes, features, means, or instructions for
coupling a terminal to said conductive layer.
[0019] Some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above may
further include processes, features, means, or instructions for
submerging the glass sheets having been stacked in an electrical
insulating liquid.
[0020] In some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above,
said submerging comprises submerging under vacuum.
[0021] In some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above,
said submerging comprises submerging said glass sheets having been
stacked in a liquid selected from the group of liquids comprising:
silicone fluid, mineral oil, synthetic ester, vegetable oil,
rapeseed oil, aromatic insulating fluid (such as biphenyls) and
combinations thereof.
[0022] Some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above may
further include processes, features, means, or instructions for
applying a voltage across separate ones of said plurality of foil
sheets.
[0023] Some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above may
further include processes, features, means, or instructions for
applying said voltage across said separate ones of said plurality
of foil sheets by pulsing said voltage.
[0024] Some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above may
further include processes, features, means, or instructions for
applying said voltage under vacuum.
[0025] Some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above may
further include processes, features, means, or instructions for
coating each of said plurality of glass sheets with polymer coating
prior to said stacking.
[0026] Some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above may
further include processes, features, means, or instructions for
coating each of said plurality of glass sheets with inorganic
ceramic coating prior to said stacking.
[0027] Some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above may
further include processes, features, means, or instructions for
plasma cleaning the plurality of glass sheets and the plurality of
foil sheets.
[0028] Some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above may
further include processes, features, means, or instructions for
placing into a vacuum furnace the plurality of glass sheets and the
plurality of foil sheets.
[0029] Some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above may
further include processes, features, means, or instructions for
cleaning the plurality of glass sheets prior to said stacking.
[0030] Some examples of the method, non-transitory
computer-readable medium, system, and apparatus described above may
further include processes, features, means, or instructions for
cleaning the plurality of foil sheets prior to said stacking.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 shows a diagram of a stacked glass/foil
capacitor.
[0032] FIG. 2 shows a diagram of a stacked metalized glass
capacitor.
[0033] FIG. 3 shows a diagram of a stacked hybrid electrode
capacitor.
[0034] FIGS. 4 through 5 show diagrams of a capacitor manufacturing
system that supports making glass dielectric capacitors using
sheets of glass, foil, hybrid metalized glass, or combinations
thereof in accordance with aspects of the present disclosure.
[0035] FIGS. 6 through 13 show flowcharts of a process for making
glass dielectric capacitors using sheets of glass, foil, hybrid
metalized glass, or combinations thereof in accordance with aspects
of the present disclosure.
DETAILED DESCRIPTION
[0036] The following description is not to be taken in a limiting
sense, but is made merely for the purpose of describing the general
principles of exemplary embodiments. The scope of the invention
should be determined with reference to the claims.
[0037] Reference throughout this specification to "one embodiment,"
"an embodiment," or similar language means that a particular
feature, structure, or characteristic described in connection with
the embodiment is included in at least one embodiment of the
present invention. Thus, appearances of the phrases "in one
embodiment," "in an embodiment," and similar language throughout
this specification may, but do not necessarily, all refer to the
same embodiment.
[0038] Furthermore, the described features, structures, or
characteristics of the invention may be combined in any suitable
manner in one or more embodiments. In the following description,
numerous specific details are provided, such as examples of
programming, software modules, user selections, network
transactions, database queries, database structures, hardware
modules, hardware circuits, hardware chips, etc., to provide a
thorough understanding of embodiments of the invention. One skilled
in the relevant art will recognize, however, that the invention can
be practiced without one or more of the specific details, or with
other methods, components, materials, and so forth. In other
instances, well-known structures, materials, or operations are not
shown or described in detail to avoid obscuring aspects of the
invention.
[0039] In some cases, capacitors may generate high temperatures
under continuous operation. For example, continuous operation of
high voltage or high energy density capacitors may generate
temperatures that exceed 150.degree. C. The temperature limits of
the capacitor may depend on the type of dielectric material used.
Polymer/foil capacitors may break down at temperatures as low as
80.degree. C.-100.degree. C. This may make them unsuitable for some
continuous high voltage operations. Glass dielectric capacitors may
be used for high temperature applications. For example, glass
dielectric capacitors may survive temperatures up to 400.degree.
C.
[0040] Glass coatings may increase the mechanical strength of a
glass dielectric capacitor. For example, the glass may be dipped in
a cyanoresin polymer solution and dried (e.g., at 100.degree. C.).
