Patent ID: 12260997

The same reference numerals refer to the same elements throughout the various Figures.

DETAILED DESCRIPTION

A capacitor10is shown inFIGS.1-3, as well as in other Figures to be described below. The capacitor10is adapted to replace any one of a large number of capacitors. Therefore, a serviceman may carry a capacitor10on a service call and, upon encountering a failed capacitor, the serviceman can utilize the capacitor10to replace the failed capacitor with the capacitor10being connected to provide the same capacitance value or values of the failed capacitor.

The capacitor10has a capacitive element12having a plurality of capacitor sections, each having a capacitance value. The capacitive element12is also shown inFIGS.4and5. In the preferred embodiment described herein, the capacitive element12has six capacitor sections20-25. The capacitive element12is a wound cylindrical element manufactured by extension of the techniques described in my prior U.S. Pat. No. 3,921,041, my U.S. Pat. No. 4,028,595, my U.S. Pat. No. 4,352,145 and my U.S. Pat. No. 5,313,360, incorporated herein by reference. Those patents relate to capacitive elements having two capacitor sections rather than a larger plurality of capacitor sections, such as the six capacitor sections20-25of the capacitive element12. Accordingly, the capacitive element12has a central spool or mandrel28, which has a central opening29. First and second dielectric films, each having a metalized layer on one side thereof, are wound in cylindrical form on the mandrel28with the non-metalized side of one film being in contact with the metalized side of the other. Selected portions of one or both of the metalized layers are removed in order to provide a multiple section capacitive element. Element insulation barriers are inserted into the winding to separate the capacitor sections, the element insulation barriers also assuming a cylindrical configuration. Five element insulation barriers30-34are provided to separate the six capacitor sections20-25, with element insulation barrier30separating capacitor sections20and21, element insulation barrier31separating capacitor sections21and22, element insulation barrier32separating capacitor sections22and23, element insulation barrier33separating capacitor sections23and24, and element insulation barrier34separating capacitor sections24and25.

The element insulation barriers are insulating polymer sheet material, which in the capacitive element12is polypropylene having a thickness of 0.005 inches, wound into the capacitive element12. Thickness of 0.0025 to 0.007 may be used. Other materials may also be used. The barriers each have about 2¾-4 wraps of the polypropylene sheet material, wherein the element insulation barriers have a thickness of about 0.013 to 0.020 inches. The barriers30-34are thicker than used before in capacitors with fewer capacitor sections. The important characteristic of the barriers30-34is that they are able to withstand heat from adjacent soldering without losing integrity of electrical insulation, such that adjacent sections can become bridged.

As is known in the art, the metalized films each have one unmetalized marginal edge, such that the metalized marginal edge of one film is exposed at one end of the wound capacitive element12and the metalized marginal edge of the other film is exposed at the other end of the capacitive element12. With reference toFIGS.3and5, at the lower end of the capacitance element12, the barriers30-34do not extend from the film, and an element common terminal36is established contacting the exposed metalized marginal edges of one metalized film of all the capacitor sections20-25. The element common terminal36is preferably a zinc spray applied onto the end of the capacitive element12.

At the top end of the capacitive element12as depicted inFIGS.3and5, the element insulation barriers30-34extend above the wound metalized film. An individual capacitor element section terminal is provided for each of the capacitive sections20-25, also by applying a zinc or other metallic spray onto the end of the capacitive element12with the zinc being deployed on each of the capacitor sections20-25between and adjacent the element insulation barriers30-34. The element section terminals are identified by numerals40-45. Element section terminal40of capacitor section20extends from the outer-most element insulation barrier30to the outer surface of the capacitive element12, and the element section terminal45of capacitor section25extends from the inner-most element insulation barrier34to the central mandrel28. Element section terminals41-44are respectively deployed on the capacitor sections21-24.

Conductors preferably in the form of six insulated wires50-55each have one of their ends respectively soldered to the element section terminals40-45, as best seen inFIG.5. The thickness of the polypropylene barriers30-34resists any burn-through as a result of the soldering to connect wires50-55to the terminals40-45.

The insulation of the wires50-55is color coded to facilitate identifying which wire is connected to which capacitor section. Wire50connected to element section terminal40of capacitor section20has blue insulation, wire51connected to element section terminal41of capacitor section21has yellow insulation, wire52connected to element section terminal42of capacitor section22has red insulation, wire53connected to element section terminal43of capacitor section23has white insulation, wire54connection to element section terminal44of capacitor section24has white insulation, and wire55connected to element section terminal45of capacitor section25has green insulation. These colors are indicated onFIG.4.

The capacitive element12is further provided with foil strip conductor38, having one end attached to the element common terminal36at37. The foil strip conductor38is coated with insulation, except for the point of attachment37and the distal end39thereof. The conductor50connected to the outer capacitor element section20and its terminal30may also be a foil strip conductor. If desired, foil or wire conductors may be utilized for all connections.

In the capacitive element12used in the capacitor10, the capacitor section20has a value of 25.0 microfarads and the capacitor section21has a capacitance of 20.0 microfarads. The capacitor section22has a capacitance of 10.0 microfarads. The capacitor section23has a capacitance of 5.5 microfarads, but is identified as having a capacitance of 5.0 microfarads for purposes further discussed below. The capacitor section24has a capacitance of 4.5 microfarads but is labeled as having a capacitance of 5 microfarads, again for purposes described below. The capacitor section25has a capacitance of 2.8 microfarads. The capacitor section20with the largest capacitance value also has the most metallic film, and is therefore advantageously located as the outer section or at least one of the three outer sections of the capacitive element12.

The capacitor10also has a case60, best seen inFIGS.1-3, having a cylindrical side wall62, a bottom wall64, and an open top66of side wall62. The case60is formed of aluminum and the cylindrical side wall62has an outside diameter of 2.50 inches. This is a very common diameter for capacitors of this type, wherein the capacitor10will be readily received in the mounting space and with the mounting hardware provided for the capacitor being replaced. Other diameters may, however, be used, and the case may also be plastic or of other suitable material.

The capacitive element12with the wires50-55and the foil strip38are received in the case60with the element common terminal36adjacent the bottom wall64of the case. An insulating bottom cup70is preferably provided for insulating the capacitive element12from the bottom wall64, the bottom cup70having a center post72that is received in the center opening29of the mandrel28, and an up-turned skirt74that embraces the lower side wall of the cylindrical capacitive element12and spaces it from the side wall62of the case60.

An insulating fluid76is provided within the case60, at least partly and preferably substantially surrounding the capacitive element12. The fluid76may be the fluid described in my U.S. Pat. No. 6,014,308, incorporated herein by reference, or one of the other insulating fluids used in the trade, such as polybutene.

The capacitor10also has a pressure interrupter cover assembly80best seen inFIGS.1-3,8-10and24. The cover assembly80includes a deformable circular cover82having an upstanding cylindrical skirt84and a peripheral rim86as best seen inFIGS.9and10. The skirt84fits into the open top66cylindrical side wall62of case60, and the peripheral rim86is crimped to the open top66of the case60to seal the interior of the capacitor10and the fluid76contained therein, as shown inFIGS.1and3.

The pressure interrupter cover assembly80includes seven cover terminals mounted on the deformable cover82. A common cover terminal88is mounted generally centrally on the cover82, and section cover terminals90-95, each respectively corresponding to one of the capacitor sections20-25, are mounted at spaced apart locations surrounding the common cover terminal88. With particular reference toFIGS.1,2,9and10, the section cover terminal91has three upstanding blades98,100and102mounted on the upper end of a terminal post104. Terminal post104has a distal end105, opposite the blades98,100and102. The cover82has an opening106for accommodating the terminal post104, and has a beveled lip107surrounding the opening. A shaped silicone insulator108fits snuggly under the cover in the beveled lip107and the terminal post104passes through the insulator108. On the upper side of the cover, an insulator cup110also surrounds the post104, and the insulator cup110sits atop the silicone insulator108; thus, the terminal91and its terminal post104are well insulated from the cover82. The other cover section terminals92-95are similarly mounted with an insulator cup and a silicone insulator.

The common cover terminal88has four blades120, and a terminal post122that passes through a silicone insulator112. The common cover terminal88mounts cover insulator barrier114that includes an elongated cylindrical center barrier cup116surrounding and extending above the blades120of the common cover terminal88, and six barrier fins118that extend respectively radially outwardly from the elongated center barrier cup116such that they are deployed between adjacent section cover terminals90-95. This provides additional protection against any arcing or bridging contact between adjacent section cover terminals or with the common cover terminal88. Alternatively, the common cover terminal88may be provided with an insulator cup116, preferably extending above blades120but with no separating barrier fins, although the barrier fins118are preferred. The terminal post122extends through an opening in the bottom of the base117of the insulating barrier cup116, and through the silicone insulator112, to a distal end124.

The pressure interrupter cover assembly80has a fiberboard disc126through which the terminal posts122, terminal post104and the terminal posts of the other section cover terminals extend. The disc126may be also fabricated of other suitable material, such as polymers. The terminal posts104,122, etc. are configured as rivets with rivet flanges128for assembly purposes. The terminal posts104,122, etc. are inserted through the disc126, insulators108,112, insulator cups110and barrier cup116, and the cover terminals88,90-95are spot welded to the ends of the rivets opposite the rivet flanges128. Thus, the rivet flanges128secure the cover terminals88,90-95in the cover82, together with the insulator barrier114, insulator cups110and silicone insulators108,112. The fiberboard disc126facilitates this assembly, but may be omitted, if desired. The distal ends of the terminal posts are preferably exposed below the rivet flanges128.

The cover assembly80has a disconnect plate130, perhaps best seen inFIGS.3,9and10. The disconnect plate130is made of a rigid insulating material, such as a phenolic, is spaced below the cover82by a spacer134in the form of a skirt. The disconnect plate130is provided with openings accommodating the distal ends of the terminal posts, such as opening136accommodating the distal end105of terminal post104and opening138accommodating the distal end124of the terminal post122. With particular reference toFIG.9, the disconnect plate130may be provided with raised guides, such as linear guides140and dimple guides142, generally adjacent the openings accommodating the distal ends of terminal posts. These guides are for positioning purposes as discussed below.

In prior capacitors having three or fewer capacitor sections, the conductors between the capacitor sections and the terminal posts were generally foil strips, such as the one used for the common element terminal36of the capacitive element12herein. The foil strips were positioned on a breaker plate over the distal ends of terminal posts, and were welded to the distal ends of the terminal posts. In capacitor10, the distal end39of the foil strip38is connected to the distal end124of terminal post122by welding, as in prior capacitors.

The wires50-55are not well-configured for welding to the distal ends of the terminal posts of the cover section terminals. However, the wires50-55are desirable in place of foil strips because they are better accommodated in the case60and have good insulating properties, resist nicking and are readily available with colored insulations. In order to make the necessary connection of the wires50-55to their respective terminal posts, foil tabs56are welded to each of the distal ends of the terminal posts of the section cover terminals90-95, and the guides140,142are helpful in positioning the foil tabs56for the welding procedure. The attachment may be accomplished by welding the distal end of a foil strip to the terminal post, and then cutting the foil strip to leave the foil tab56. Thereafter, and as best seen inFIGS.6,7and10, the conductor58of wire50is soldered to the tab56, by solder57. The insulation59of wire50has been stripped to expose the conductor58. The other wires51-55are similarly connected to their respective cover section terminals. Alternatively, the foil tabs may be soldered to the wires and the tabs may then be welded to the terminal posts, if desired, or other conductive attachment may be employed.

Accordingly, each of the capacitor sections20-25is connected to a corresponding section cover terminal90-95by a respective one of color coded wires50-55. The insulator cups110associated with each of the section cover terminals90-95are also color coded, using the same color scheme as used in the wires50-55. This facilitates assembly, in that each capacitor section and its wire conductor are readily associated with the correct corresponding section cover terminal, so that the correct capacitor sections can be identified on the cover to make the desired connections for establishing a selected capacitance value.

The connections of the wires50-55and the foil38to the terminal posts are made prior to placing the capacitive element12in the case60, adding the insulating fluid76, and sealing the cover82of cover assembly80to the case60. The case60may be labeled with the capacitance values of the capacitance sections20-25adjacent the cover terminals, such as on the side of case60near the cover82or on the cover82.

