Capacitor forming method

Abstract

The capacitor forming method utilizes a plurality of metal sheet manipulating rollers and a glass supply, which, in combination, make a metal-glass laminate and glass or devitrifying glass dielectric to form a capacitor. Several embodiments of the method manufacture ferroelectric crystal dielectrics by utilizing heat-treatment and annealing to form and devitrify glass while the glass is in a metal-glass spool or flat form.

1 . A capacitor forming method, comprising the steps of:
 forming a first dielectric sheet from viscous glass material, the first dielectric sheet having a first and a second surface;   rolling a first thin metal foil onto the first surface of the first dielectric sheet while the first dielectric sheet is in a semi-viscous condition;   rolling a second thin metal foil onto the second surface of the first dielectric sheet while the first dielectric sheet is in a semi-viscous condition;   forming a second dielectric sheet from viscous glass material, the second dielectric sheet having a first and a second surface; and   rolling a third thin metal foil into the second dielectric sheet while the second dielectric sheet is in a semi-viscous condition, the third thin metal foil being disposed approximately halfway between the first and the second surfaces of the second dielectric sheet;   cooling the dielectric sheets concurrently with the thin metal foil rolling steps; and   combining the first and the second dielectric sheets, thereby forming a capacitor.   
     
     
         2 . The capacitor forming method according to  claim 1 , further comprising the step of rolling a fourth thin metal foil into said first dielectric sheet while said first dielectric sheet is in a semi-viscous condition, said fourth thin metal foil being disposed approximately half way between said first and said second surfaces of said first dielectric sheet, the fourth thin metal foil being interposed between said first and said second surfaces of said first dielectric sheet, whereby a super capacitor is formed. 
     
     
         3 . The capacitor forming method according to  claim 1 , further comprising the step of rolling said capacitor into a spool. 
     
     
         4 . The capacitor forming method according to  claim 2 , further comprising the step of rolling said super capacitor into a spool. 
     
     
         5 . The capacitor forming method according to  claim 1 , wherein the viscous glass material is a devitrifying glass material. 
     
     
         6 . The capacitor forming method according to  claim 5 , wherein the devitrifying glass material is a ferroelectric material. 
     
     
         7 . A capacitor forming method, comprising the steps of:
 forming first, second, third and fourth dielectric sheets of viscous glass material, each of the sheets having a first and a second surface;   rolling a first thin metal foil onto the first surface of the first dielectric sheet while the first dielectric sheet is in a semi-viscous condition;   rolling a second thin metal foil onto the first surface of the second dielectric sheet while the second dielectric sheet is in a semi-viscous condition;   rolling a third thin metal foil onto the first surface of the third dielectric sheet while the third dielectric sheet is in a semi-viscous condition;   rolling a fourth thin metal foil onto the first surface of the fourth dielectric sheet while the fourth dielectric sheet is in a semi-viscous condition;   combining the first, the second, the, third, and the fourth dielectric sheets, the first dielectric sheet being on a top layer, the fourth dielectric sheet being on a bottom layer;   rolling a fifth thin metal foil onto the second surface of the fourth dielectric sheet while the fourth dielectric sheet is in a semi-viscous condition, thereby forming a five metal foil-glass laminate;   cooling the dielectric sheets concurrently with the thin metal foil rolling steps;   heat-soaking the glass portion of the five metal foil-glass laminate; and   annealing the five metal foil-glass laminate, whereby a super capacitor in a flat configuration is formed.   
     
     
         8 . The capacitor forming method according to  claim 7 , further comprising the step of infusing cooling air directly onto the glass dielectric sheets. 
     
     
         9 . The capacitor forming method according to  claim 7 , wherein a roll dispensing rate of said fifth metal foil is approximately one foot per second. 
     
     
         10 . The capacitor forming method according to  claim 7 , further comprising the step of subjecting said five metal foil-glass laminate to forced air cooling before the start of the devitrification process. 
     
     
         11 . A capacitor forming method, comprising the steps of:
 forming a first dielectric sheet from viscous glass material, the first dielectric sheet having a first and a second surface;   rolling a first thin metal foil onto the first surface of the first dielectric sheet while the first dielectric sheet is in a semi-viscous condition;   rolling a second thin metal foil onto the second surface of the first dielectric sheet while the first dielectric sheet is in a semi-viscous condition;   constraining the first dielectric sheet to a small volume, thereby allowing continuous quenching of the first dielectric sheet when the first dielectric sheet is brought into contact with the first and second thin metal foils; and   heat soaking the first dielectric sheet thereby devitrifying the first dielectric sheet.   
     
     
         12 . The capacitor forming method according to  claim 11 , further comprising the steps of:
 forming a second dielectric sheet from viscous glass material, said second dielectric sheet having a first and a second surface;   rolling a third thin metal foil onto said first surface of said second dielectric sheet while said second dielectric sheet is in a semi-viscous condition;   rolling a fourth thin metal foil onto said second surface of said second dielectric sheet while said second dielectric sheet is in a semi-viscous condition;   constraining said second dielectric sheet to a small volume, thereby allowing continuous quenching of said second dielectric sheet when said second dielectric sheet is brought into contact with said third and fourth thin metal foils;   combining said first dielectric sheet with said second dielectric sheet; and   heat soaking said second dielectric sheet thereby devitrifying said second dielectric sheet.   
     
     
         13 . The capacitor forming method according to  claim 11 , wherein a capacitor is formed in a flat configuration. 
     
     
         14 . The capacitor forming method according to  claim 11 , wherein said quenching of said first dielectric sheet drops a temperature of said first dielectric sheet by approximately 200° C. to 300° C. 
     
     
         15 . The capacitor forming method according to  claim 12 , wherein a plurality of back-to-back capacitors is formed in a flat configuration. 
     
     
         16 . The capacitor forming method according to  claim 12 , wherein said quenching of said second dielectric sheet drops a temperature of said second dielectric sheet by approximately 200° C. to 300° C.