In another example, the glass may be metalized. An inorganic
ceramic coating may increase mechanical strength and resistance to
breakdown (i.e., through the blocking of charge injection).
[0041] Additionally, or alternatively, an insulating inorganic
coating applied over the outside edge of the metalized electrode
may increase flashover resistance and breakdown strength by
blocking charge movement in certain areas. Plasma treatment may
also increase glass capacitor breakdown strength. In one example, a
glass capacitor with either tin or lead foil is placed in a plasma
cleaner with CF4 gas. When a plasma is formed from the gas,
compounds may accumulate on the edge of the electrode which may
increase the breakdown strength. The compounds may also prevent
charge emission from the electrode edge.
[0042] Irregularities such as asperities on the edge of a foil
sheet or particulate contamination may contribute to dielectric
breakdown. In some examples, foil sheets may be cut with a laser to
produce a smooth edge and reduce asperities. Capacitors may also be
cleaned to remove particulate contamination. For example,
capacitors may be cleaned using an ultrasonic cleaning procedure.
In another example, particles may be blown off the glass using
compressed nitrogen. In yet another example, the particles may be
debrided from the surface of the glass using pressurized CO2 ice.
In yet another example, surfaces of the capacitor may be wiped with
a solvent-wetted cloth. To clean the foil component, the capacitor
may be wiped with a solvent on a smooth sheet of metal or glass.
This may also smooth out any wrinkles in the foil that may cause
air bubbles or breakdown sites.
[0043] Referring to FIG. 1, shown is a diagram 100 of a stacked
glass/foil capacitor 105. In some examples, stacked glass/foil
capacitor 105 may include glass sheets 110 and foil sheets 115.
Foil sheet 115 may be made of aluminum, lead, tin or any other
suitable metal, and incorporate aspects of foil sheet 315 as
described with reference to FIG. 3.
[0044] In a first example (not shown) of a stacked glass/foil
capacitor 105, individual foil sheets 115 may alternate with glass
sheets 110. In this example, the foil sheets 115 may become
electrostatically stuck to one of the adjacent glass sheets 110,
which may cause capacitance to vary significantly.
[0045] In a second example (as illustrated) of a stacked glass/foil
capacitor 105, glass sheets 110 may be alternated with two foil
sheets 115. In this example, each foil sheet 115 is adjacent to
(and thus, may adhere to) a single glass sheet 110. This may
significantly improve capacitance or reduce variation in
capacitance between layers.
[0046] In a stacked glass/foil capacitor 105, a voltage may be
applied to the capacitor to permanently adhere the foil sheets 115
to each glass sheet 110. For example, a 4. 5 kV rated glass
capacitor may be treated with a constant voltage of 2 kV for 30
minutes, or a pulsed 2. 5 kV at 50 Hz. In some cases, the voltage
may result in the growth of a high permittivity metal oxide coating
on the edge of the electrode. This may passivate asperities on the
foil edge, which may prevent breakdown.
[0047] The voltage treatment may be applied under vacuum to ensure
all air bubbles are removed between the foil sheet 115 and the
glass sheet 110. Optionally, the voltage treated stacked glass/foil
capacitor 105 may then be placed in a vacuum and submerged in an
electrical insulating liquid to fill any gaps between the glass
sheet 110 and foil sheets 115. The electrical insulating liquid may
be silicone oil, mineral oil, rapeseed oil, or another capacitor
impregnant. In some examples, fluorinated liquids (e.g., Fluorinert
or Novec) may be used.
[0048] The capacitor may then be sealed hermetically to preserve
the impregnation process. This process may be performed on double
foil glass capacitors that have undergone voltage treatment, to
prevent impregnation material from getting in between the foil and
glass. The impregnation process may increase the breakdown strength
of the capacitor.
[0049] In another example, thermal bonding may be used on the
stacked glass/foil capacitor 105, and may remove the need for an
impregnant between the layers. A capacitor stack may be placed in a
vacuum furnace and heated to beyond its glass transition
temperature. The glass layers would partially melt, slightly fusing
with adjacent layers to create a solid glass capacitor. This
assembly may be cooled very slowly thereafter to prevent mechanical
stress.
[0050] In yet another example, the stacked glass/foil capacitor 105
may be operated in a pressurized gaseous environment. Operation in
this environment may significantly increase the breakdown strength
of a capacitor relative to atmosphere or liquid impregnates. The
pressurized gas prevents charge emission from the electrodes, which
may cause glass capacitors to break down. Suitable gasses may
include sulfur hexafluoride (SF6). The capacitors may be provided
in a case filled with pressurized gas, or used in an environment
that is already pressurized.