The capacitor10may be used to replace a failed capacitor of any one of over two hundred different capacitance values, including both single and dual applications. Therefore, a serviceman is able to replace virtually any failed capacitor he may encounter as he makes service calls on equipment of various manufacturers, models, ages and the like.

As noted above, the capacitor10is expected to be used most widely in servicing air conditioning units. Air conditioning units typically have two capacitors; a capacitor for the compressor motor which may or may not be of relatively high capacitance value and a capacitor of relatively low capacitance value for a fan motor. The compressor motor capacitors typically have capacitances of from 20 to about 60 microfarads. The fan motor capacitors typically have capacitance values from about 2.5 to 12.5 microfarads, and sometimes as high as 15 microfarads, although values at the lower end of the range are most common.

With reference toFIG.11, capacitor10is connected to replace a compressor motor capacitor and a fan motor capacitor, where the compressor motor capacitor has a value of 25.0 microfarads and the fan motor capacitor has a value of 4.0 microfarads. The 25.0 microfarad replacement capacitance for the compressor motor is made by one of the compressor motor leads160being connected to one of the blades of the blue section cover terminal90of capacitor section20, which has a capacitance value of 25.0 microfarads, and the other compressor motor lead161being connected to one of the blades120of common cover terminal88. The lead162from the fan motor is connected to the white section cover terminal94of capacitor section24, and the second lead163from the fan motor is also connected to the common cover terminal88. As set forth above, the actual capacitance value of the capacitor section24that is connected to the section cover terminal94is 4.5 microfarads, and the instructions and/or labeling for the capacitor10indicate that the capacitor section24as represented at terminal94should be used for a 4.0 microfarad replacement. Preferred labeling for this purpose can be “5.0 (4.0) microfarads” or similar. The 4.5 microfarad capacitance value is within approximately 10% of the specified 4.0 microfarad value, and that is within acceptable tolerances for proper operation of the fan motor. Of course, the capacitor section24and terminal94may be connected to replace a 5.0 microfarad capacitance value as well, whereby the 4.5 microfarad actual capacitance value of capacitor section24gives added flexibility in replacing failed capacitors. Similarly, the 5.5 microfarad capacitor section23can be used for either 5.0 microfarad or 6.0 microfarad replacement, and the 2.8 microfarad capacitor section25can be used for a 3.0 microfarad replacement or for a 2.5 microfarad additive value.FIG.12schematically illustrates the connection of capacitor sections20and24to the compressor motor and fan motor shown inFIG.11.

FIG.13illustrates another connection of the capacitor10for replacing a 60.0 microfarad compressor motor capacitor and a 7.5 microfarad fan motor capacitor. The formula for the total capacitance value for capacitors connected in parallel is additive namely: Ct=C1+C2+C3. . . . Therefore, with reference toFIG.13, a 60.0 microfarad capacitance value for the compressor motor is achieved by connecting in parallel the section cover terminal90(capacitor section20at a value of 25.0 microfarads), section cover terminal91(capacitor section21at a value of 20.0 microfarads), section cover terminal92(capacitor section22at a value of 10.0 microfarads) and section cover terminal93(capacitor section23at a nominal value of 5.0 microfarads). The foregoing connections are made by means of jumpers164,165and166, which may be supplied with the capacitor10. Lead167is connected from the section cover terminal90of the capacitor section20to the compressor motor, and lead168is connected from the common cover terminal88to the compressor motor. This has the effect of connecting the specified capacitor sections20,21,22and23in parallel, giving a total of 60.0 microfarad capacitance; to wit: 25+20+10+5=60. It is preferred but not required to connect the lead from the compressor motor or the fan motor to the highest value capacitor section used in providing the total capacitance.

Similarly, a 7.5 microfarad capacitance is provided to the fan motor by connecting section cover terminal94of the 5.0 microfarad capacitor section24and the section cover terminal95of the nominal 2.5 microfarad capacitor section25in parallel via jumper169. Leads170and171connect the fan motor to the common cover terminal88and the section cover terminal95of the capacitor section25.FIG.14diagrammatically illustrates the connection of the capacitor10shown inFIG.13.

It will be appreciated that various other jumper connections between section cover terminals can be utilized to connect selected capacitor sections in parallel, in order to provide a wide variety of capacitance replacement values.

The capacitor sections can also be connected in series to utilize capacitor10as a single value replacement capacitor. This has the added advantage of increasing the voltage rating of the capacitor10in a series application, i.e. the capacitor10can safely operate at higher voltages when its sections are connected in series. As a practical matter, the operating voltage will not be increased as it is established by the existing equipment and circuit, and the increased voltage rating derived from a series connection will increase the life of the capacitor10because it will be operating well below its maximum rating.

With reference toFIG.15, the capacitor10is shown with capacitor section22(terminal92) having a value of 10.0 microfarads connected in series with capacitor section25(terminal95) having a nominal value of 2.5 microfarads to provide a replacement capacitance value of 2.0 microfarads. Leads175and176make the connections from the respective section cover terminals92and95to the motor, and the element common terminal36connects the capacitor sections22and25of capacitive element12. With reference toFIG.16, the connection of capacitor10shown inFIG.15is illustrated diagrammatically. In bothFIGS.15and16, it will be seen that the common cover terminal88is not used in making series connections.

The formula for capacitance of capacitors connected in series is

1CT=1C1+1C2+1C3⁢⁢…
Therefore,

CT=C1×C2C1+C2,
and the total capacitance of the capacitor sections22and25connected as shown inFIGS.15and16is

CT=10.0×2.510.0+2.5=2512.5=2.0
microfarads. The capacitance of each of the capacitor sections20-25is rated at 440 volts. However, when two or more capacitor sections20-25are connected in series, the applied voltage section is divided between the capacitor sections in inverse proportion to their value. Thus, in the series connection ofFIGS.15and16, the nominal 2.5 microfarad section sees about 80% of the applied voltage and the 10.0 microfarad section sees about 20% of the applied voltage. The net effect is that the capacitor10provides the 2.0 microfarad replacement value at a higher rating, due to the series connection. In this configuration, the capacitor10is lightly stressed and is apt to have an extremely long life.

With reference toFIG.17, the capacitor sections of the capacitor10are shown connected in a combination of parallel and series connections to provide additional capacitive values at high voltage ratings, in this case 5.0 microfarads. The two capacitor sections23and24each having a nominal value of 5.0 microfarads is connected in parallel by jumper177between their respective cover section terminals93and94. The leads178and179from a compressor motor are connected to the section cover terminal92of capacitor section22having a value of 10.0 microfarads, and the other lead is connected to cover section terminal94of capacitor section24. Thus, a capacitance value of 5.0 microfarads is provided according to the following formula

1CT=1C1+1C2,
where C1is a parallel connection having the value C+C, in this case 5.0+5.0 for a C1of 10.0 microfarads. With that substitution, the total value is

CT=10.0×10.010+10=10020=5.0
microfarads. The connection of capacitor10illustrated inFIG.17is shown diagrammatically inFIG.18.

FIG.19is a chart showing single capacitance values that can be provided by the capacitor10connected in parallel. The values are derived by connecting individual capacitor sections into a circuit, or by parallel connections of capacitor sections. The chart should be interpreted remembering that the 2.8 microfarad capacitor section can be used as a 2.5 or 3.0 microfarad replacement, and that the two 5.0 microfarad values are actually 4.5 and 5.5 microfarad capacitor sections, also with possibilities for more replacements.

FIGS.20-23are charts showing applications of capacitor10in replacing both a fan motor capacitor and a compressor motor capacitor. This is an important capability, because many air conditioning systems are equipped with dual value capacitors and when one of the values fails, another dual value capacitor must be substituted into the mounting space bracket.

The chart ofFIG.20shows dual value capacitances that can be provided by capacitor10wherein the nominal 2.5 microfarad capacitor section25is used for one of the dual values, usually the fan motor. Fan motors are generally not rigid in their requirements for an exact capacitance value, wherein the capacitor section25may also be used for fan motors specifying a 3.0 microfarad capacitor. The remaining capacitor sections20-24are available for connection individually or in parallel to the compressor motor, providing capacitance values from 5.0 to 65.0 microfarads in 5.0 microfarad increments.

The chart ofFIG.21also shows dual value capacitances that can be provided by capacitor10. In the chart ofFIG.21, one of the dual values is 5.0 microfarads that can be provided by either capacitor section23having an actual capacitance value of 5.5 microfarads or by capacitor section24having an actual capacitance of 4.5 microfarads. As discussed above, the capacitor section24can also be used for a 4.0 microfarad replacement value, and capacitor section23could be used for a 6.0 microfarad replacement value. Thus, theFIG.21chart represents more dual replacement values than are specifically listed. The other capacitor section may be used in various parallel connections to achieve the second of the dual capacitance values.

The chart ofFIG.22illustrates yet additional dual value capacitances that can be provided by capacitor10. Capacitor section25(nominal 2.5 microfarads) is connected in parallel with one of capacitor section23(5.5 microfarads) or capacitor section24(4.5 microfarads) to provide a 7.5 microfarad capacitance value as one of the dual value capacitances. The remaining capacitor sections are used individually or in parallel to provide the second of the dual value capacitances.

TheFIG.23chart illustrates yet additional dual value capacitances that can be provided by capacitor10, where capacitor section22(10 microfarads) is dedicated to provide one of the dual values. The remaining capacitor sections are used individually or in parallel for the other of the dual values.

It will be appreciated that any one or group of capacitor sections may be used for one of a dual value, with a selected one or group of the remaining capacitor sections connected to provide another capacitance value. Although there are no known applications, it will also be appreciated that the capacitor10could provide six individual capacitance values corresponding to the capacitor sections, or three, four or five capacitance values in selected individual and parallel connections. Additional single values can be derived from series connections.

The six capacitor sections20-25can provide hundreds of replacement values, including single and dual values. It will further be appreciated that if fewer replacement values are required, the capacitor10can be made with five or even four capacitor sections, and that if more replacement values were desired, the capacitor10could be made with more than six capacitor sections. It is believed that, at least in the intended field of use for replacement of air conditioner capacitors, there should be a minimum of five capacitor sections and preferably six capacitor sections to provide an adequate number of replacement values.

As is known in the art, there are occasional failures of capacitive elements made of wound metalized polymer film. If the capacitive element fails, it may do so in a sudden and violent manner, producing heat and outgassing such that high internal pressures are developed within the housing. Pressure responsive interrupter systems have been designed to break the connection between the capacitive element and the cover terminals in response to the high internal pressure, thereby removing the capacitive element from a circuit and stopping the high heat and overpressure condition within the housing before the housing ruptures. Such pressure interrupter systems have been provided for capacitors having two and three cover terminals, including the common terminal, but it has not been known to provide a capacitor with four or more capacitor sections and a pressure interrupter cover assembly.

The pressure interrupter cover assembly80provides such protection for the capacitor10and its capacitive element12. With reference toFIG.24, the capacitor10is shown after failure. Outgassing has caused the circular cover82to deform upwardly into a generally domed shape. When the cover82deforms in the manner shown, the terminal posts104,122are also displaced upwardly from the disconnect plate130, and the weld connection of the distal end124of common cover terminal post122to the distal end39foil lead38from the element common terminal36of the capacitive element12is broken, and the welds between the foil tabs56and the terminal posts104of the section cover terminals90-95are also broken, the separation at section cover terminals91and94being shown.

Although the preferred pressure interrupter cover assembly includes the foil lead38and foil tabs56, frangibly connected to the distal ends of the terminal posts, the frangible connections both known in the art and to be developed may be used. As an example, the terminal posts themselves may be frangible.

It should be noted that although it is desirable that the connections of the capacitive element and all cover terminals break, it is not necessary that they all do so in order to disconnect the capacitive element12from a circuit. For all instances in which the capacitor10is used with its capacitor sections connected individually or in parallel, only the terminal post122of common cover terminal88must be disconnected in order to remove the capacitive element12from the circuit. Locating the common cover terminal88in the center of the cover82, where the deformation of the cover82is the greatest, ensures that the common cover terminal connection is broken both first and with certainty in the event of a failure of the capacitive element12.

