Abstract: A double layer capacitor (DLC) containing at least one double layer capacitor cell is provided. Each double layer capacitor cell contains two current collectors, each containing a metallized carrier film with upper and lower planar surfaces, two thin electrode layers in direct contact with the lower and upper planar surfaces of the metallized carrier films of the first and second current collectors, and a polymer electrolyte layer in direct contact with the first and the second thin electrode layers. The polymer electrolyte is applied as a liquid which impregnates and encases the electrode layers and then solidified to form the electrolyte layer. The resulting DLC is preferably no thicker than about 20 microns, and may be as thin as 5 microns. Methods of producing a DLC and for forming a cross-linked electrolyte are also provided.

Abstract: A double layer capacitor (DLC) containing at least one double layer capacitor cell is provided. Each double layer capacitor cell contains two current collectors, each containing a metallized carrier film with upper and lower planar surfaces, two thin electrode layers in direct contact with the lower and upper planar surfaces of the metallized carrier films of the first and second current collectors, and a polymer electrolyte layer in direct contact with the first and the second thin electrode layers. The polymer electrolyte is applied as a liquid which impregnates and encases the electrode layers and then solidified to form the electrolyte layer. The resulting DLC is preferably no thicker than about 20 microns, and may be as thin as 5 microns. Methods of producing a DLC and for forming a cross-linked electrolyte are also provided.

Abstract: A plastic film capacitor shield wherein the shield is secured to an outer surface of plastic film capacitor. The shield is sufficient to protect the plastic film capacitor from excessive radiant infrared energy during infrared reflow soldering which could damage the plastic film capacitor. The plastic film capacitor shield can be composed of many different materials such as electrical grade tape, electrical grade plastic, metal tape, or epoxy. The shield can be attached to the capacitor in various ways, which includes: securing a shield to an upper surface of the capacitor; having a shield on an upper and lower surface of the capacitor, wrapping and securing a shield to the plastic film capacitor on four sides of the capacitor; securing a shield on all sides of the capacitor; and securing a combination of different shields to the outer surfaces of the capacitor.

Abstract: A capacitor is made from a laminated structure having multiple layers of metallized, dielectric film and having a solderable, metal termination at each of two ends. The metal termination at each of the ends is generally rectangular with a top edge, a bottom edge, and two side edges and is finished so as to have a finished surface, which is characterized by a three-dimensional pattern of ridges having solderable surfaces and grooves having solderable surfaces. The ridges alternate with the grooves and the ridges and the grooves at both of the ends are parallel to the side edges. Thus, the three-dimensional pattern facilitates reflow soldering to the finished surface.

Abstract: A capacitor is made from a laminated structure having multiple layers of metallized dielectric film and having a solderable metal termination at each of two ends. The metal termination at each of the ends is generally rectangular with a top edge, a bottom edge, and two side edges and is finished so as to have a finished surface, which is characterized by a three-dimensional pattern of ridges having solderable surfaces and grooves having solderable surfaces. The ridges alternate with the grooves and the ridges and the grooves at both of the ends are parallel to the side edges. Thus, the three-dimensional pattern facilitates reflow soldering to the finished surface.

Abstract: An improved method for producing spirally wound film-foil or metallized film capacitors. The capacitors are formed by spirally winding alternating layers of dielectric film and metal foil (or two layers of metallized film) around a mandrel to form a cylinder. The dielectric film is oriented, i.e., heated and stretched along one or more axes, prior to winding. The wound cylinder is subjected to infrared radiant energy, which causes the dielectric film to shrink back toward its original unoriented state, thereby forcing air out between the layers of the winding and resulting in a more rigid cylinder. The application of radiant energy enables the cylinder to be heated from the inner turns to the outer turns. This manner of heating enables significant improvements in capacitor properties to be obtained and greatly reduces the time required for the heat shrink operation.