[0051] Referring next to FIG. 2, shown is a diagram 200 of a
stacked metalized glass capacitor 205. In some examples, stacked
metalized glass capacitor 205 may include stacked hybrid metalized
glass sheets 210. Hybrid metalized glass sheets 210 may incorporate
aspects of hybrid metalized glass sheet 310 as described with
reference to FIG. 3.
[0052] In a stacked metalized glass capacitor 205, a metal layer
(e.g., gold or gallium) may be deposited on both sides of a glass
sheet to form a hybrid metalized glass sheet 210. The metal layer
may be formed with a thickness of greater than 500 nm. In some
cases, hybrid metalized glass sheets 210 may be stacked without
foil sheets (as described with reference to FIG. 3). In some cases,
the hybrid metalized glass sheets 210 may be offset laterally.
[0053] Conductive material may be deposited on the edges of the
glass sheets to electrically connect the layers (e.g., using a
flame spray, a cold spray or sputter procedure). In some cases,
terminals may be soldered or adhered to the conductive material
using electrically conductive epoxy or adhesive. The solder process
may include a solder preform, which is a piece of material wetting
the metal layer on the glass sheet when the assembly is heated.
Gallium may be an example of a material suitable for wetting the
glass (and hence, may be used for the solder preform).
[0054] Referring to FIG. 3, shown is a diagram 300 of a stacked
hybrid electrode capacitor 305. In some examples, the stacked
hybrid electrode capacitor 305 may include hybrid metalized glass
sheets 310 stacked with foil sheets 315. The hybrid metalized glass
sheet 310 may incorporate aspects of the hybrid metalized glass
sheet 210 as described with reference to FIG. 2. The foil sheet 315
may incorporate aspects of foil sheet 115 as described with
reference to FIG. 1.
[0055] In a stacked hybrid electrode capacitor 305, hybrid
metalized glass sheets 310 may be alternated with one or more foil
sheets 315 to form the capacitor. In some cases, the foil sheets
315 may extend out of the capacitor to allow attachment of
terminals. In some cases, a stacked hybrid electrode capacitor 305
may be voltage treated as described above.
[0056] Referring to FIG. 4, shown is a diagram 400 of a capacitor
manufacturing system 405 that supports making glass dielectric
capacitors using sheets of glass, foil, hybrid metalized glass, or
combinations thereof in accordance with aspects of the present
disclosure.
[0057] Capacitor manufacturing system 405 may incorporate aspects
of the capacitor manufacturing system 505 as described with
reference to FIG. 5. In some examples, the capacitor manufacturing
system 405 may include a foil sheet component 410, a laser foil
cutter 415, a glass sheet component 420, and a stacking component
425.
[0058] The foil sheet component 410 may provide a plurality of foil
sheets (e.g., of 4 micrometers to 25 micrometers thickness). The
foil sheet component 410 may incorporate aspects of the foil sheet
component 510 as described with reference to FIG. 5.
[0059] The laser foil cutter 415 may cut each of the plurality of
foil sheets with a laser beam by melting each of the plurality of
foil sheets, thereby forming a respective smooth foil edge on each
of the plurality of foil sheets during the cutting. The laser foil
cutter 415 may incorporate aspects of the laser foil cutter 515 as
described with reference to FIG. 5. Alternatively, or in addition,
some or all of the plurality of foil sheets may be cut by die
cutting or blade cutting (such as with a razor blade).
[0060] The glass sheet component 420 may provide a plurality of
glass sheets (which may be metalized glass sheets as described
above). The glass sheet component 420 may incorporate aspects of
the glass sheet component 520 as described with reference to FIG.
5.
[0061] The stacking component 425 may stack the plurality of foil
sheets in alternating layers with the plurality of glass sheets.
The stacking component 425 may also stack metalized glass sheets
without foil sheets between them. The stacking component 425 may
incorporate aspects of the stacking component 525 as described with
reference to FIG. 5.
[0062] In some cases, the stacking comprises stacking two or more
of the plurality of foil sheets between alternating layers of the
plurality of glass sheets. In some cases, the stacking comprises
stacking the plurality of foil sheets in alternating layers with
the plurality of glass sheets with the plurality of foil sheets
extending out beyond a respective edge of each of the plurality of
glass sheets, wherein an extended portion of each of the plurality
of foil sheets allows for attachment of a terminal. In some cases,
the stacking comprises stacking the plurality of foil sheets in
alternating layers with the plurality of glass sheets with the
plurality of glass sheets offset from one another.