If the capacitor sections of the capacitor10are utilized in a series connection, it is necessary that only one of the terminal posts used in the series connection be disconnected from its foil tab at the disconnect plate130to remove the capacitive element from an electrical circuit. In this regard, it should be noted that the outgassing condition will persist until the pressure interrupter cover assembly80deforms sufficiently to cause disconnection from the circuit, and it is believed that an incremental amount of outgassing may occur as required to cause sufficient deformation and breakage of the circuit connection at the terminal post of one of the section cover terminal. However, in the most common applications of the capacitor10, the common cover terminal88will be used and the central location of the common cover terminal88will cause fast and certain disconnect upon any failure of the capacitive element.

Two other aspects of the design are pertinent to the performance of the pressure interrupter system. First, with respect to series connections only, the common cover terminal88may be twisted to pre-break the connection of the terminal post122with the foil strip38, thus eliminating the requirement of any force to break that connection in the event of a failure of the capacitive element12. The force that would otherwise be required to break the connection of common cover terminal post122is then applied to the terminal posts of the section cover terminals, whereby the section cover terminals are more readily disconnected. This makes the pressure interrupter cover assembly80highly responsive in a series connection configuration.

Second, the structural aspects of welding foil tabs to the distal ends of the terminal posts corresponding to the various capacitor sections and thereafter soldering the connecting wires onto the foil tabs56is also believed to make the pressure interrupter cover assembly80more responsive to failure of the capacitive element12. In particular, the solder and wire greatly enhance the rigidity of the foil tabs56wherein upon deformation of the cover82, the terminal posts break cleanly from the foil tabs56instead of pulling the foil tabs partially through the disconnect plate before separating. Thus, the capacitor10, despite having a common cover terminal and section cover terminals for six capacitor sections, is able to satisfy safety requirements for fluid-filled metalized film capacitors, which is considered a substantial advance in the art.

Another capacitor200according to the invention herein is illustrated inFIGS.26-28. The capacitor200has the same or similar external appearance and functionality as capacitor10, and is adapted to replace any one of a large number of capacitors with the capacitor200connected to provide the same capacitance value or values of a failed capacitor.

The capacitor200is characterized by a capacitive element212having two wound cylindrical capacitive elements214and216stacked in axial alignment in case60. The first wound cylindrical capacitive element214provides three capacitor sections20a,22aand23a, and the second wound cylindrical element216provides an additional three capacitive sections21a,24aand25a. These capacitor sections correspond in capacitance value to the capacitor sections20-25of capacitor10, i.e. capacitor sections20and20ahave the same capacitance value, capacitor sections21and21ahave the same capacitance value, etc.

The wound cylindrical capacitive element214has a central spool or mandrel228, which has a central opening229. First and second dielectric films, each having metalized layer on one side thereof, are wound in cylindrical form on the mandrel228with the non-metalized size of one film being in contact with the metalized side of the other. Selected portions of one or both of the metalized layers are removed in order to provide multiple sections in the wound cylindrical capacitive element. Element insulation barriers230and231are inserted into the winding to separate the capacitor sections, the element insulation barriers also assuming a cylindrical configuration, with the element insulation barrier230separating capacitor sections20aand22a, and element insulation barrier231separating capacitor sections22aand23a. Zinc or other metal spray is applied between the barriers to form section terminals40a,42aand43aat one end of wound cylindrical capacitive element214, and first common element terminal36a.

The second wound cylindrical capacitive element216is similarly formed, on a mandrel226with central opening227, providing three capacitor sections21a,24aand25a, with insulation barriers232and233separating the sections. The insulation barriers may be as described above with respect to capacitive element12, i.e. polypropylene barriers sufficient to withstand heat from adjacent soldering without loosing the integrity of electrical insulation. The capacitor sections21a,24aand25aare also metal sprayed to form section terminals41a,44aand45awith capacitance values respectively corresponding to sections41,44and45of capacitive element12.

Element common terminal36a′ is also formed. Element common terminal36aof wound cylindrical capacitive element214connects the sections20a,22aand23athereof, and an element common terminal36a′ of wound cylindrical capacitive element216electrically connects the capacitor sections21a,24aand25a. The element common terminals36aand36a′ are connected by a foil strip236, wherein they become the common terminal for all capacitor sections. The wound cylindrical capacitive elements214and216are stacked vertically in the case60, with the common element terminals36a,36a′ adjacent to each other such that any contact between these common element terminals is normal and acceptable because they are connected as the common terminal for all capacitor sections. An insulator cup270is positioned in the bottom of case60, to protect element section terminals21a,24aand25afrom contact with the case60and a post272keeps the wound cylindrical elements214and216aligned and centered in case60.

Conductors50a-55a, preferably in the form of six insulated foil strips or insulated wires, each have one of their respective ends soldered to corresponding element section terminals20a-25a, and have their other respective ends connected to the corresponding terminal posts of pressure interrupter cover assembly80. One of the element common terminals36a,36a′ is connected to the common cover terminal post122by conductor38a. When the conductors are foil strips, all of the conductors may be connected as described above with respect to the foil strip38, and if the conductors are insulated wire conductors they may be connected as described above with respect to the insulated wires50-55. The case60is filled with an insulating fluid76.

The length L of the two wound cylindrical capacitives214and216, i.e. the length of the mandrels226and228on which the metalized dielectric sheet is wound, is selected in part to provide the desired capacitance values. The outer capacitor sections having the greater circumferencial dimension contain more metalized dielectric film than the capacitor sections more closely adjacent to the mandrels, and therefore provide a larger capacitance value. Thus, the longer wound cylindrical capacitive element214provides the 25 microfarad capacitor section20aand the 10 microfarad capacitor section22a, with the 5.5 microfarad capacitor section23aadjacent mandrel238. The shorter wound cylindrical capacitive element216provides the 20 microfarad capacitor section21a, the 4.5 microfarad capacitor section24aand the 2.8 microfarad capacitor section25a.

A capacitive element212made up of two wound cylindrical capacitive elements214and216therefore provides the same capacitance values in its various capacitor sections as capacitive element12and, when connected to the cover section terminals90-95, may be connected in the same way as described above with respect to the capacitor10and to provide the same replacement capacitance values shown in the charts ofFIGS.19-23.

With reference toFIGS.28-30, another capacitor300is shown, also having the same or similar exterior appearance as the capacitor10and having the same functionality and replacing failed capacitors of varying values. The capacitor300includes case60and pressure interrupter cover assembly80, and the capacitor300is characterized by a capacitive element provided in six separate wound cylindrical capacitive elements320-325, each wound cylindrical capacitive element providing one capacitor section20b-25bof the total capacitive element312.

Accordingly, the capacitive element includes a first wound cylindrical capacitive element320which provides a capacitive section20b, preferably having a capacitance value of 25 microfarads. The capacitive section20bhas a section terminal40bwhich is connected by conductor50bto section cover terminal90of the cover assembly80, and has bottom common terminal360. Wound cylindrical capacitor element321provides the capacitor section21bhaving a value of 20 microfarads, having a section terminal41bconnected to the cover section terminal91by a conductor51b. This section also has a bottom terminal361. Similarly, a wound cylindrical capacitive element322provides the capacitor section22bof capacitance value 10 microfarads, with section terminal42bconnected to the corresponding section cover terminal92by conductor52c, and has a bottom terminal362. Wound cylindrical capacitive element325provides capacitor section25bhaving sectional terminal45bconnected to the section cover terminal95by insulated wire conductor55b. It also has a bottom terminal325. The wound cylindrical capacitive element325, providing only 2.8 microfarads of capacitance value, is quite small compared to the wound cylindrical capacitive elements320,321and322.

The four wound cylindrical capacitive elements320,321,322and325are oriented vertically within the case60, but provide sufficient head room to accommodate two additional wound cylindrical capacitive elements323and324, which are placed horizontally under the cover assembly80. The wound capacitive element323provides capacitor section23b, preferably having a value of 4.5 microfarads, and the wound cylindrical capacitive element324provides capacitor section24bhaving a value of 5.5 microfarads. These capacitor sections have, respectively, section terminals43band44bconnected to cover terminals93and94by conductors53band54band bottom terminals323and324.

All of the bottom terminals320-325are connected together to form common element terminal36b, and are connected to the common cover terminal88. As best seen inFIG.29, the bottom terminals320,321,322and325of the capacitor sections20b,21b,22band25bare connected together by strips soldered or welded thereto, these strips providing both an electrical connection and a mechanical connection holding the assemblies together. Additionally, they may be wrapped with insulating tape. An insulated foil strip38bconnects the aforesaid bottom terminals to the common cover terminal. The bottom terminals323and324of capacitor sections23band24bare also connected together, and are further connected to the common cover terminal by an insulated foil strip38b′.

The wound cylindrical capacitive elements320-325are placed in case60with an insulating fluid76. The capacitor300may be used in the same way as described above with respect to capacitor10, to provide selected replacement values for a large number of different failed capacitors.

It will be noted that the wound cylindrical capacitive elements320-325occupy less space in the case60than the single wound cylindrical capacitive element12of capacitor10. This is achieved by using thinner dielectric film wherein the capacitance values can be provided in less volume; however, the voltage rating of the wound cylindrical capacitive elements320-325is correspondingly less because of the thinner dielectric material. Thus, the capacitors made with this technique may have a shorter life, but benefit from a lower cost of manufacture.

Referring toFIGS.31A-C, a capacitor400is presented that includes an elliptical-shaped case402(e.g., an oval-shaped case), which is partially shown in the exploded perspective view ofFIG.31A. The capacitor400provides a similar functionality as the capacitor10, and is adapted to replace any of a large number of capacitors with the capacitor400being connected to provide a substantially similar (or equivalent) capacitance value or values of one or more failed capacitors. The capacitor400may include one or more of the design aspects, features, materials, etc. employed by the capacitors presented and described with respect toFIGS.1-30. In this arrangement, the capacitor400includes two wound cylindrical capacitive elements404and406that are stacked on their respective sides such that the longitudinal axes of the elements are substantially parallel to each other. In some arrangements, the corresponding portions of each element's side may come into contact; although the sides of the elements may be separated by a distance in some arrangements (e.g., through the use a spacing device, a bracket, etc.). This positioning of the capacitive elements404and406may depend upon (or even defined in part by) the dimensions of the elliptically-shaped case402. For example, due to the diameter, height, cylindrical shape, etc. of the capacitive elements, the geometry of the case402may constrain the layout of the components. However, in some arrangements one or more dimensions of a similarly elliptically-shaped case (e.g., an oval-shaped case) may adjusted (e.g., increased) to allow the capacitive elements to be positioned differently. For example, one or both of the capacitive elements may be rotated (with respect to their longitudinal axis by 90°) such that each element is vertically oriented (in comparison to the horizontal orientation illustrated in the figure). The manner in which the capacitive elements may be stacked amongst themselves may also be adjusted. For example, pairs of elements may be stacked end-to-end (a vertical stack) rather than side-by-side as shown in the figure.

In general, the capacitor400provides a functionality that is similar to the capacitor10and can be considered as being adaptable to replace any one of a large number of capacitors (with the capacitor400) to provide the same capacitance value or values of a failed capacitor. Each of the capacitive elements404and406of the capacitor400can be implemented by using one or more production techniques, such as being wound elements like the two wound cylindrical capacitive elements214and216. In this example, each of the capacitive elements404and406provide two capacitor sections, however in some arrangements either or both of the capacitive elements may provide more or less capacitive sections. Each capacitor section has a capacitance value that may be equivalent or different. In one arrangement, each of the capacitive elements may be used to provide the same pair of capacitance values. For example, capacitive element404may provide a 1.5 microfarads capacitance value and 5.0 microfarads capacitance, and, capacitive element406may similarly provide a 1.5 microfarads capacitance value and 5.0 microfarads capacitance. Other capacitance values may be provided either or both of the capacitive elements404and406(e.g., including values that are greater or less than values mentioned above), thereby providing a range of values. For example, the combined capacitance values provided by the capacitive elements may range from single digits (e.g., 1 microfarad) to two and three digits (e.g., tens or even hundreds of microfarads).

Similar to capacitive element214, each of the capacitive elements404and406has a central spool or mandrel, which has a central opening. First and second dielectric films, each having a metalized layer on one side thereof, are wound in cylindrical form on the mandrel with the non-metalized side of one film being in contact with the metalized side of the other. Selected portions of one or both of the metalized layers are removed in order to provide multiple sections in the wound cylindrical capacitive element. Element insulation barriers (similar to barriers230and231shown inFIG.25) may be inserted into the winding to separate the capacitor sections, the element insulation barriers also assuming a cylindrical configuration. Zinc or other metal spray may be applied between the barriers to form section terminals at one end of each of the wound cylindrical capacitive elements404and406, along with a common element terminal for each capacitive element. The insulation barriers may be produced for a variety of materials such as polypropylene to withstand heat from soldering or other activities without losing the integrity of electrical insulation. Capacitor sections may also be metal sprayed to form section terminals.

