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 device includes an electrode stack including a plurality of conductive anodes, a plurality of conductive cathodes, a plurality of separators arranged between the conductive anodes and the conductive cathodes, and a dielectric material disposed on a surface of each of the conductive anodes. The stack has a top surface, a bottom surface, and an edge extending between the top surface and the bottom surface. A continuous electrically insulating film overlies the edge, peripheral portions of the top surface and peripheral portions of the bottom surface so that a central portion of the top surface and a central portion of the bottom surface are exposed. An electrolyte is disposed between the conductive anodes and the conductive cathodes.

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 being crimped to 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 electrically isolates the ferrule from the electrode assembly and encapsulates 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: 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: Anode foil, preferably aluminum anode foil, is etched using a process of treating the foil in an electrolyte bath composition comprising a persulfate, a halide, an oxidizing agent, and a sulfate. An etch resist can be added to the anode foil prior to etching. The anode foil and the attached etch resist can be heated prior to immersing both in an electrolyte bath composition. The anode foil is etched in the electrolyte bath composition by passing a charge through the bath, while maintaining a constant level of persulfate. The etched anode foil is suitable for use in an electrolytic capacitor.

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: Fabricating a capacitor includes obtaining a sheet of material having a first phase of an anode metal oxide on an anode metal. The anode metal oxide is an oxide of the anode metal. A portion of the first phase of the anode metal oxide is converted to a second phase of the anode metal oxide. At least a portion of the second phase of the anode metal oxide is removed from the sheet of material. In some instances, the first phase of the anode metal is converted to the second phase of the anode metal oxide as a result of the process used to extract a capacitor anode from the sheet of material.

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

Abstract: Anode foil, preferably aluminum anode foil, is etched using a process of adding an etch resist to the anode foil and treating the foil in an electrolyte bath composition comprising a sulfate, a halide, an oxidizing agent, a surface active agent, and a non-ionic surfactant. 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 capacitor and methods of processing an anode metal foil are presented. The capacitor includes a housing, one or more anodes disposed within the housing, one or more cathodes disposed within the housing, one or more separators disposed between an adjacent anode and cathode, and an electrolyte disposed around the one or more anodes, one or more cathodes, and one or more separators within the housing. The one or more anodes each include a metal foil that includes a first plurality of tunnels through a thickness of the metal foil in a first ordered arrangement, the first ordered arrangement being a close packed hexagonal array arrangement, and having a first diameter, and a second plurality of tunnels through the thickness of the metal foil having a second ordered arrangement and a second diameter greater than the first diameter.

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

Abstract: Designs of a capacitor housing and method of assembly are presented. A case for an electrolytic capacitor includes a non-conducting cover, a non-conducting ring component, and a non-conducting plate. The non-conducting cover has a patterned groove on a surface of the non-conducting cover. The non-conducting ring component has a shape that is substantially the same as a shape of the non-conducting cover, and is coupled to the non-conducting cover via the patterned groove of the non-conducting cover. The non-conducting plate has a shape that is substantially the same as the shape of the non-conducting cover, and has a patterned groove on a surface of the non-conducting plate. The non-conducting ring component is coupled to the non-conducting plate via the groove of the non-conducting plate.

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: Fabricating a capacitor includes obtaining a sheet of material having a first phase of an anode metal oxide on an anode metal. The anode metal oxide is an oxide of the anode metal. A portion of the first phase of the anode metal oxide is converted to a second phase of the anode metal oxide. At least a portion of the second phase of the anode metal oxide is removed from the sheet of material. In some instances, the first phase of the anode metal is converted to the second phase of the anode metal oxide as a result of the process used to extract a capacitor anode from the sheet of material.

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 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: 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: 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.