[0063] Referring to FIG. 5, shown is a diagram 500 of a capacitor
manufacturing system 505 that supports making a glass dielectric
capacitor using sheets of glass, foil, hybrid metalized glass, or
combinations thereof in accordance with aspects of the present
disclosure.
[0064] The capacitor manufacturing system 505 may incorporate
aspects of the capacitor manufacturing system 405 as described with
reference to FIG. 4. In some examples, the capacitor manufacturing
system 505 may include: a foil sheet component 510, a laser foil
cutter 515, a glass sheet component 520, and a stacking component
525. Optionally, the capacitor manufacturing system 505 may also
include a depositing component 530, a coupling component 535, a
submerging apparatus 540, a coating component 545, a cleaning
component 550, a vacuum furnace 555, and a voltage application
component 560.
[0065] The foil sheet component 510 may provide a plurality of foil
sheets. The foil sheet component 510 may incorporate aspects of the
foil sheet component 410 as described with reference to FIG. 4.
[0066] The laser foil cutter 515 may cut each of the plurality of
foil sheets with a laser beam. The laser foil cutter 515 may
incorporate aspects of the laser foil cutter 415 as described with
reference to FIG. 4.
[0067] The glass sheet component 520 may provide a plurality of
glass sheets. The glass sheet component 520 may incorporate aspects
of the glass sheet component 420 as described with reference to
FIG. 4.
[0068] The stacking component 525 may stack the plurality of foil
sheets in alternating layers with the plurality of glass sheets.
The stacking component 525 may incorporate aspects of stacking
component 425 as described with reference to FIG. 4.
[0069] The depositing component 530 may deposit a metalized layer
on both sides of each one of the plurality of glass sheets prior to
the stacking of the plurality of foil sheets in alternating layers
with the plurality of glass sheets; deposit metal on a side of the
plurality of glass sheets having been stacked; deposit electrically
conductive epoxy on a side of the plurality of glass sheets having
been stacked; and deposit a conductive layer on a side of the
plurality of glass sheets having been stacked.
[0070] In some cases, the depositing of the metalized layer
comprises depositing the metalized layer on an area of each of the
plurality of glass sheets that extends beyond an area of each of
the plurality of glass sheets juxtaposed respectively to one of the
plurality of foil sheets.
[0071] The coupling component 535 may couple a terminal to the
conductive layer.
[0072] The submerging apparatus 540 may submerge the glass sheets
having been stacked in an electrical insulating liquid. In some
cases, the submerging comprises submerging under vacuum. In some
cases, the submerging comprises submerging the glass sheets having
been stacked in a liquid selected from the group of liquids
comprising: silicone fluid, mineral oil, synthetic ester, vegetable
oil, rapeseed oil, aromatic insulating fluid (such as biphenyls)
and combinations thereof.
[0073] The coating component 545 may coat each of the plurality of
glass sheets with polymer coating prior to the stacking and coat
each of the plurality of glass sheets with inorganic ceramic
coating prior to the stacking.
[0074] The cleaning component 550 may plasma clean the plurality of
glass sheets and the plurality of foil sheets having been stacked
or prior to the stacking. In some cases the cleaning comprises
plasma cleaning.
[0075] The vacuum furnace 555 may be used to burn away undesired
material or particles from a stacked glass capacitor. For example,
the capacitor manufacturing system 505 may place into a vacuum
furnace 555 the plurality of glass sheets and the plurality of foil
sheets before or after the stacking.
[0076] The voltage application component 560 may apply a voltage
across separate ones of the plurality of foil sheets. The voltage
may be pulsed or applied under vacuum, or both.
[0077] Referring to FIG. 6, shown is a flowchart 600 of a process
for making glass dielectric capacitors using sheets of glass, foil,
hybrid metalized glass, or combinations thereof in accordance with
aspects of the present disclosure. In some examples, a capacitor
manufacturing system may execute a set of codes to control
functional elements of the system that perform the described
functions. Additionally, or alternatively, a capacitor
manufacturing system may use special-purpose hardware.
[0078] At block 605 the capacitor manufacturing system may provide
a plurality of foil sheets of 4 micrometers to 25 micrometers
thickness. These operations may be performed according to the
methods and processes described in accordance with aspects of the
present disclosure. For example, the operations may be composed of
various substeps, or may be performed in conjunction with other
operations described herein. In certain examples, aspects of the
described operations may be performed by the foil sheet component
410 and 510 as described with reference to FIGS. 4 and 5.