In some arrangements capacitive elements may be adjusted to occupy more or less space. This may be achieved by using thinner dielectric film wherein the capacitance values can be provided in less volume; however, the voltage rating of the wound cylindrical capacitive elements may be correspondingly less due to the thinner dielectric material. Thus, the capacitors made with this technique may have a shorter life, but benefit from a lower cost of manufacture.

The common terminal of each capacitive element404and406respectively connects the sections of the corresponding element. In some arrangements, the element common terminals of the two capacitive elements404and406are connected using one or more conductors (e.g., foil strip(s), wire(s), etc.), wherein they become the common terminal for all capacitor sections. In some arrangements, an insulator cup408(e.g., similar to the insulator cup270shown inFIG.25) is positioned in the bottom of the elliptically-shaped case402, to protect the elements such as the lower positioned capacitive element406(and potentially other portions of the elements such as section terminals) from contact with the case. One or more mechanical mechanisms such as a bracket, a post, etc. may keep one or both of the wound cylindrical elements404and406in proper alignment.

Conductors, preferably in the form of insulated foil strips or insulated wires, each have one of their respective ends soldered to corresponding element section terminals and have their other respective ends connected to the corresponding terminal posts of a cover assembly such as a cover assembly410. In some arrangements, the cover assembly410can assist in providing the functionality of a pressure interrupter, as described above. Typically a common terminal of each element is connected to a common cover terminal post by one or more conductors. The conductors may be foil strips, insulated wire conductors, etc., and one or more connection techniques may be employed. In some arrangements the case402may be filled with an insulating fluid (such as insulating fluid76), however in some arrangements, an insulating fluid may not be used.

Geometry (length, shape, etc.), dimensions (e.g., length, diameter, etc.), etc. of either or both of the two wound cylindrical capacitive elements404and406may be selected in part to provide the desired capacitance values. The outer capacitor sections generally have greater circumferential dimension and contain more metalized dielectric film compared to the capacitor sections more closely adjacent to the mandrels, and therefore provide a larger capacitance value.

Each capacitive section has a section terminal which is connected by conductor to a corresponding one of the section cover terminals412,414and416of the cover assembly410, and has a bottom common terminal. Each of the bottom terminals of the capacitive elements404,406are connected together to form a common element terminal, and is connected to the common cover terminal418. The bottom terminals of the capacitor sections may be connected together by strips soldered, welded, etc., with these strips providing both an electrical connection and a mechanical connection holding the assemblies together. Additionally, they may be wrapped with insulating tape. An insulated foil strip may connect the bottom terminals to the common cover terminal418.

As similarly illustrated inFIG.10, each cover terminal (such as cover terminal412) includes a number of upstanding blades (e.g., two blades) mounted on the upper end of a terminal post. The terminal post has a distal end, opposite the blades. The cover assembly410has an opening for accommodating the terminal post, and the opening may be formed of one or more shapes and include a variety of features such as a beveled lip that surrounds the opening.

Referring toFIGS.32A-C, perspective views of the capacitor400are presented that show both the internal components of the capacitor (e.g., the capacitive elements404and406) and portions of the elliptically-shaped case402. In particular,FIG.32Apresents a front view of the capacitor400whileFIG.32BandFIG.32Cpresent left side and right side views of the capacitor400. By representing the elliptically-shaped case as being somewhat transparent, the electrical connections between components are also presented. In this particular arrangement, a conductor420is used to connect a portion of capacitive element404and a portion of capacitive element406to connect capacitors in parallel to provide one capacitance value. A connector422then connects the parallel-connected capacitors to the cover terminal412. Connectors424and426respectively connect individual capacitor sections of the capacitive elements404and406to the respective cover terminals414and416. For a common connection, a connector428connects the respective common terminal of each capacitive element404and406to the common cover terminal418. As mentioned above, one or more types of techniques may be employed for establishing the electrical connections, for example, one or more of the connectors may be electrical wires, metallic film, etc.

Referring toFIGS.33A-C, three perspective views are provided for the cover assembly410, which includes the three cover terminals412,414and416along with the common cover terminal418. With reference toFIGS.3,9and10, the cover assembly410may include a disconnect plate430that may be produced from a rigid insulating material, such as a phenolic. The disconnect plate430may include openings to accommodate the distal ends of the terminal posts for the cover terminals (e.g., the cover terminals412,414and416, the common cover terminal418). The disconnect plate430may be provided with raised guides, such as linear guides and dimple guides, generally adjacent the openings accommodating the distal ends of terminal posts.

To provide protection to the capacitor400, the cover assembly410may provide the functionality of a pressure interrupter. For example, if one or more of the capacitive elements404,406, or a portion of either or both elements were to fail; the elliptically-shaped cover of the cover assembly (or a portion of the cover) may deform upwardly due to outgassing of the failed element or elements. When deformed, the terminal posts are generally displaced upwardly from the disconnect plate430, and the connection (e.g., a weld connection) between one or more terminals and the capacitive elements404,406are broken.

In this particular arrangement, the cover terminals412,414and416are positioned on the cover assembly410to form triangular-shaped group. The common cover terminal418is positioned at a location that can be considered slightly separated from the triangular-shaped group of the cover terminals412,414and416. Similar to the presented layout, other layouts, patterns, designs etc. may be employed to position the cover terminals and the common cover terminal upon the cover assembly. For example, the cover terminals412,414and416may be positioned to generally surround the common cover terminal418in a manner similarly illustrated inFIG.1andFIG.2, for example. In some arrangements one or more insulator techniques and mechanisms may be incorporated into the cover assembly410. For example, and with reference toFIGS.1and2, the cover assembly410may include an insulator barrier capable of separating two or more of the cover terminals and/or the common cover terminal. For example, the insulator barrier may include an elongated cylindrical center barrier cup capable of surrounding one or more of the terminals (e.g., the common cover terminal418, cover terminal412, etc.). In some arrangements the height of the barrier cup wall may extend above the height of the surrounded terminal or terminals. Insulation may also be provided by one or more fins that may extend between two or more terminals. For example, similar to the fins presented inFIGS.1and2, fins may extend respectively radially outwardly from an elongated center barrier cup such that they are deployed between adjacent terminals (e.g., cover terminals). In some arrangements the height of the fins may extend above the height of the corresponding terminals, however, fins may also be employed that to not fully extend above the height of one or more of the terminals.

The elliptical shape of the cross section of the capacitor's case and the cover assembly may both approximately share a common ellipse shape. In general, the ellipse shape can be considered a curve on a plane surrounding two focal points such that a straight line drawn from one of the focal points to any point on the curve and then back to the other focal point has the same length for every point on the curve. An ellipse shape can also be considered as the set of points such that the ratio of the distance of each point on the curve from a given point (called a focus or focal point) to the distance from that same point on the curve to a given line (called the directrix) is a constant, referred to as the eccentricity of the ellipse. A circle can be considered as having an ellipse shape in which both focal points are positioned at the same location. The shape of an ellipse (e.g., how ‘elongated’ it is) is represented by its eccentricity which for an ellipse can be represented by any number from 0 (the limiting case of a circle) to arbitrarily close to but less than 1, for example. Ellipses can also be considered a closed type of conic section: a plane curve formed from the intersection of a cone by a plane.

Referring toFIG.34, a schematic diagram of one potential arrangement for the circuitry of the capacitor400is presented. In this example, the capacitive elements are each produced to include two capacitor sections that correspondingly provide two capacitance values. In some arrangements, one or both of the capacitive elements may be used produced to provide more or less than two capacitive values. For example, on one potential arrangement, the capacitive element404may provide three capacitance values and capacitive element406may provide one capacitive value. Rather than providing a total of four capacitive values between the two capacitive elements404,406, more or less capacitive values may be provided. Further, while two capacitive elements404,406are employed in this example, more or less capacitive elements may be used to provide capacitive values for a capacitor.

In this particular example, each of the capacitive elements404,406provide equivalent capacitance values (e.g., 1.5 microfarad and 5.0 microfarad); however in some arrangements the elements may provide only one common value or entirely different capacitance values. The capacitance values provided by the capacitive elements404and406may also different in other arrangements. For example, values greater or less than 1.5 microfarads and/or 5.0 microfarads may be provided by the capacitive elements.

In this particular example, two of the cover terminals (i.e., cover terminals414and416) are connected to the capacitive elements (by respective conductors424and426) to each provide 5.0 microfarads (by electrically connecting to either cover terminal and the common cover terminal418). The third cover terminal412is connected to both of the 1.5 microfarads capacitance values provided by the capacitive elements404,406. Connected in parallel, these two capacitance values combine to provide a capacitance value of 3.0 microfarads at the cover terminal412. Along with connecting the two common sides of the capacitive elements, the conductor428also provides a connection to the common cover terminal418included in the cover assembly410.

From the capacitance values (e.g., 1.5 microfarads and 5.0 microfarads) provided by the two capacitance elements404and406, a variety of capacitance values are available from the capacitor400. For example, by connecting the cover terminals412,414,416and the common cover terminal418in different variations, for example by using jumper wires, additional capacitance values may be provided. In the illustrated arrangement, along with the 5.0 microfarads capacitance provided by either of the cover terminals414and416, a capacitance of 3.0 microfarad is provided by the cover terminal412(due the two 1.5 microfarad capacitance values connected in parallel). By connected either cover terminal414or416to the cover terminal412a capacitance value of 6.5 microfarad is provided (from the 1.5 microfarad capacitance value being connected in parallel with one of the 5.0 microfarad capacitance values). A capacitance value if 10.0 microfarad may be provided by connecting cover terminals414and416to place the two 5.0 microfarad capacitance values in parallel. By connecting all three of the cover terminals412,414,416a capacitance value of 13.0 microfarad is provided between the connected terminals (that connect each of the four capacitance values in parallel) and the common cover terminal418. By adjusting the capacitance values provided by the capacitive elements404and406, other levels of capacitance can be attained.

While the capacitor400illustrated inFIGS.31-34has largely been described as including two capacitive elements404,406, in some implementations, a capacitor may include a single capacitive element. Further, while the capacitor400has largely been described as including three section cover terminals412,414,416, in some implementations, fewer section cover terminals may be included. For example, in implementations in which a capacitor includes a single capacitive element, two section cover terminals may be included (e.g., in addition to a common cover terminal). The capacitive element may include two capacitor sections, with each capacitor section providing a capacitive value (e.g., the same or different capacitive values).

Referring toFIGS.35and36, an illustration of a wound capacitive element3500and a corresponding schematic diagram3600are presented. The capacitive element3500is an example of a capacitive device. A capacitive device can take on other forms besides a capacitive element. For example, a capacitive device may be a discrete capacitor, a section of a capacitor, or any other component that can provide a capacitance value. Therefore, while a capacitive element (e.g., a wound capacitive element) is an example of a capacitive device, other capacitive devices may be incorporated into the capacitors described herein.

As illustrated in the schematic diagram3600, the capacitive element3500includes a pair of capacitors that share a common single plate3520. To produce this capacitive element3500, the two films can be wound on the spindle of a winding machine for a preselected number of revolutions. The number of revolutions generally depends upon the capacitance value desired. If the capacitance values of the dual capacitors are to be equal, one-half of the total length of the film is first wound. Once this portion is wound, the winding machine is stopped and voltage is applied to the metal layer of the film (e.g., by an electrode). The winding process is then continued, for example at a slower speed, and the metallic layer is vaporized, leaving a non-metallized intermediate region. The length of the non-metallized region is generally sufficient to encircle the capacitive element3500at least once. During the interval of winding the region around the capacitive element3500, there is inserted into the section a non-conductive sheet3536of a material, such as a plastic. The sheet3536is generally not centered along the length of the cylindrical section of the element. As illustrated inFIG.36, accordingly, upon continued winding the sheet3536forms a circular barrier which extends outwardly from that end of the capacitive element3500having the metallized edge of film. Winding is continued and terminated for the first and second films and the completed element may be wrapped, for example, by a suitable tape3538.

