Abstract: A cathode subassembly for use in an electrolytic capacitor may include a first separator sheet including a surface having first and second regions, where the second region extends from a perimeter of the first region to a first peripheral edge of the first sheet, a second peripheral edge of a second sheet is substantially aligned with the first peripheral edge, a conductive foil is sandwiched between the first and second sheets and disposed within the first region, the first and second sheets are adhered to each other in a sealing region extending from the second region to a region of a surface of the second sheet facing the second region, and the first sheet includes at least one first recess portion at the first peripheral edge aligned with at least one second recess portion at the second peripheral edge of the second sheet.

Abstract: A cathode subassembly for use in an electrolytic capacitor may include a first separator sheet including a surface having first and second regions, where the second region extends from a perimeter of the first region to a first peripheral edge of the first sheet, a second peripheral edge of a second sheet is substantially aligned with the first peripheral edge, a conductive foil is sandwiched between the first and second sheets and disposed within the first region, the first and second sheets are adhered to each other in a sealing region extending from the second region to a region of a surface of the second sheet facing the second region, and the first sheet includes at least one first recessed portion at the first peripheral edge aligned with at least one second recessed portion at the second peripheral edge of the second sheet.

Abstract: A capacitor and a method of processing an anode metal foil are presented. The method includes electrochemically etching the metal foil to form a plurality of tunnels. Next, the etched metal foil is disposed within a widening solution to widen the plurality of tunnels. Exposed surfaces of the etched metal foil are then oxidized. The method includes removing a section of the etched metal foil, where the section of the etched metal foil includes exposed metal along an edge. The section of the etched metal foil is placed into a bath comprising water to form a hydration layer over the exposed metal on the section of the etched metal foil. The method also includes assembling the section of the etched metal foil having the hydration layer as an anode within a capacitor.

Abstract: Fabricating a capacitor includes forming conduits in a porous layer of material. The porous layer of material has particles that each includes a dielectric on a core. The formation of the conduits causes a portion of the dielectric to convert from a first phase to a second phase. The method also includes removing at least a portion of the second phase of the dielectric from the porous layer of material.

Abstract: A method of producing a capacitor electrode includes forming an oxide layer on a foil. The method also includes inducing defects in the oxide layer followed by reforming the oxide layer. The oxide layer is reformed so as to generate a reformed oxide layer that is an aluminum oxide with a boehmite phase and a pseudo-boehmite phase. The amount of the boehmite phase in the reformed oxide layer is greater than the amount of the pseudo-boehmite phase in the reformed oxide layer.

Abstract: Disclosed herein is an electrode feedthru assembly for an electronic device and method of manufacturing. The feedthru assembly includes a ferrule, an electrode assembly, and an elastomer. The ferrule includes a bore through which the electrode assembly is positioned. The electrode assembly includes an electrode wire attached to a crimp pin. The crimp pin includes a crimp terminal portion and a pin terminal portion, the crimp terminal portion crimped to the a portion of the electrode wire to form a connected portion of the electrode assembly. The elastomer is disposed in the bore of the ferrule between the ferrule and the electrode assembly. The elastomer is configured to electrically isolate the ferrule from the electrode assembly and to encapsulate at least the connected portion of the electrode assembly.

Abstract: A capacitor and a method of processing an anode metal foil are presented. The method includes electrochemically etching the metal foil to form a plurality of tunnels. Next, the etched metal foil is disposed within a widening solution to widen the plurality of tunnels. Exposed surfaces of the etched metal foil are then oxidized. The method includes removing a section of the etched metal foil, where the section of the etched metal foil includes exposed metal along an edge. The section of the etched metal foil is placed into a bath comprising water to form a hydration layer over the exposed metal on the section of the etched metal foil. The method also includes assembling the section of the etched metal foil having the hydration layer as an anode within a capacitor.

Abstract: A method of producing an electrode for use in the manufacture of electrolytic capacitors for implantable cardioverter defibrillators comprises first growing a hydrate layer and/or formed oxide layers of the foil, applying a laser beam to portions of the foil to ablate the aluminum oxide foil surface before etching in order to induce etching in the specific areas, and then, etching the foil. The laser marks the oxide layer in a pulsed spot pattern through the hydrate layer and/or formed oxide layer leaving a dimpled nascent aluminum surface. The oxide layer left behind is a mask and the fresh aluminum areas are the high etching activation sites. After marking the aluminum oxide foil surface, the foil may be electrochemically etched in an electrolyte containing chloride and/or various oxidative species.

Abstract: A chemical etch is performed on a sheet of material. An electrochemical etch is performed on the sheet of material after the chemical etch is performed on the sheet of material. A capacitor is fabricated such that an electrode included in the capacitor includes material from the sheet of material after the electrochemical etch was performed on the sheet of material. In some instances, the chemical etch included at least partially immersing the sheet of material in an etch bath that includes molybdenum. Additionally or alternately, the chemical etch can be performed for a period of time less than 60 s.

Abstract: Disclosed herein is an electrode feedthru assembly for an electronic device and method of manufacturing. The feedthru assembly includes a ferrule, an electrode assembly, and an elastomer. The ferrule includes a bore through which the electrode assembly is positioned. The electrode assembly includes an electrode wire attached to a crimp pin. The crimp pin includes a crimp terminal portion and a pin terminal portion, the crimp terminal portion crimped to the a portion of the electrode wire to form a connected portion of the electrode assembly. The elastomer is disposed in the bore of the ferrule between the ferrule and the electrode assembly. The elastomer is configured to electrically isolate the ferrule from the electrode assembly and to encapsulate at least the connected portion of the electrode assembly.