[0079] At block 610 the capacitor manufacturing system may cut each
of the plurality of foil sheets with a laser beam by melting each
of the plurality of foil sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the laser
foil cutter 415 and 515 as described with reference to FIGS. 4 and
5.
[0080] At block 615 the capacitor manufacturing system may form a
respective smooth foil edge on each of the plurality of foil sheets
during the cutting. These operations may be performed according to
the methods and processes described in accordance with aspects of
the present disclosure. For example, the operations may be composed
of various substeps, or may be performed in conjunction with other
operations described herein. In certain examples, aspects of the
described operations may be performed by the laser foil cutter 415
and 515 as described with reference to FIGS. 4 and 5.
[0081] At block 620 the capacitor manufacturing system may provide
a plurality of glass sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the glass
sheet component 420 and 520 as described with reference to FIGS. 4
and 5.
[0082] At block 625 the capacitor manufacturing system may stack
the plurality of foil sheets in alternating layers with the
plurality of glass sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the
stacking component 425 and 525 as described with reference to FIGS.
4 and 5.
[0083] Referring to FIG. 7, shows a flowchart 700 of a process for
making glass dielectric capacitors using sheets of glass, foil,
hybrid metalized glass, or combinations thereof in accordance with
aspects of the present disclosure. In some examples, a capacitor
manufacturing system may execute a set of codes to control
functional elements of the system that perform the described
functions. Additionally, or alternatively, a capacitor
manufacturing system may use special-purpose hardware.
[0084] At block 705 the capacitor manufacturing system may provide
a plurality of foil sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the foil
sheet component 410 and 510 as described with reference to FIGS. 4
and 5.
[0085] At block 710 the capacitor manufacturing system may cut each
of the plurality of foil sheets with a laser beam. These operations
may be performed according to the methods and processes described
in accordance with aspects of the present disclosure. For example,
the operations may be composed of various substeps, or may be
performed in conjunction with other operations described herein. In
certain examples, aspects of the described operations may be
performed by the laser foil cutter 415 and 515 as described with
reference to FIGS. 4 and 5.
[0086] At block 715 the capacitor manufacturing system may form a
respective smooth foil edge on each of the plurality of foil
sheets. These operations may be performed according to the methods
and processes described in accordance with aspects of the present
disclosure. For example, the operations may be composed of various
substeps, or may be performed in conjunction with other operations
described herein. In certain examples, aspects of the described
operations may be performed by the laser foil cutter 415 and 515 as
described with reference to FIGS. 4 and 5.
[0087] At block 720 the capacitor manufacturing system may provide
a plurality of glass sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the glass
sheet component 420 and 520 as described with reference to FIGS. 4
and 5.
[0088] At block 725 the capacitor manufacturing system may deposit
a metalized layer on both sides of each one of the plurality of
glass sheets. These operations may be performed according to the
methods and processes described in accordance with aspects of the
present disclosure. For example, the operations may be composed of
various substeps, or may be performed in conjunction with other
operations described herein. In certain examples, aspects of the
described operations may be performed by the depositing component
530 as described with reference to FIG. 5.
[0089] At block 730 the capacitor manufacturing system may stack
the plurality of foil sheets in alternating layers with the
plurality of glass sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the
stacking component 425 and 525 as described with reference to FIGS.
4 and 5.
[0090] Referring to FIG. 8, shown is a flowchart 800 of a process
for making glass dielectric capacitors using sheets of glass, foil,
hybrid metalized glass, or combinations thereof in accordance with
aspects of the present disclosure. In some examples, a capacitor
manufacturing system may execute a set of codes to control
functional elements of the system that perform the described
functions. Additionally, or alternatively, a capacitor
manufacturing system may use special-purpose hardware.
[0091] At block 820 the capacitor manufacturing system may provide
a plurality of glass sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the glass
sheet component 420 and 520 as described with reference to FIGS. 4
and 5.
[0092] At block 825 the capacitor manufacturing system may deposit
a metalized layer on both sides of each one of the plurality of
glass sheets. These operations may be performed according to the
methods and processes described in accordance with aspects of the
present disclosure. For example, the operations may be composed of
various substeps, or may be performed in conjunction with other
operations described herein. In certain examples, aspects of the
described operations may be performed by the depositing component
530 as described with reference to FIG. 5.
[0093] At block 827 the capacitor manufacturing system may stack
the plurality glass sheets with the plurality of glass sheets
offset from one another. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the
stacking component 425 and 525 as described with reference to FIGS.