As illustrated inFIG.35, the capacitive element3500is metal plated in a manner employed for attaching leads, e.g. the ends are sprayed with molten copper to which a layer of solder is applied. Thereafter, the barrier formed by sheet3536is trimmed as shown inFIG.37. The completed element, as shown inFIGS.35and37includes on one end, for example, a copper-solder layer3550which electrically engages the metallized layer3520of the first film (for the common single plate). The opposite end of the capacitive element3500includes a similar layer3542which, however, is interrupted by the barrier formed by sheet3536so that the inner layer engages that portion of metallized layer3524of the second film (for one capacitor plate) while the outer portion engages the metallized layer3524which succeeded the formation of the non-metallic region (for another capacitor plate). Thereafter, conductors3544,3546may be soldered to these regions as indicated, and an opposite end of the conductors3544,3546may be soldered to a corresponding section cover terminal, as described herein. A conductor3548may be similarly soldered to the opposite end, and an opposite end of the conductor3548may be soldered to a corresponding common cover terminal, as described herein. For example, because the capacitive element3500can provide two capacitor sections, two section cover terminals may be included. Generally, the capacitive element3500formed from metallized film is generally compact in size and simultaneously provides for the attachment of leads and maintaining the separate electrical integrity of the multiple capacitors included in the element. One or more of the techniques described herein may be employed for producing such capacitive elements.

Another capacitor3800according to the invention herein is illustrated inFIG.38. In the illustrated example, the capacitor3800includes an elliptical-shaped case3802(e.g., an oval-shaped case). The capacitor3800may provide a similar functionality as the other capacitors described herein, and may be adapted to replace a number of capacitors with the capacitor3800being connected to provide a substantially similar (or equivalent) capacitance value or values of one or more failed capacitors. The capacitor3800may include one or more of the design aspects, features, materials, etc. employed by the capacitors presented and described with respect toFIGS.1-37. In this arrangement, the capacitor3800includes a single wound cylindrical capacitive element3804. In some arrangements, additional capacitive elements may be provided.

In general, the capacitor3800can provide a functionality that is similar to the other capacitors described herein. The capacitive element3804can be implemented by using one or more production techniques, such as being a wound element like the wound cylindrical capacitive elements214or216. In the illustrated example, the capacitive element3804provides two capacitor sections, however, in some arrangements, the capacitive element3804may provide additional or fewer capacitive sections. Each capacitor section has a capacitance value that may be equivalent or different.

A common terminal of the capacitive element3804connects the sections of the capacitive element3804. An insulator cup3808is positioned in the bottom of the case3802(e.g., to protect the elements such as the capacitive element3804, and potentially other portions of the elements such as section terminals, from contact with the case3802. One or more mechanical mechanisms such as a bracket, a post, etc. may keep the capacitive element3804in proper alignment.

Conductors, preferably in the form of insulated foil strips or insulated wires, each have one of their respective ends soldered to corresponding section terminals and have their other respective ends connected to the corresponding terminal posts of a cover assembly, such as a cover assembly3810. In some arrangements, the cover assembly3810can assist in providing the functionality of a pressure interrupter, as described above. Typically, a common terminal of the capacitive element3804is connected to a common cover terminal post by one or more conductors. The conductors may be foil strips, insulated wire conductors, etc., and one or more connection techniques may be employed. In some arrangements, the case3802may be filled with an insulating fluid (such as insulating fluid76), however in some arrangements, an insulating fluid may not be used.

Geometry (length, shape, etc.), dimensions (e.g., length, diameter, etc.), etc. of the capacitive element3804may be selected in part to provide the desired capacitance values. The outer capacitor section generally has greater circumferential dimension and contains more metalized dielectric film compared to the capacitor section more closely adjacent to the mandrels, and therefore provides a larger capacitance value.

Each capacitive section has a section terminal which is connected by conductor to a corresponding one of the section cover terminals3812,3814of the cover assembly3810, and has a bottom terminal. The bottom terminals are connected to the common cover terminal3818. The bottom terminals may be connected together by strips soldered, welded, etc., with these strips providing both an electrical connection and a mechanical connection holding the assemblies together. Additionally, they may be wrapped with insulating tape. An insulated foil strip may connect the bottom terminals to the common cover terminal3818.

In some implementations, the capacitive element3804includes a first capacitive section and a second capacitive section. The capacitive value provided by the first capacitive section may be 2.5 microfarads (or, e.g., approximately 2.5 microfarads) and the capacitive value provided by the second capacitive section may be 5.0 microfarads (or, e.g., approximately 5.0 microfarads). For example, the first capacitive section may include a section terminal that is connected by a conductor to one of the section cover terminals (e.g., the section cover terminal3812), and the second capacitive section may include a section terminal that is connected by a conductor to the other section cover terminal (e.g., the section cover terminal3814). Each of the capacitive sections may include a common terminal (e.g., sometimes referred to as bottom terminals) that are connected by a conductor to the common cover terminal3818. In this way, a user can connect the section cover terminal3812and the common cover terminal3818to a device (e.g., an air conditioning system) to provide a capacitance value of 2.5 microfarads, and/or the user can connect the section cover terminal3814and the common cover terminal3818to a device to provide a capacitance value of 5.0 microfarads. The two capacitive sections can also be connected in parallel to provide a capacitance value of 7.5 microfarads. Such a capacitor may require two section cover terminals3812,3814and one common cover terminal3818. It should be understood that the first capacitive section and/or the second capacitive section may provide other capacitive values than those specifically described herein.

In some implementations, the capacitor3800may include one or more magnetic elements for assisting in mounting of the capacitor3800(e.g., to an air conditioning system). In the illustrated example, the capacitor3800includes a magnet3820positioned toward a bottom end of the capacitor3800. In particular, the magnet3820is positioned near a bottom wall of the case3802of the capacitor3800on the insulator cup3808. In some implementations, the magnet3820may be positioned between the bottom wall of the case3802of the capacitor3800and the insulator cup3808. The magnet3820is configured to create magnetic attraction between the magnet3820and a magnetic surface in proximity to the capacitor3800. For example, the magnet3820may cause the bottom wall of the case3802to be attracted to a metallic surface of an air conditioning system, thereby improving the integrity of a mounting between the capacitor3800and the air conditioning system after installation. The magnet3820may be designed such that the strength of magnetic attraction between the magnet3820and the air conditioning system is such that the magnet3820may remain firmly in place in response to possible vibration and/or other movement of the air conditioning system during operational use. In some implementations, the strength of magnetic attraction between the magnet3820and the air condition system is such that a user (e.g., a technician installing or uninstalling the capacitor3800) can remove the capacitor from the surface of the air conditioning system without requiring excessive effort.

While the magnet3820is illustrated as being positioned interior to the case3802of the capacitor3800, in some implementations, the magnet3820may be positioned outside of the case3802on an exterior of the bottom wall of the case3802. For example, the magnet3820may have a disk shape that is positioned outside of the case3802at an outer surface of a base of the case3802.

In some examples, the magnet3820may have a rectangular shape. For example, the magnet3820may be a rectangular strip that runs along the bottom wall of the case3802of the capacitor3800. In particular, the rectangular strip may have a particular thickness, a first dimension that runs from the left side of the capacitor3800to the right side of the capacitor3800, and a second dimension that is perpendicular to the first dimension and smaller than the first dimension. In some implementations, the magnet3820may have a square shape (e.g., such that the first dimension is equal to or substantially equal to the second dimension). In some implementations, the magnet3820may have a rod shape. In some implementations, the magnet3820may have a circular shape (e.g., a disk shape) or a hollow circular shape (e.g., a ring shape). For example, in some implementations, the magnet3820may have dimensions equal to or substantially equal to the dimensions of a disk-shaped battery (e.g., a watch battery such as a CR2032 battery). In some implementations, the magnet3820is a disk-shape with a thickness of approximately 4 mm and a diameter of approximately 160 mm. In some implementations, the magnet3820is a disk-shape with a thickness of approximately 4 mm and a diameter of approximately 40 mm. In some implementations, the magnet3820is a disk-shape with a thickness of approximately 4.5-5 mm and a diameter of about 60 mm. In some implementations, the magnet3820is a disk-shape with a thickness of approximately 5 mm and a diameter of about 60 mm

In some implementations, other shapes, a combination of shapes, etc. may be employed; for example, various types of curves may be incorporated into one or more magnetic strips (e.g., elongated oval shaped strips). Patterns of magnetic material may be used; for example, two crossed magnetic strips, a pattern of crosses, circles, etc. may be attached, incorporated into the bottom wall, side wall, etc. of the capacitor3800.

The particular shape and/or dimensions of the magnet3820may be chosen to achieve the desired strength of magnetic attraction. For example, the magnet3820may be designed with a particular shape and/or larger dimensions and/or larger thicknesses to achieve a relatively higher strength of magnetic attraction with a magnetic surface. In some implementations, increased surface area of the magnet3820toward the bottom wall of the case3802of the capacitor3800may increase the strength of magnetic attraction.

In some implementations, the magnet3820has a strength of approximately 30-40 milliTeslas (mT) or a strength of approximately 65-75 mT. In some implementations, the strength of magnetic attraction can be increased by stacking multiple magnets3820(e.g., on top of each other). In some implementations, two stacked magnets3820can have a strength of approximately 70-80 mT, 60-80 mT, or 130-150 mT, although other ranges are also possible. In some implementations, the magnet3820may be a D40×4 ferrite ceramic magnet manufactured by Hangzhou Honesun Magnet Co., Ltd.

In some implementations, the magnet3820may be magnetized using one or more of a plurality of techniques. For example, in some implementations, the magnet3820may be magnetized such that a north and a south pole of the magnet3820is located at a particular position of the magnet3820. For example, the techniques for magnetizing the magnet3820may cause the north and/or south pole to be located at various thicknesses of the magnet3820, various axial positions of the magnet3820, various diametric positions of the magnet3820, and/or various radial positions of the magnet3820. In some implementations, the magnet3820may be a multi-pole magnet.

In some implementations, the magnet3820is a permanent magnet that is made from a material that is magnetized and creates its own persistent magnetic field. For example, the magnet3820may be made from a ferromagnetic material that can be magnetized, such as iron, nickel, cobalt, and/or an alloy of rare-earth metals, among others. In some implementations, the magnet3820is a ferrite and/or ceramic magnet. In some implementations, the magnet3820may include one or more of ferric oxide, iron oxide, barium, barium carbonate, strontium, and/or strontium carbonate. The magnet3820may include one or more magnetically “hard” materials (e.g., materials that tend to stay magnetized). Alternatively or additionally, the magnet3820may include one or more magnetically “soft” materials.

In some implementations, the magnet3820may be a rare-earth magnet. A rare-earth magnet is typically a relatively strong permanent magnet that is made from one or more alloys of rare-earth elements. Example of rare-earth elements that can be used in a rare-earth magnet include elements in the lanthanide series, scandium, and yttrium, although other elements may also or alternatively be used. In some implementations, the rare-earth magnet may produce a magnetic field of greater than 1.0T (teslas). In some implementations, the rare-earth magnet may include one or both of samarium-cobalt and neodymium.

In some implementations, the magnet3820may be made from one or more ceramic compounds (e.g., ferrite) that can be produced by combining iron oxide and one or more metallic elements. In some implementations, such ceramic compounds may be electrically nonconductive. The use of such ceramic compounds for the magnet3820may eliminate the inclusion of electrically conductive elements in the capacitor3800that may otherwise affect the operation of the capacitor3800.

In some implementations, the magnet3820may have a grade that corresponds to a particular standard (e.g., a National and/or International standard). In some implementations, the grade of the magnet3820corresponds to the Chinese ferrite magnet nomenclature system. For example, in some implementations, the magnet3820is grade Y10T, Y25, Y30, Y33, Y35, Y30BH, or Y33BH, although other grades are also possible. In some implementations, the grade corresponds to a working temperature of 250° C. In some implementations, the grade of the magnet3820corresponds to a Feroba, an American (e.g., “C”), or a European (e.g., “HF”) grading standard.

In some implementations, the magnet3820may be an electromagnet that produces a magnetic field by introducing an electric current. In some implementations, the electromagnet may include a magnetic core and a wire (e.g., an insulated wire) wound into a coil around the magnetic core. The magnetic core may be made from a ferromagnetic or a ferrimagnetic material such as iron or steel. The magnetic core may be made from a “soft” magnetic material (e.g., a magnetic material that can allow magnetic domains in the material to align upon introduction of the current through the coil).