Abstract: A method of producing an oxide layer on a foil for use in a capacitor includes immersing the foil in a first solution; maintaining a target current between the immersed anodic foil and the first solution until a first target voltage is reached to form an oxide layer overlying the foil; maintaining the target current between the immersed foil and the first solution until a second target voltage is reached to reform the oxide layer; removing the foil from the first solution and heating the foil; immersing the heat treated foil in a second solution; maintaining the target current between the immersed foil and the second solution until a third target voltage is reached; and discharging the immersed foil after each of the first, second, and third target voltages are reached.

Abstract: The present invention is directed to a method of etching anode foil in a non-uniform manner which minimizes thermal oxidation during foil cutting. Having less oxide improves the ability to cut through aluminum anodes with lower energy rates. In aluminum foils, it has been found that a masking step before etching reduces conversion of boehmite aluminum oxide to alpha-phase corundum during laser cutting of anodes, which increases edge quality and productivity. Additionally, the non-etched anode frame allows for less surface area to form during the aging process. As a result, the leakage current is reduced by the proportion of edge to anode surface area, and the aging process will be faster, leading to higher productivity.

Abstract: A method of producing an oxide layer on a foil for use in a capacitor includes immersing the foil in a first solution; maintaining a target current between the immersed anodic foil and the first solution until a first target voltage is reached to form an oxide layer overlying the foil; maintaining the target current between the immersed foil and the first solution until a second target voltage is reached to reform the oxide layer; removing the foil from the first solution and heating the foil; immersing the heat treated foil in a second solution; maintaining the target current between the immersed foil and the second solution until a third target voltage is reached; and discharging the immersed foil after each of the first, second, and third target voltages are reached.

Abstract: A capacitor is fabricated by generating a sheet of material that has a first active region that includes tunnels extending into an electrode metal. The sheet of material has a first inactive region that includes the electrode metal but does not include the tunnels extending into the electrode metal. The first inactive region has a first shape that includes multiple first projections that each projects from a perimeter of a circle. An electrode is removed from the sheet of material such that the electrode includes a portion of the inactive region. Additionally or alternately, fabricating a capacitor include using a first etching solution to etch a first sheet of material so as to generate a spent etchant. At least one chemical component is recovered from the spent etchant. A second etching solution is used to etch a second sheet of material. The second etchant includes at least one of the chemical components that was recovered from the spent etchant.

Abstract: A method of producing an oxide layer on a foil for use in a capacitor includes immersing the foil in a first solution; maintaining a target current between the immersed anodic foil and the first solution until a first target voltage is reached to form an oxide layer overlying the foil; maintaining the target current between the immersed foil and the first solution until a second target voltage is reached to reform the oxide layer; removing the foil from the first solution and heating the foil; immersing the heat treated foil in a second solution; maintaining the target current between the immersed foil and the second solution until a third target voltage is reached; and discharging the immersed foil after each of the first, second, and third target voltages are reached.

Abstract: Fabricating a capacitor includes using a fluid jet to form a conduit in a sheet of material. A capacitor can include at least a portion of the sheet of material in an anode. In some instances, the sheet of material is porous before the fluid jet is used to form the conduit.

Abstract: Electrolytic capacitors, and methods and apparatus for making the same are disclosed in herein. In one embodiment, a cathode comprises a conductive sheet having a central portion defined by a peripheral edge, a first tail extending out from the peripheral edge in a first direction, and a second tail extending out from the peripheral edge in a second direction opposite the first direction, wherein each of the first tail and the second tail has a first recess at a free end thereof.

Abstract: Anode foil, preferably aluminum anode foil, is etched using a process of treating the foil in an electrolyte bath composition comprising a sulfate, a halide, an oxidizing agent, and a surface active agent. The anode foil is etched in the electrolyte bath composition by passing a charge through the bath. The etched anode foil is suitable for use in an electrolytic capacitor.

Abstract: A process and apparatus are presented for cleaning the tunnels of an electrochemically etched anode foil. The apparatus includes a tank, a fluid inlet and a fluid outlet, and one or more tranducers. The tank is designed to receive a plurality of cartridges, each of the plurality of cartridges having a reservoir and being designed to hold a metal foil. The fluid inlet and fluid outlet are coupled with at least one of the plurality of cartridges, and are designed to introduce and expel, respectively, a liquid from the reservoir within at least one of the plurality of cartridges. The one or more transducers are coupled to at least one wall of each reservoir, the one or more transducers being designed to sonicate the liquid within each reservoir at a frequency less than 300 Hz.

Abstract: A method of processing a metal foil to produce a cathode for an electrolytic capacitor includes printing one or more layers of conductive ink on the metal foil to form a pattern of cathode plates, each of the one or more layers being a predetermined thickness, and the pattern arranged at a distance from a cathode tab and an edge of the cathode plates. The method also includes heating the deposited one or more layers of conductive ink to evaporate a solvent within the conductive ink such that conductive particles of the conductive ink remain deposited on the metal foil. The method further includes sintering the conductive particles and cutting the cathode plates from the metal foil, thereby producing the cathode plates suitable for use in the electrolytic capacitor.