4 and 5.
[0094] At block 830 the capacitor manufacturing system may deposit
metal or electrically conductive epoxy on a side of the plurality
of glass sheets. These operations may be performed according to the
methods and processes described in accordance with aspects of the
present disclosure. For example, the operations may be composed of
various substeps, or may be performed in conjunction with other
operations described herein. In certain examples, aspects of the
described operations may be performed by the depositing component
530 as described with reference to FIG. 5.
[0095] In operation, the glass sheets each may be placed into a
fixture that covers only the edges (for example, margins at the
periphery) of the glass sheets. The fixture has a hole in the
middle of the fixture that exposes an area of the surface of the
glass sheet in the desired shape of the metal to be deposited. When
metal is deposited the fixture covers the edges (for example,
margins) so no metal is deposited at the edges (for example,
margins). When the glass is removed from the fixture no metal is
around the edges, so as to prevent shorting of the resulting
capacitor.
[0096] Referring to FIG. 9, shown is a flowchart 900 of a process
for making glass dielectric capacitors using sheets of glass, foil,
hybrid metalized glass, or combinations thereof in accordance with
aspects of the present disclosure. In some examples, a capacitor
manufacturing system may execute a set of codes to control
functional elements of the system that perform the described
functions. Additionally, or alternatively, a capacitor
manufacturing system may use special-purpose hardware.
[0097] At block 905 the capacitor manufacturing system may provide
a plurality of foil sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the foil
sheet component 410 and 510 as described with reference to FIGS. 4
and 5.
[0098] At block 910 the capacitor manufacturing system may cut each
of the plurality of foil sheets with a laser beam. These operations
may be performed according to the methods and processes described
in accordance with aspects of the present disclosure. For example,
the operations may be composed of various substeps, or may be
performed in conjunction with other operations described herein. In
certain examples, aspects of the described operations may be
performed by the laser foil cutter 415 and 515 as described with
reference to FIGS. 4 and 5.
[0099] At block 915 the capacitor manufacturing system may form a
respective smooth foil edge on each of the plurality of foil
sheets. These operations may be performed according to the methods
and processes described in accordance with aspects of the present
disclosure. For example, the operations may be composed of various
substeps, or may be performed in conjunction with other operations
described herein. In certain examples, aspects of the described
operations may be performed by the laser foil cutter 415 and 515 as
described with reference to FIGS. 4 and 5.
[0100] At block 920 the capacitor manufacturing system may provide
a plurality of glass sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the glass
sheet component 420 and 520 as described with reference to FIGS. 4
and 5.
[0101] At block 925 the capacitor manufacturing system may stack
the plurality of foil sheets in alternating layers with the
plurality of glass sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the
stacking component 425 and 525 as described with reference to FIGS.
4 and 5.
[0102] At block 930 the capacitor manufacturing system may deposit
a metalized layer on both sides of each one of the plurality of
glass sheets. These operations may be performed according to the
methods and processes described in accordance with aspects of the
present disclosure. For example, the operations may be composed of
various substeps, or may be performed in conjunction with other
operations described herein. In certain examples, aspects of the
described operations may be performed by the depositing component
530 as described with reference to FIG. 5.
[0103] At block 945 the capacitor manufacturing system may submerge
the glass sheets having been stacked in an electrical insulating
liquid. These operations may be performed according to the methods
and processes described in accordance with aspects of the present
disclosure. For example, the operations may be composed of various
substeps, or may be performed in conjunction with other operations
described herein. In certain examples, aspects of the described
operations may be performed by the submerging apparatus 540 as
described with reference to FIG. 5.
[0104] Referring to FIG. 10, shown is a flowchart 1000 of a process
for making glass dielectric capacitors using sheets of glass, foil,
hybrid metalized glass, or combinations thereof in accordance with
aspects of the present disclosure. In some examples, a capacitor
manufacturing system may execute a set of codes to control
functional elements of the system that perform the described
functions. Additionally, or alternatively, a capacitor
manufacturing system may use special-purpose hardware.
[0105] At block 1005 the capacitor manufacturing system may provide
a plurality of foil sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the foil
sheet component 410 and 510 as described with reference to FIGS. 4
and 5.
[0106] At block 1010 the capacitor manufacturing system may cut
each of the plurality of foil sheets with a laser beam. These
operations may be performed according to the methods and processes
described in accordance with aspects of the present disclosure. For
example, the operations may be composed of various substeps, or may
be performed in conjunction with other operations described herein.