By using an electromagnet as the magnet3820, the strength of magnetic attraction can be turned on and off and/or customized according to the current passed through the coil. For example, current can be applied through the coil to cause the electromagnet to generate a magnetic field, and the current can be removed from the coil to cause the electromagnetic to cease generating the magnetic field. In some implementations, the strength of the magnetic field (and, e.g., the strength of magnetic attraction created by the electromagnet) can be adjusted based on the magnitude of electrical current passed through the coil. For example, relatively higher magnitudes of electrical current correspond to higher magnetic field strengths and therefore higher strengths of magnetic attraction (e.g., with a magnetic surface), and relatively lower magnitudes of electrical current correspond to lower magnetic field strengths and therefore lower strength of magnetic attraction.

In some implementations, the particular material used for the core of the electromagnet and/or the dimensions of the core may be chosen to achieve the desired strength of magnetic attraction. The core may be made from a material such as one or both of iron and steel. In some implementations, the dimensions of the coil and/or the number of turns of the coil may also be chosen to achieve the desired strength of magnetic attraction.

In some implementations, the current that is provided through the coil may be provided by a connection with one or both of the section cover terminals3812,3814and the common cover terminal3818of the capacitor3800. For example, a conductor (e.g., a wire) may be used to connect one or both of the section cover terminals3812,3814to a first end of the coil and a conductor may be used to connect another one of the section cover terminals3812,3814or the common cover terminal3818to a second end of the coil. In this way, the current that otherwise runs through the electrical components of the capacitor3800can also be used to power the electromagnetic, thereby causing the electromagnet to generate a magnetic field.

In some implementations, the capacitor3800may include one or more different and/or additional electrical components that can be used by the electromagnet to generate the magnetic field. For example, the capacitor3800may include a separate capacitor that is configured to store a charge to be used to subsequently apply current through the coil of the electromagnetic. In this way, the electromagnet may have a separate power source that can be used when generation of a magnetic field is desired.

In some implementations, the capacitor3800may include a switch that can be toggled by a user (e.g., a technician or an operator of the capacitor3800) to cause the electromagnetic to generate or cease generating the magnetic field. The switch may cause an electrical connection in the coil to be temporarily broken and restored. In some implementations (e.g., implementations in which the coil is connected to one or both of the section cover terminals3812,3814and/or the common cover terminal3818), the switch may cause the conductor that connects the coil to one or both of the section cover terminals3812,3814and/or the conductor that connects the coil to the common cover terminal3818to be temporarily broken and restored, such that the magnetic field generated by the electromagnet can be toggled on and off. In this way, the user can toggle the magnetic field on when mounting of the capacitor3800is desired (e.g., at the time of installation) and toggle the magnetic field off when mounting of the capacitor3800is not desired (e.g., when the capacitor3800is not in use and/or being stored) or when magnetic attraction is not desired (e.g., when mounting the capacitor3800at a location that does not include a magnetic surface).

In some implementations, the capacitive element3804(e.g., one or both of the sections of the capacitive element3804) may be used to store the charge that is subsequently provided to the coil of the electromagnet to cause the magnetic field to be generated. In this way, electrical charge that is otherwise stored by the capacitor3800during typical use can also be used to power the electromagnet.

While the capacitor3800shown in the illustrated example includes one magnet3820, additional magnets may also be provided. For example, a plurality of magnets may be positioned on the insulator cup3808or between the bottom wall of the case3802of the capacitor3800and the insulator cup3808. The plurality of magnets may have dimensions that are relatively smaller than dimensions that may be chosen for implementations in which only a single magnet3820is used. The plurality of magnets may have dimensions substantially similar to dimensions of a watch battery, such as a CR2032 battery. The plurality of magnets may be positioned at various locations at the bottom wall of the case3802. For example, the plurality of magnets may be arranged in a ring around a perimeter of the bottom wall such that the plurality of magnets are spaced approximately equidistant from one another. In some implementations, the plurality of magnets may be arranged in groups of two, three, etc. magnets. Any number of magnets may be provided to achieve the desired strength of magnetic attraction.

In some implementations, the capacitor3800includes two magnets3820positioned between the bottom wall of the case3802of the capacitor3800and the insulator cup3808of the capacitor3800. In some implementations, the two magnets3820are each circular shape (e.g., disk shaped). The two magnets3820may have a stacked configuration such that a first disk shaped magnet is stacked on top of a second disk shaped magnet. In some implementations, the two magnets3820may have a combined strength of approximately 70-80 mT, 60-80 mT, or 130-150 mT, although other ranges are also possible. The two magnets3820may have the same or different diameters. In some implementations, the two magnets3820may be positioned at a location that is misaligned with a center of the bottom wall of the case3802. For example, the center of the magnets3820may be misaligned with the center of the bottom wall of the case3802such that the magnets3820are positioned proximate to a side wall of the case3802. In some implementations, the center of the magnets3820may be aligned with the center of the bottom wall of the case3802. In some implementations, the centers of the two magnets3820may be misaligned relative to each other. In other words, a center of one of the magnets may be misaligned with a center of the other magnet.

Another capacitor3900according to the invention herein is illustrated inFIG.39. In the illustrated example, the capacitor3900includes an elliptical-shaped case3902(e.g., an oval-shaped case). The capacitor3900may provide a similar functionality as the other capacitors described herein, and may be adapted to replace a number of capacitors with the capacitor3900being connected to provide a substantially similar (or equivalent) capacitance value or values of one or more failed capacitors. The capacitor3900may include one or more of the design aspects, features, materials, etc. employed by the capacitors presented and described with respect toFIGS.1-38. In this arrangement, the capacitor3900includes a single wound cylindrical capacitive element3904. In some arrangements, additional capacitive elements may be provided.

In general, the capacitor3900can provide a functionality that is similar to the other capacitors described herein. The capacitive element3904can be implemented by using one or more production techniques. In the illustrated example, the capacitive element3904provides two capacitor sections, however, in some arrangements, the capacitive element3904may provide additional or fewer capacitive sections. Each capacitor section has a capacitance value that may be equivalent or different.

A common terminal of the capacitive element3904connects the sections of the capacitive element3904. An insulator cup3908is positioned in the bottom of the case3902(e.g., to protect the elements such as the capacitive element3904, and potentially other portions of the elements such as section terminals, from contact with the case3902. One or more mechanical mechanisms such as a bracket, a post, etc. may keep the capacitive element3904in proper alignment.

Conductors, preferably in the form of insulated foil strips or insulated wires, each have one of their respective ends soldered to corresponding section terminals and have their other respective ends connected to the corresponding terminal posts of a cover assembly, such as a cover assembly3910. In some arrangements, the cover assembly3910can assist in providing the functionality of a pressure interrupter, as described above. Typically, a common terminal of the capacitive element3904is connected to a common cover terminal post by one or more conductors. The conductors may be foil strips, insulated wire conductors, etc., and one or more connection techniques may be employed. In some arrangements, the case3902may be filled with an insulating fluid, however in some arrangements, an insulating fluid may not be used.

Geometry (length, shape, etc.), dimensions (e.g., length, diameter, etc.), etc. of the capacitive element3904may be selected in part to provide the desired capacitance values. The outer capacitor section generally has greater circumferential dimension and contains more metalized dielectric film compared to the capacitor section more closely adjacent to the mandrels, and therefore provides a larger capacitance value.

Each capacitive section has a section terminal which is connected by conductor to a corresponding one of the section cover terminals3912,3914of the cover assembly3910, and has a bottom terminal. The bottom terminals are connected to the common cover terminal3918. The bottom terminals may be connected together by strips soldered, welded, etc., with these strips providing both an electrical connection and a mechanical connection holding the assemblies together. Additionally, they may be wrapped with insulating tape. An insulated foil strip may connect the bottom terminals to the common cover terminal3918.

In some implementations, the capacitive element3904includes a first capacitive section and a second capacitive section. The capacitive value provided by the first capacitive section may be 2.5 microfarads (or, e.g., approximately 2.5 microfarads) and the capacitive value provided by the second capacitive section may be 5.0 microfarads (or, e.g., approximately 5.0 microfarads). For example, the first capacitive section may include a section terminal that is connected by a conductor to one of the section cover terminals (e.g., the section cover terminal3912), and the second capacitive section may include a section terminal that is connected by a conductor to the other section cover terminal (e.g., the section cover terminal3914). Each of the capacitive sections may include a common terminal (e.g., sometimes referred to as bottom terminals) that are connected by a conductor to the common cover terminal3918. In this way, a user can connect the section cover terminal3912and the common cover terminal3918to a device (e.g., an air conditioning system) to provide a capacitance value of 2.5 microfarads, and/or the user can connect the section cover terminal3914and the common cover terminal3918to a device to provide a capacitance value of 5.0 microfarads. The two capacitive sections can also be connected in parallel to provide a capacitance value of 7.5 microfarads. Such a capacitor may require two section cover terminals3912,3914and one common cover terminal3918. It should be understood that the first capacitive section and/or the second capacitive section may provide other capacitive values than those specifically described herein.

In some implementations, the capacitor3900may include one or more magnetic elements for assisting in mounting of the capacitor3900(e.g., to an air conditioning system). In the illustrated example, the capacitor3900includes a magnet3920positioned inside a side wall of the case3902of the capacitor3900. The magnet3920is configured to create magnetic attraction between the magnet3920and a magnetic surface in proximity to the capacitor3900. For example, the magnet3920may cause the side wall of the case3902to be attracted to a metallic surface of an air conditioning system, thereby improving the integrity of a mounting between the capacitor3900and the air conditioning system after installation. The magnet3920may be designed such that the strength of magnetic attraction between the magnet3920and the air conditioning system is such that the magnet3920may remain firmly in place in response to possible vibration and/or other movement of the air conditioning system during operational use. In some implementations, the strength of magnetic attraction between the magnet3920and the air condition system is such that a user (e.g., a technician installing or uninstalling the capacitor3900) can remove the capacitor3900from the surface of the air conditioning system without requiring excessive effort.

In some examples, the magnet3920may have a rectangular shape. For example, the magnet3920may be a rectangular strip that runs from top to bottom along the side wall of the case3902of the capacitor3900. In particular, the rectangular strip may have a particular thickness, a first dimension that runs from the top end of the capacitor3900to the bottom end of the capacitor3900, and a second dimension that is perpendicular to the first dimension and smaller than the first dimension. In some implementations, the magnet3920may have a square shape (e.g., such that the first dimension is equal to or substantially equal to the second dimension). In some implementations, the magnet3920may have a rod shape. In some implementations, the magnet3920may have a circular shape (e.g., a disk shape) or a hollow circular shape (e.g., a ring shape). For example, in some implementations, the magnet3920may have dimensions equal to or substantially equal to the dimensions of a disk-shaped battery (e.g., a watch battery such as a CR2032 battery). In some implementations, other shapes, a combination of shapes, etc. may be employed; for example, various types of curves may be incorporated into one or more magnetic strips (e.g., elongated oval shaped strips). Patterns of magnetic material may be used; for example, two crossed magnetic strips, a pattern of crosses, circles, etc. may be attached, incorporated into the bottom wall, side wall, etc. of the capacitor3900.

In some implementations, the magnet3920may have a curved shape that matches or substantially matches a curve of the case3902of the capacitor3900. For example, the magnet3920may have a curve that allows the magnet3920to make continuous contact with the side wall of the case3902of the capacitor3900.

In some implementations, the magnet3920may have dimensions of approximately 1 inch×1 inch and a thickness of about 1/10 of an inch. Such a magnet3920may be curved such that the magnet3920is configured to interface with an inner wall of the case3902of the capacitor3900(e.g., interior to the case3900).

In some implementations, the magnet3920(e.g., the curved magnet) may be positioned exterior to the case3902of the capacitor3900. In some implementations, a first surface of the magnet3920may be curved such that the first surface of the magnet3920interfaces with an exterior wall of the case3902of the capacitor3900, and a second surface opposite of the first surface may have a substantially flat shape that is configured to interface with a flat surface of a separate object (e.g., a surface or wall of an air conditioning system). In some implementations, multiple curved magnets3920may be provided in one or more of the configurations described herein (e.g., including multiple curved magnets, a curved and a non-curved magnet, etc.).

