Polymeric monolithic capacitor

Abstract

Prismatic polymer monolithic capacitor structure that includes multiple interleaving radiation-cured polymer dielectric layers and metal layers. Method for fabrication of same. The chemical composition of polymer dielectric and the electrode resistivity parameters are chosen to maximize the capacitor self-healing properties and energy density, and to assure the stability of the capacitance and dissipation factor over the operating temperature range. The termination electrode that extends beyond the active capacitor area and beyond the polymer dielectric layers has a thickness larger than that used industrially to provide resistance to thermomechanical stress. The glass transition temperature of the polymer dielectric is specifically chosen to avoid mechanical relaxation from occurring in the operating temperature range, which prevents high moisture permeation (otherwise increasing a dissipation factor and electrode corrosion) into the structure. The geometry and shape of the capacitor are appropriately controlled to minimize losses when the capacitor is exposed to pulse and alternating currents.

1 . A metallized polymer capacitor formed in the vacuum, the capacitor comprising:
 polymer dielectric layers stacked with metallized electrodes, at least one of said metallized electrodes having
 a first electrode portion in an active capacitor area, and 
 a second electrode portion in a capacitor termination area that extends beyond the active capacitor area and beyond a polymer dielectric layer of the capacitor, 
   wherein said second electrode portion has a sheet resistance that is lower than 1,000 mOhm per square.   
     
     
         2 . The capacitor of  claim 1 , wherein said second thickness corresponds to the sheet resistance value that is lower than 500 mOhm per square. 
     
     
         3 . The capacitor of  claim 1 , wherein a material of said polymer dielectric layer has a chemical structure with a hydrogen-to-carbon ratio of at least 1.0 and an oxygen-to-carbon ratio of at least 0.1. 
     
     
         4 . The capacitor of  claim 1 , wherein the material of said polymer dielectric layer has a glass transition temperature greater than 100° C. 
     
     
         5 . The capacitor of  claim 1 , wherein the first electrode portion in the active area has a sheet resistance value between 10 Ohm/square and 100 Ohm/square 
     
     
         6 . The capacitor of  claim 1 , characterized by a dissipation factor that is smaller than 0.02 at 100° C. 
     
     
         7 . The capacitor of  claim 1 , comprising two or more internal electrical connections configured in series. 
     
     
         8 . The capacitor of  claim 1 , wherein said capacitor has a prismatic shape with transverse dimensions L, W, and H, wherein L represents a first extent of the capacitor along which the capacitor is equipped with said electrical termination, W represents a second extent of the capacitor, and H represents a third extent of the capacitor in a direction in which said polymer dielectric layers and metallized electrodes are stacked, and wherein the ratio of said first extent to said second extent is greater than 1. 
     
     
         9 . The capacitor of  claim 8 , wherein said ratio is greater than 2. 
     
     
         10 . An article of manufacture that includes the capacitor of  claim 1 . 
     
     
         11 . A metallized polymer capacitor formed in the vacuum, the capacitor comprising:
 at least one polymer dielectric layer that has a thickness smaller than one micrometer, and   aluminum-metallized electrodes with a first electrode portion in an active capacitor area and a second electrode portion in a capacitor termination area,   wherein the second electrode portion extends beyond the active capacitor area and beyond a polymer dielectric layer and has a second sheet resistance lower than 1,000 mOhm per square.   
     
     
         12 . The capacitor of  claim 11 , wherein a material of said polymer dielectric layer has a chemical structure with a hydrogen-to-carbon ratio of at least 1.0 and an oxygen-to-carbon ratio of at least 0.1. 
     
     
         13 . The capacitor of  claim 11 , wherein the material of the polymer dielectric layer has a glass transition temperature greater than 100° C. 
     
     
         14 . The capacitor of  claim 11 , that has a dissipation factor with a value smaller than 0.02 at 100° C. 
     
     
         15 . The capacitor of  claim 11 , comprising two or more internal electrical connections configured in series. 
     
     
         16 . The capacitor of  claim 11 , wherein said capacitor has a prismatic shape with transverse dimensions L, W, and H, wherein L represents a first extent of the capacitor along which the capacitor is equipped with said electrical termination, W represents a second extent of the capacitor, and H represents a third extent of the capacitor in a direction in which said polymer dielectric layers and metallized electrodes are stacked, and wherein the ratio of said first extent to said second extent is greater than 1. 
     
     
         17 . The capacitor of  claim 16 , wherein said ratio is greater than 2. 
     
     
         18 . An article of manufacture that includes the capacitor of  claim 11 . 
     
     
         19 . A high-voltage metallized polymer capacitor formed in the vacuum, the capacitor comprising:
 multiple internal sections of the capacitor, said sections electrically-connected in series; and   metallized electrodes in each of the multiple internal sections;   wherein, at least one of said metallized electrodes has a first electrode portion in an active capacitor area of the capacitor and a second electrode portion in a capacitor termination area of the capacitor,   wherein the second electrode portion extends beyond the active capacitor area and beyond the polymer dielectric layer and has a sheet resistance value lower than 1,000 mOhm per square.   
     
     
         20 . An article of manufacture that includes the capacitor of  claim 19 .