In certain examples, aspects of the described operations may be
performed by the laser foil cutter 415 and 515 as described with
reference to FIGS. 4 and 5.
[0107] At block 1015 the capacitor manufacturing system may form a
respective smooth foil edge on each of the plurality of foil
sheets. These operations may be performed according to the methods
and processes described in accordance with aspects of the present
disclosure. For example, the operations may be composed of various
substeps, or may be performed in conjunction with other operations
described herein. In certain examples, aspects of the described
operations may be performed by the laser foil cutter 415 and 515 as
described with reference to FIGS. 4 and 5.
[0108] At block 1020 the capacitor manufacturing system may provide
a plurality of glass sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the glass
sheet component 420 and 520 as described with reference to FIGS. 4
and 5.
[0109] At block 1025 the capacitor manufacturing system may stack
the plurality of foil sheets in alternating layers with the
plurality of glass sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the
stacking component 425 and 525 as described with reference to FIGS.
4 and 5.
[0110] At block 1030 the capacitor manufacturing system may apply a
voltage across separate ones of the plurality of foil sheets. These
operations may be performed according to the methods and processes
described in accordance with aspects of the present disclosure. For
example, the operations may be composed of various substeps, or may
be performed in conjunction with other operations described herein.
In certain examples, aspects of the described operations may be
performed by the voltage application component 560 as described
with reference to FIG. 5.
[0111] Referring to FIG. 11, shown is a flowchart 1100 of a process
for making glass dielectric capacitors using sheets of glass, foil,
hybrid metalized glass, or combinations thereof in accordance with
aspects of the present disclosure. In some examples, a capacitor
manufacturing system may execute a set of codes to control
functional elements of the system that performs the described
functions. Additionally, or alternatively, a capacitor
manufacturing system may use special-purpose hardware.
[0112] At block 1105 the capacitor manufacturing system may provide
a plurality of foil sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the foil
sheet component 410 and 510 as described with reference to FIGS. 4
and 5.
[0113] At block 1110 the capacitor manufacturing system may cut
each of the plurality of foil sheets with a laser beam. These
operations may be performed according to the methods and processes
described in accordance with aspects of the present disclosure. For
example, the operations may be composed of various substeps, or may
be performed in conjunction with other operations described herein.
In certain examples, aspects of the described operations may be
performed by the laser foil cutter 415 and 515 as described with
reference to FIGS. 4 and 5.
[0114] At block 1115 the capacitor manufacturing system may form a
respective smooth foil edge on each of the plurality of foil
sheets. These operations may be performed according to the methods
and processes described in accordance with aspects of the present
disclosure. For example, the operations may be composed of various
substeps, or may be performed in conjunction with other operations
described herein. In certain examples, aspects of the described
operations may be performed by the laser foil cutter 415 and 515 as
described with reference to FIGS. 4 and 5.
[0115] At block 1120 the capacitor manufacturing system may provide
a plurality of glass sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the glass
sheet component 420 and 520 as described with reference to FIGS. 4
and 5.
[0116] At block 1125 the capacitor manufacturing system may coat
each of the plurality of glass sheets with a polymer or inorganic
ceramic coating. These operations may be performed according to the
methods and processes described in accordance with aspects of the
present disclosure. For example, the operations may be composed of
various substeps, or may be performed in conjunction with other
operations described herein. In certain examples, aspects of the
described operations may be performed by the coating component 545
as described with reference to FIG. 5.
[0117] At block 1130 the capacitor manufacturing system may stack
the plurality of foil sheets in alternating layers with the
plurality of glass sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the
stacking component 425 and 525 as described with reference to FIGS.
4 and 5.
[0118] Referring to FIG. 12, shown is a flowchart 1200 of a process
for making glass dielectric capacitors using sheets of glass, foil,
hybrid metalized glass, or combinations thereof in accordance with
aspects of the present disclosure. In some examples, a capacitor
manufacturing system may execute a set of codes to control
functional elements of the system that perform the described
functions. Additionally, or alternatively, a capacitor
manufacturing system may use special-purpose hardware.
[0119] At block 1205 the capacitor manufacturing system may provide
a plurality of foil sheets of 4 micrometers to 25 micrometers
thickness. These operations may be performed according to the
methods and processes described in accordance with aspects of the
present disclosure. For example, the operations may be composed of
various substeps, or may be performed in conjunction with other
operations described herein. In certain examples, aspects of the
described operations may be performed by the foil sheet component
410 and 510 as described with reference to FIGS. 4 and 5.