In some implementations, the magnet3920may run along (e.g., make continuous contact) with the full perimeter of the side wall of the case3902. That is, the magnet3920may have a sleeve shape with a diameter that is slightly less than a diameter of the capacitor3900. In this way, substantially all of the side wall of the case3902of the capacitor3900may be magnetic such that the user can affix any portion of the side wall of the capacitor3900to a magnetic surface (e.g., without needing to rotate the capacitor3900to find a surface that is in line with the magnet3920, as may be the case in implementations in which a magnet3920having a strip shape is used).

The particular shape and/or dimensions of the magnet3920may be chosen to achieve the desired strength of magnetic attraction. For example, the magnet3920may be designed with a particular shape and/or larger dimensions and/or larger thicknesses to achieve a relatively higher strength of magnetic attraction with a magnetic surface. In some implementations, increased surface area of the magnet3920toward the side wall of the case3902of the capacitor3900may increase the strength of magnetic attraction.

In some implementations, the magnet3920has a strength of approximately 30-40 milliTeslas (mT) or a strength of approximately 65-75 mT. In some implementations, the strength of magnetic attraction can be increased by stacking multiple magnets3920(e.g., one beside the other). In some implementations, two stacked magnets3920can have a strength of approximately 70-80 mT, 60-80 mT, or 130-150 mT, although other ranges are also possible. In some implementations, the magnet3920may be a D40×4 ferrite ceramic magnet manufactured by Hangzhou Honesun Magnet Co., Ltd.

In some implementations, the magnet3920may be magnetized using one or more of a plurality of techniques. For example, in some implementations, the magnet3920may be magnetized such that a north and a south pole of the magnet3920is located at a particular position of the magnet3920. For example, the techniques for magnetizing the magnet3920may cause the north and/or south pole to be located at various thicknesses of the magnet3920, etc. In some implementations, the magnet3920may be a multi-pole magnet

In some implementations, the magnet3920is a permanent magnet that is made from a material that is magnetized and creates its own persistent magnetic field. For example, the magnet3920may be made from a ferromagnetic material that can be magnetized, such as iron, nickel, cobalt, and/or an alloy of rare-earth metals, among others. In some implementations, the magnet3920is a ferrite and/or ceramic magnet. In some implementations, the magnet3920may include one or more of ferric oxide, iron oxide, barium, barium carbonate, strontium, and/or strontium carbonate. The magnet3920may include one or more magnetically “hard” materials (e.g., materials that tend to stay magnetized). Alternatively or additionally, the magnet3920may include one or more magnetically “soft” materials.

In some implementations, the magnet3920may be a rare-earth magnet. A rare-earth magnet is typically a relatively strong permanent magnet that is made from one or more alloys of rare-earth elements. Example of rare-earth elements that can be used in a rare-earth magnet include elements in the lanthanide series, scandium, and yttrium, although other elements may also or alternatively be used. In some implementations, the rare-earth magnet may produce a magnetic field of greater than 1.0T. In some implementations, the rare-earth magnet may include one or both of samarium-cobalt and neodymium.

In some implementations, the magnet3920may be made from one or more ceramic compounds (e.g., ferrite) that can be produced by combining iron oxide and one or more metallic elements. In some implementations, such ceramic compounds may be electrically nonconductive. The use of such ceramic compounds for the magnet3920may eliminate the inclusion of electrically conductive elements in the capacitor3900that may otherwise affect the operation of the capacitor3900.

In some implementations, the magnet3920may have a grade that corresponds to a particular standard (e.g., a National and/or International standard). In some implementations, the grade of the magnet3920corresponds to the Chinese ferrite magnet nomenclature system. For example, in some implementations, the magnet3920is grade Y10T, Y25, Y30, Y33, Y35, Y30BH, or Y33BH, although other grades are also possible. In some implementations, the grade corresponds to a working temperature of 250° C. In some implementations, the grade of the magnet3920corresponds to a Feroba, an American (e.g., “C”), or a European (e.g., “HF”) grading standard.

Like the magnet3820described above with respect toFIG.38, the magnet3920illustrated inFIG.39can also be an electromagnet that includes a core and a coil wrapped around the core, in which the materials, dimensions, configuration, and/or operating characteristics of the electromagnet can be chosen to achieve the desired strength of magnetic attraction.

While the capacitor3900shown in the illustrated example includes one magnet3920, additional magnets may also be provided. For example, a plurality of magnets may be positioned proximate to the side wall of the case3902of the capacitor3900. The plurality of magnets may have dimensions that are relatively smaller than dimensions that may be chosen for implementations in which only a single magnet3920is used. The plurality of magnets may have dimensions substantially similar to dimensions of a watch battery, such as a CR2032 battery. The plurality of magnets may be positioned at various locations proximate to the side wall of the case3902. For example, the plurality of magnets may be arranged in a ring around a perimeter of the side wall such that the plurality of magnets are spaced approximately equidistant from one another. In some implementations, the plurality of magnets may be arranged in groups of two, three, etc. magnets. Any number of magnets may be provided to achieve the desired strength of magnetic attraction.

In some implementations, the capacitors3800,3900may be configured to accept the magnet3820,3920after manufacture of the capacitor3800,3900. For example, the capacitor3800,3900may include one or more movable surfaces (e.g., doors or compartments) that can be opened by the user such that the user can place the magnet3820,3920inside the capacitor3800,3900. In this way, the user can add and/or remove the magnet3820,3920if magnetic attraction is desired or on longer desired. Further, the user can add additional magnets or remove magnets if a lesser strength of magnetic attraction is desired. For example, if a surface to which the capacitor3800,3900is mounted is highly magnetic, the strength of magnetic attraction provided by the configuration of the magnets may be excessive. As such, the user can remove one or more of the magnets from the capacitor3800,3900until the desired strength of magnetic attraction is achieved. On the other hand, if a surface to which the capacitor3800,3900is mounted is relatively non-magnetic, the strength of magnetic attraction provided by the configuration of the magnets may be too low. As such, the user can add one or more additional magnets to the capacitor3800,3900until the desired strength of magnetic attraction is achieved.

In some implementations, a bottom end of the capacitor3800(e.g., an area proximate to and including the bottom wall of the case3802) may be removable from the rest of the case3802of the capacitor3800. In some implementations, the bottom end of the capacitor3800may be attached by threading such that the bottom end of the capacitor3800may be removed by twisting the bottom end of the capacitor3800away from the rest of the case3802. Removing the bottom end of the capacitor3800may reveal a compartment within which the magnet3820(and, e.g., additional magnets) can be placed and/or removed. In some implementations, the side wall of the case3902of the capacitor3900may include a slidable and/or otherwise openable door that reveals a compartment of the capacitor3900within which the magnet3920(and, e.g., additional magnets) can be placed and/or removed.

In some implementations, the case3802,3902of the capacitor3800,3900may be made from a magnetic material (e.g., a metallic material). The magnet3820,3920may be held in place at least in part by magnetic attraction between the magnet3820,3920and the case3802,3902. For example, the magnet3802may be magnetically attracted to the bottom wall of the case3802of the capacitor3800, and the magnet3920may be magnetically attracted to the side wall of the case3902of the capacitor3900. In some implementations, the case3802,3902may be made from a non-magnetic material such as a plastic material. In such implementations, one or more other mechanisms or techniques may be used to fix the magnet3820,3920in place, as described below.

In some implementations, the magnet3820,3920may be affixed to a surface of the capacitor3800,3900by one or more mounting mechanisms. For example, one or more brackets may be used to affix the magnet3820to the bottom wall of the case3802. In some implementations, a bracket may be positioned around a surface of the magnet3820, and one or more fasteners may be used to affix the bracket against the bottom wall of the case3802. Similarly, one or more brackets may be used to affix the magnet3920to the side wall of the case3902. In some implementations, a bracket may be positioned around a surface of the magnet3920, and one or more fasteners may be used to affix the bracket against the side wall of the case3902. In some implementations, an adhesive may be used to affix the magnet3820,3920to the bottom wall of the case3802and/or the insulator cup3808and the side wall of the case3902. In some implementations, the magnet3820,3920may be held sufficiently in place by being wedged between the bottom wall of the case3802and the insulator cup3808, or by being wedged between the side wall of the case3902and other components of the capacitor3900. In some implementations, magnetic attraction between the magnet3820,3920and other components of the capacitor3800,3900(e.g., the case3802,3902) may assist in holding the magnet3820,3920in place.

In some implementations, the magnet3820,3920may be held in place at least in part by an epoxy. For example, once the magnet3820,3920is positioned at its desired position within the case3802,3902of the capacitor3800,3900, an epoxy can be introduced in proximity to the magnet3820,3920. Upon curing, the epoxy can provide sufficient strength for holding the magnet3820,3920in its desired mounting location.

In some implementations, a cutout (e.g., a recess) may be provided in which the magnet3820,3920can be seated (e.g., to assist in holding the magnet3820,3920in place at its desired mounting location). The cutout may be provided in the case3802,3902of the capacitor3800,3900and/or in the insulator cup3808of the capacitor3800. The cutout may provide a ridge that surrounds a perimeter of the magnet3820,3920to keep the magnet3820,3920in place. In this way, the magnet3820,3920is prevented from sliding to other locations within the case3802,3902of the capacitor3800,3900.

While the magnets3820,3920have been illustrated as being positioned within the case3802,3902of the capacitor3800,3900, in some implementations, the magnet3820,3920may be mounted to an exterior of the case3802,3902. For example, in some implementations, the magnet3820may be mounted to a bottom surface of the bottom wall of the case3802of the capacitor3800. The magnet3820may have a shape that substantially matches the shape of the bottom surface of the bottom wall. In this way, when the capacitor3800is mounted to a magnetic object (e.g., an air conditioning system), the capacitor3800can be positioned flush with the surface of the object. Similarly, in some implementations, the magnet3920may be mounted to an outside surface of the side wall of the case3902of the capacitor3900. In some examples, the magnet3920may be wrapped around or substantially around the outside surface of the side wall of the case3902such that substantially all outside surfaces of the case3902are magnetic. The magnet3820,3920may be mounted using one or more mounting mechanisms (e.g., brackets), an adhesive, an epoxy, one or more fasteners, etc. For example, one or more brackets may be used to mount the magnet3820,3920in an interior of the case3802,3902or at an exterior of the case3802,3902. In some implementations, the magnet3820,3920may be a magnetic film that is applied to a portion of the case3802,3902of the capacitor3800,3900. For example, the magnet3820,3920may be a magnetic film applied to the exterior of the case3802,3902.

In some implementations, the magnet3820,3920may have a thickness of approximately 4 mm. For example, in implementations in which the magnet3820is mounted to the bottom surface of the bottom wall of the case3802of the capacitor3800, a width of approximately 4 mm for the magnet3820may provide sufficient strength of magnetic attraction without making the capacitor3800unwieldy (e.g., by adding excessive height to the capacitor3800). Therefore, the capacitor3800does not take up excessive volume at its mounting location (e.g., at or within an air conditioning system).

In some implementations, one or more portions of the case3802,3902of the capacitor3800,3900are themselves magnetic, and/or the insulator cup3808,3908is magnetic. For example, the capacitor3800,3900may be designed such that the case3802,3902is made from a magnetic material. In this way, the capacitor3800,3900can be mounted in a variety of configurations as required for the particular application. For example, the bottom wall of the case3802of the capacitor3800and/or the insulator cup3808,3908of the capacitor3800,3900may be made from a magnetic material such that the bottom wall of the capacitor3800can be magnetically attracted to a magnetic object, and/or the side wall of the case3902of the capacitor3900may be made from a magnetic material such that the side wall of the capacitor3900may be magnetically attracted to a magnetic object.

While the magnets3820,3920have been illustrated and described as belonging to different capacitors3800,3900, in some implementations, the magnet3820ofFIG.38and/or the magnet3920ofFIG.39may be incorporated into other capacitors described herein. For example, in some implementations, the magnet3920may also be incorporated into the capacitor3800(e.g., instead of or in addition to the magnet3820), and vice versa. In some implementations, one or both of the magnet3820and the magnet3920may be incorporated into the other capacitors described herein, such as the capacitor10and/or the capacitor200and/or the capacitor300and/or the capacitor400.

