Abstract:
A method of making a monolithic or essentially monolithic single layer capacitor with high structural strength and capacitance. Sheets of green-state ceramic dielectric material and ceramic/metal composite material are laminated together, diced into individual chips, and fired to sinter the ceramic together. The composite material may contain an amount of metal sufficient to render the composite conductive whereby the composite may be used for one or both electrodes and for mounting the capacitor to the pc board. Alternatively, the composite material may contain an amount of metal insufficient to render the composite conductive but sufficient to act as seed points for an electroplating process wherein the composite is preferentially coated with conductive metal, and the coated composite is mounted to the pc board and the coating provides an electrical connection to an internal electrode. Vertically-oriented surface mountable capacitors and hybrid capacitors are provided.
Abstract:
A monolithic capacitor structure includes at least first and second plates internal to a dielectric body, the plates extending inward from opposed conductive contacts on surfaces of the body, and forming capacitor(s) therebetween. A third plate extends within said body, electrically floating relative to the exterior contacts, and forming a capacitor with the first and second plates, and further forming a capacitor with additional conductive structures connected to the conductive contacts on the body. The resulting array of combined series and parallel capacitors formed by the third plate, in conjunction with the capacitor(s) formed by the first and second plates, provides effective wideband performance in an integrated, cost-effective structure.
Abstract:
A method of fabricating a ceramic tube with electrodes thereon suitable for use as a tubular reaction chamber for a fuel cell. In one embodiment, the method includes wrapping a first electrode material around a mandrel, then wrapping a green ceramic material over the first electrode material, and then wrapping a second electrode material over the green ceramic material. The wrapped layers are laminated together, and then removed from the mandrel and sintered, in either sequence, to produce the laminated ceramic tube having an inner first electrode and an outer second electrode. Alternatively, a first electrode tube is provided in place of the mandrel and around which the green ceramic material is wrapped. The outer second electrode may be produced by wrapping a second electrode material around the green ceramic material, before or after laminating, or by printing the electrode material onto the sintered ceramic tube. The present invention further provides a method of making a ceramic tube in which a sacrificial organic material is first wrapped around the mandrel to a desired thickness prior to wrapping the green ceramic material to increase the green material thickness. During sintering, the organic material is burned away leaving only a laminated ceramic tube, optionally with electrodes thereon.
Abstract:
A multilayer chip capacitor includes electrodes comprised of numerous, closely spaced conductive layers interposed within a dielectric laminate. Adjacent conductive layers are essentially non-overlapping, so that fringe capacitance between opposing electrodes provides substantially all of the capacitance. The conductive layers may be shaped to form a non-planer boundary between electrodes. An additional high frequency integrated capacitor is formed from external electrode plates. The non-planar electrode boundary principle is also applied to discoidal capacitors in the form of a non-concentric electrode boundary.
Abstract:
An interposer connector for connecting an interdigitated capacitor to a substrate having a first track to be electrically connected to first capacitor terminals and an opposed second track to be electrically connected to second capacitor terminals. The interposer connector supports the interdigitated capacitor and has a first electrical conductor electrically connectable to the first track and the first capacitor terminals and a second electrical conductor electrically connectable to the second track substrate and the second capacitor terminals.
Abstract:
A method of manufacturing a furnace setter is disclosed. The method includes placing one or more layers of ceramic tape on a form that has a shape corresponding to a desired shape of the furnace setter. The method further includes applying pressure to the assembly that includes the form and the tape layers. The application of pressure to the assembly compresses the ceramic tape layers together to generate an integrated body having the desired shape of the furnace setter. The method further includes removing the integrated body from the form and applying a heat treatment to the integrated body to generate the furnace setter as a sintered solid body. According to a further embodiment, a furnace setter is disclosed that has a weight to area ratio that is less than 10 g/in2, less than 5 g/in2, less than 3 g/in2, or less than 2 g/in2.
Abstract:
A multilayer ceramic capacitor, having a plurality of electrode layers and a plurality of substantially titanium dioxide dielectric layers, wherein each respective titanium dioxide dielectric layer is substantially free of porosity, wherein each respective substantially titanium dioxide dielectric layer is positioned between two respective electrode layers, wherein each respective substantially titanium dioxide dielectric layer has an average grain size of between about 200 and about 400 nanometers, wherein each respective substantially titanium dioxide dielectric layer has maximum particle size of less than about 500 nanometers. Typically, each respective substantially titanium dioxide dielectric layer further includes at least one dopant selected from the group including P, V, Nb, Ta, Mo, W, and combinations thereof, and the included dopant is typically present in amounts of less than about 0.01 atomic percent.
Abstract:
A multilayer ceramic capacitor, having a plurality of electrode layers and a plurality of substantially titanium dioxide dielectric layers, wherein each respective titanium dioxide dielectric layer is substantially free of porosity, wherein each respective substantially titanium dioxide dielectric layer is positioned between two respective electrode layers, wherein each respective substantially titanium dioxide dielectric layer has an average grain size of between about 200 and about 400 nanometers, wherein each respective substantially titanium dioxide dielectric layer has maximum particle size of less than about 500 nanometers. Typically, each respective substantially titanium dioxide dielectric layer further includes at least one dopant selected from the group including P, V, Nb, Ta, Mo, W, and combinations thereof, and the included dopant is typically present in amounts of less than about 0.01 atomic percent.
Abstract:
A method of fabricating a ceramic tube with electrodes thereon suitable for use as a tubular reaction chamber for a fuel cell. In one embodiment, the method includes wrapping a first electrode material around a mandrel, then wrapping a green ceramic material over the first electrode material, and then wrapping a second electrode material over the green ceramic material. The wrapped layers are laminated together, and then removed from the mandrel and sintered, in either sequence, to produce the laminated ceramic tube having an inner first electrode and an outer second electrode. Alternatively, a first electrode tube is provided in place of the mandrel and around which the green ceramic material is wrapped. The outer second electrode may be produced by wrapping a second electrode material around the green ceramic material, before or after laminating, or by printing the electrode material onto the sintered ceramic tube. The present invention further provides a method of making a ceramic tube in which a sacrificial organic material is first wrapped around the mandrel to a desired thickness prior to wrapping the green ceramic material to increase the green material thickness. During sintering, the organic material is burned away leaving only a laminated ceramic tube, optionally with electrodes thereon.
Abstract:
A high power resistor device and method for making a high power resistor device. A resistor is formed on a first end of a fired, ceramic chip with multiple internal conductor electrodes, and end terminations are then applied to both ends of the chip. A power resistor device having a high power rating is thus provided having buried conductor electrodes electrically connected to end terminations, where the connection at the first end is through the resistor to form a power resistor structured to dissipate heat efficiently. In an alternative method of the present invention, both ends of the chip may be dipped in resistor paste to form resistors on both ends of the chip. In yet another alternative method of the present invention, a conductor under-layer is formed under the resistor, such as by first dipping the end of the chip in a conductor paste and firing the chip.