[0120] At block 1210 the capacitor manufacturing system may cut
each of the plurality of foil sheets with a laser beam by melting
each of the plurality of foil sheets. Alternatively, or in
addition, some of all of the foil sheets may be die cut or blade
cut (for example with the razor blade). These operations may be
performed according to the methods and processes described in
accordance with aspects of the present disclosure. For example, the
operations may be composed of various substeps, or may be performed
in conjunction with other operations described herein. In certain
examples, aspects of the described operations may be performed by
the laser foil cutter 415 and 515 as described with reference to
FIGS. 4 and 5.
[0121] At block 1215 the capacitor manufacturing system may form a
respective smooth foil edge on each of the plurality of foil sheets
during the cutting. These operations may be performed according to
the methods and processes described in accordance with aspects of
the present disclosure. For example, the operations may be composed
of various substeps, or may be performed in conjunction with other
operations described herein. In certain examples, aspects of the
described operations may be performed by the laser foil cutter 415
and 515 as described with reference to FIGS. 4 and 5.
[0122] At block 1220 the capacitor manufacturing system may provide
a plurality of glass sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the glass
sheet component 420 and 520 as described with reference to FIGS. 4
and 5.
[0123] At block 1225 the capacitor manufacturing system may stack
the plurality of foil sheets in alternating layers with the
plurality of glass sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the
stacking component 425 and 525 as described with reference to FIGS.
4 and 5.
[0124] At block 1230 the capacitor manufacturing system may place
into a vacuum furnace the plurality of glass sheets and the
plurality of foil sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the vacuum
furnace 555 as described with reference to FIG. 5.
[0125] Referring to FIG. 13, shown is a flowchart 1300 of a process
for making glass dielectric capacitors using sheets of glass, foil,
hybrid metalized glass, or combinations thereof in accordance with
aspects of the present disclosure. In some examples, a capacitor
manufacturing system may execute a set of codes to control
functional elements of the system that perform the described
functions. Additionally, or alternatively, a capacitor
manufacturing system may use special-purpose hardware.
[0126] At block 1305 the capacitor manufacturing system may provide
a plurality of foil sheets of 4 micrometers to 25 micrometers
thickness. These operations may be performed according to the
methods and processes described in accordance with aspects of the
present disclosure. For example, the operations may be composed of
various substeps, or may be performed in conjunction with other
operations described herein. In certain examples, aspects of the
described operations may be performed by the foil sheet component
410 and 510 as described with reference to FIGS. 4 and 5.
[0127] At block 1310 the capacitor manufacturing system may cut
each of the plurality of foil sheets with a laser beam by melting
each of the plurality of foil sheets. These operations may be
performed according to the methods and processes described in
accordance with aspects of the present disclosure. For example, the
operations may be composed of various substeps, or may be performed
in conjunction with other operations described herein. In certain
examples, aspects of the described operations may be performed by
the laser foil cutter 415 and 515 as described with reference to
FIGS. 4 and 5.
[0128] At block 1315 the capacitor manufacturing system may form a
respective smooth foil edge on each of the plurality of foil sheets
during the cutting. These operations may be performed according to
the methods and processes described in accordance with aspects of
the present disclosure. For example, the operations may be composed
of various substeps, or may be performed in conjunction with other
operations described herein. In certain examples, aspects of the
described operations may be performed by the laser foil cutter 415
and 515 as described with reference to FIGS. 4 and 5.
[0129] At block 1320 the capacitor manufacturing system may provide
a plurality of glass sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the glass
sheet component 420 and 520 as described with reference to FIGS. 4
and 5.
[0130] At block 1325 the capacitor manufacturing system may clean
the plurality of glass sheets, the plurality of foil sheets, or
both prior to the stacking. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the
cleaning component 550 as described with reference to FIG. 5.
[0131] At block 1330 the capacitor manufacturing system may stack
the plurality of foil sheets in alternating layers with the
plurality of glass sheets. These operations may be performed
according to the methods and processes described in accordance with
aspects of the present disclosure. For example, the operations may
be composed of various substeps, or may be performed in conjunction
with other operations described herein. In certain examples,
aspects of the described operations may be performed by the
stacking component 425 and 525 as described with reference to FIGS.
4 and 5.
[0132] While the invention herein disclosed has been described by
means of specific embodiments, examples and applications thereof,
numerous modifications and variations could be made thereto by
those skilled in the art without departing from the scope of the
invention set forth in the claims.
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