While many implementations have been described above (e.g., such as the implementations described with respect toFIGS.38and39), other implementations are also possible. In some implementations, the capacitors described herein (e.g., the capacitor10,200,300,400,3800, and/or3900) may include multiple stacked magnets toward the bottom of the capacitor (e.g., similar to the capacitor3800ofFIG.38, and as described above, on the bottom wall of the case3802and/or between the bottom wall of the case3802and the insulator cup3808). For example, two magnets having a circular shape (e.g. disk shape) may be stacked on top of each other such that the centers of the two magnets are in alignment. In some implementations, the two magnets may be made from one or more ceramic compounds (e.g., ferrite), for example, which can be produced by combining iron oxide and one or more metallic elements.

In some implementations (e.g., in addition to implementations that include the two stacked magnets described above), multiple magnets may be provided at the side wall of the capacitor (e.g., the side wall of the capacitor3800,3900). For example, two magnets may be provided inside the side wall of the capacitor3800,3900. The two magnets may have a curved shape (e.g., as described above). In some implementations, each of the curved magnets may be configured to interface with an inner wall of the case3802,3902(e.g., at a location at or near, or including all or part of, the curved portion of the elliptical-shaped case3802,3902). In some implementations, the curved magnets may have dimensions of approximately 1 inch×1 inch and a thickness of approximately 1/10 of an inch. In some implementations, the two curved magnets are stacked vertically. For example, a first curved magnet may be provided at a first height between the side wall of the capacitor3800,3900and the capacitive element3804,3904, and a second curved magnet may be provided at a second height (e.g., above or below the first height) between the side wall of the capacitor3800,3900and the capacitive element3804,3904. In some implementations, each of the curved magnets may run around a full perimeter of the side wall of the capacitor3800,3900(e.g., such that the magnets have a ring- or sleeve-type elliptical/oval shape). In some implementations, one of the magnets may run around a full perimeter while the other magnet runs around less than an entirety (e.g., a portion) of the perimeter. In yet additional implementations, both of the magnets may run around less than an entire perimeter (e.g., a portion of the circumference of the side wall). In some implementations, the two curved magnets are positioned at the same vertical height along the length of the side wall. In such implementations, the two curved magnets may each run less than the entire perimeter of the side wall. In some implementations, one or both of the two curved magnets may be a rare-earth magnet that includes neodymium.

In some implementations, one or both of the magnets placed inside the side wall may be positioned between an inside surface of the side wall and a portion of the insulator cup3808,3908. For example, one or both of the curved magnets may be positioned between the side wall and an up-turned skirt portion of the insulator cup3808,3908. In some implementations, the up-turned skirt may run further up the side wall an additional length than what is illustrated in the figures (e.g., inFIGS.38and39). The multiple curved magnets may be stacked vertically or located at the same vertical height in a manner similar to that described above.

In some implementations, a liner may be positioned between the two curved magnets and the capacitive element3804,3904. For example, in implementations in which the curved magnets are not positioned between the side wall and the up-turned skirt of the insulator cup3808,3908, a liner may be applied over one or both of the curved magnets to separate the curved magnets from other components of the capacitor3800,3900. The liner may include a non-conductive material or any other material suitable for separating the magnets from other components of the capacitor3800,3900(e.g., for minimizing effects of the magnet on the performance of the capacitive element3804,3904and/or other components). In some implementations, the liner is a plastic adhesive material that can be applied over a surface of one or both of the curved magnets to separate the curved magnets from other components of the capacitor3800,3900. In some implementations, the liner can assist in holding the one or both of the curved magnets in place at the side wall of the capacitor3800,3900.

In some implementations, one or both of the two curved magnets may be positioned between the insulator cup3808,3908of the capacitor3800,3900and a bottom wall of the capacitor3800,3900. For example, one or both of the curved magnets may be placed in a position between the insulator cup3808,3908and the bottom wall of the capacitor3800,3900. The curved magnets may be placed instead of or in addition to the magnet3820ofFIG.38. The one or both of the curved magnets may be positioned in one or more of the configurations described in the preceding paragraphs. For example, the two curved magnets may be stacked vertically (e.g., one on top of the other, with the two curved magnets optionally making contact with one another) or the two curved magnets may be positioned at the same vertical height of the capacitor3800,3900(e.g., such that each of the curved magnets runs along less than an entire perimeter of the side wall, or such that each of the curved magnets runs along half of the perimeter of the side wall such that the sides of the two magnets make contact with each other). As mentioned above, one or more of the curved magnets may be a rare-earth magnet that include neodymium, while the disk shaped magnets may be made from one or more ceramic compounds (e.g., ferrite), although other materials are also possible. In some implementations, the neodymium curved magnets may have a relative higher (e.g., a substantially higher) degree of magnetic attraction as compared to that of the disk shaped ceramic magnets.

While the various disc shapes magnets and curved magnets have largely been described as being placed inside of the case3802,3902of the capacitor3800,3900, in some implementations, one or more of the magnets described herein may be placed outside of the case3802,3902. For example, one or more of the disk shaped magnets may be positioned on a bottom (e.g., outside) surface of the bottom wall of the case3802,3902. The magnets may be affixed to the outside of the case3802,3902by the strength of magnetic attraction. In some implementations, one or more mounting mechanisms (e.g., brackets), an adhesive, an epoxy, one or more fasteners, etc. may be used to assist in mounting the magnets to the outside of the case3802,3902. For example, one or more brackets may be used to mount the one or more magnets to the exterior of the case3802,3902. In some implementations, a liner (e.g., such as the liner described above) may be used to assist in mounting the one or more magnets to the case3802,3902.

Similarly, one or more of the curved magnets may be positioned on an outside surface of the side wall, of the case3802,3902. The magnets may be affixed to the outside of the case3802,3902by the strength of magnetic attraction. In some implementations, one or more mounting mechanisms (e.g., brackets), an adhesive, an epoxy, one or more fasteners, etc. may be used to assist in mounting the magnets to the outside of the case3802,3902. For example, one or more brackets may be used to mount the one or more magnets to the exterior of the case3802,3902. In some implementations, a liner (e.g., such as the liner described above) may be used to assist in mounting the one or more magnets to the case3802,3902.

While the curved magnets have been described as having a curved shape that substantially interfaces with the side wall of the case3802,3902, in some implementations, a first wall of one or more of the curved magnets may have a curved shape that interfaces with the side wall of the case3802,3902, and an opposite wall (e.g., a wall opposite of the curved wall of the one or more magnet) may have a substantially flat shape. The substantially flat shape may allow the case3802,3902to interface with a flat surface of a separate object (e.g., an air conditioning system). For example, in some implementations, one or more of the curved magnets may be positioned on an exterior of the side wall of the case3802,3902(e.g., as described above). The opposite surface of the curved magnet may have a flat shape that can substantially interface with a flat magnetically-attractive surface, such as a metal wall of an air conditioning unit or system. The flat shape of the opposite surface of the one or more magnets may allow the capacitor3800,3900to create a sufficient magnetic bond with the air conditioning unit or system, such that the capacitor cannot become inadvertently dislodged or misaligned from its intended mounting position.

In some implementations, one or more of the curved magnets may be configured to interface with both an outside of the side wall of the capacitor3800,3900and the bottom wall of the capacitor3800,3900. For example, one or more of the curved magnets may include at least five relevant surfaces: a first curved surface (e.g., inside surface) that is configured to interface with the outside surface of the side wall, a second flat surface (e.g., inside surface) that is configured to interface with the bottom wall, and three additional flat surfaces (e.g., outside surfaces) that are configured to interface with one or more mounting location (e.g., of one or more surfaces of an air conditioning unit or system). The inside surfaces can allow the magnet to make intimate contact with the case of the capacitor3800,3900, thereby allowing the one or more magnets to maintain contact with the capacitor3800,3900using one or more of the techniques described above. The three outside surfaces may allow the one or more magnets to make intimate contact with a mounting location, such as a corner mounting location that allows a bottom outside surface of the magnet to interface with a bottom mounting location, a first side outside surface perpendicular to the bottom outside surface to interface with a side mounting location, and a second side outside surface perpendicular to the bottom outside surface and the first side surface to interface with another side mounting location, thereby allowing the capacitor3800,3900to be mounted in a corner target area while being placed on a bottom surface of the target area.

In some implementations, the magnet may include two outside surfaces (e.g., without a bottom outside surface) that allows the capacitor3800,3900to be mounted in a corner target area without the capacitor3800,3900necessarily being placed on (e.g., magnetically attracted to) a bottom surface of the mounting area. In this way, the capacitor3800,3900can be mounted to a corner target area of an air conditioning unit or system while being suspended (e.g., without being placed on a bottom surface of the mounting area).

As described above, in some implementations, one or more of the curved magnets may be a rare-earth magnet that include neodymium, while the disk shaped magnets may be made from one or more ceramic compounds (e.g., ferrite), although it should be understood that other materials can additional or alternatively be used for any of the magnets described herein. In some implementations, the neodymium curved magnets may have a relative higher (e.g., a substantially higher) degree of magnetic attraction as compared to that of the disk shaped ceramic magnets. Such a configuration may, for example, provide additional magnetic mounting strength for implementations in which the capacitor3800,3900is side mounted (e.g., mounted to a side surface of a target mounting location without the bottom wall of the case3802,3902making contact with a bottom surface of the mounting location), sometimes referred to herein as a suspended mounting configuration. The relatively higher degree of magnetic attraction provided by one or more of the curved magnets may allow the capacitor3800,3900to be mounted in such configurations without becoming dislodged or misplaced from the target location. For example, the relatively higher degree of magnetic attraction may prevent the capacitor3800,3900from sliding down a wall of the mounting location due to the effects of gravity. In contrast, in implementations in which the bottom wall of the capacitor3800,3900is mounted to a bottom surface of the target mounting location (e.g., on a bottom surface of an air conditioning unit or system), such additional strength of magnetic attraction may not be necessary to maintain the capacitor3800,3900in proper mounting configuration. Nonetheless, additional curved magnets may also be included to provide additional and/or redundant magnetic attraction for mounting purposes.

In some implementations, any of the various magnets described herein (e.g., the magnet3820ofFIG.38, and/or the magnet3920ofFIG.39, and/or multiple ones of the magnets as described herein in any combination of configurations) may be mounted inside and/or outside of the case3802,3902of the capacitor3800,3900. For example, to name a few examples, and not by way of limitation, multiple disk shaped magnets may be mounted on an exterior of the case3802,3902. In particular, multiple disk shaped magnets in a stacked configuration, as described above, may be positioned on an exterior (e.g., bottom) surface of the bottom wall of the capacitor3800,3900. In some implementations, a first disk shaped magnet may be mounted inside of the case3802,3902and a second disk shaped magnet may be mounted outside of the case3802,3902(e.g., on the exterior surface of the bottom wall of the capacitor3800,3900). In some implementations, any combination of one or more disk shaped magnets, and/or one or more strip shaped magnets, and/or one or more curved magnets, etc. may be mounted in any combination of inside and/or outside of the case3802,3902of the capacitor3800,3900. In sum, while particular implementations are described herein and illustrated in the figures, it should be understood that any combination of the interior and/or exterior magnets described herein may be incorporated into the various capacitors10,200,300,400,3800, and/or3900described herein.

In some implementations, providing magnetic mounting capability for the capacitor can provide a number of advantages. For example, in some implementations, a component to which or within which the capacitor is to be mounted (e.g., an air conditioning system) may or may not include an area (e.g., a designated area) that is typically used for mounting the capacitor. However, the user may desire to mount the capacitor elsewhere. By providing magnetic mounting capability, the number of options for mounting can be greatly increased.

In some implementations, the capacitor is mounted at locations that include metallic and/or magnetic objects. Such objects may impact the performance of the capacitor. In some implementations, the user may desire to mount the capacitor at a particular location such that particular operating conditions are achieved. Magnetic mountability of the capacitor can allow the user to mount the capacitor at such locations. In some examples, the capacitor can be mounted at locations that allow for shorter conductive connections (e.g., wires) between the capacitor's section cover terminals and common cover terminal and the device to which the capacitor is connected. Without such flexibility in possible mounting locations, the wires may be excessively long and may be susceptible to being cut or broken along with being susceptible to noise and/or distortions.

The capacitor and the features thereof described above are believed to admirably achieve the objects of the invention and to provide a practical and valuable advance in the art by facilitating efficient replacement of failed capacitors. Those skilled in the art will appreciate that the foregoing description is illustrative and that various modifications may be made without departing from the spirit and scope of the invention, which is defined in the following claims.