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 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: 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: 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 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: 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 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 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: Methods are presented that includes replacing oven depolarization of a foil with a sonic vibration process for stressing the oxide. The method includes electrochemically etching the metal foil to form a plurality of tunnels in the metal foil and forming an oxide on a surface of the metal foil. The method further includes applying sonic vibration to the metal foil to induce stress fractures in the oxide, and reforming the oxide to heal at least a portion of the stress fractures.

Abstract: A method for patterning a metal substrate includes a series of surface treatments to control tunnel initiation at a micron or sub-micron level. In particular, the series of surface treatments include forming a hydration layer which acts as a mask while etching the surface of the metal substrate. The hydration layer mask enables control of the tunnel initiation on a micron or sub-micron level because the etching does not undercut the interface between the metal substrate and the hydration layer. As a result, the tunnels can be initiated in an orthogonal direction and closer together, thereby increasing the tunnel density.

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: 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: Methods are presented that includes replacing oven depolarization of a foil with a sonic vibration process for stressing the oxide. The method includes electrochemically etching the metal foil to form a plurality of tunnels in the metal foil and forming an oxide on a surface of the metal foil. The method further includes applying sonic vibration to the metal foil to induce stress fractures in the oxide, and reforming the oxide to heal at least a portion of the stress fractures.

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.

Abstract: An electrolytic capacitor is disclosed having a housing in an arced-trapezoidal shape. Disposed within the housing are one or more anodes, one or more cathodes, one or more separators disposed between anodes that are adjacent anodes cathodes, and an electrolyte disposed around the one or more anodes, the one or more cathodes, and the one or more separators within the housing. The housing of the electrolytic capacitor includes front and back walls shaped as arced-trapezoids and four sidewalls that substantially follow the outline of the front and back walls. The electrolytic capacitor is configured to connect in series with one or more electrolytic capacitors of the same shape to form a capacitor assembly. In the capacitor assembly, electrolytic capacitors are placed such that sidewalls are adjacent to each other to form a D-shaped capacitor assembly.

Abstract: A process for creating an anode foil for use in an electrolytic capacitor of an implantable cardioverter defibrillator is provided. The process includes placing a partially masked bulk metal foil in an etch electrolyte solution to etch exposed area of the bulk metal foil, removing the etch-resistant mask to expose the unetched areas, widening the bulk metal foil, and partially cutting the bulk metal foil between a plurality of unetched areas to form a partially detached etched foil anode, such that the unetched areas are not cut and the unetched areas serve as attachment tabs to keep the partially detached etched foil anode attached to the bulk metal foil. Additionally, the process may include an oxide formation step, wherein the step of partially cutting the bulk metal foil is performed after the etching and widening steps, and before the oxide formation step.

Abstract: A capacitor includes an anode foil, a cathode foil, a conductive electrolyte, and a separator between the cathode foil and the anode foil. The conductive electrolyte fills between the cathode foil and the anode foil and contains butyrolactone. The separator includes an aromatic polyamide fiber material. The aromatic polyamide fiber material is non-woven and includes a para-aromatic-polyamide synthetic fiber. The separator has a thickness in a range of about 5 ?m to about 20 ?m and a density of greater than about 1.0 g/cm3.

Abstract: Fabricating a capacitor includes performing an oxide formation operation on a sheet of material. The oxide formation operation forms an anode metal oxide on an anode metal. A thermal compression is performed on the sheet of material after the oxide formation operation is performed. The thermal compression applies thermal energy to the sheet of material while applying pressure to the sheet of material. After the thermal compression, the capacitor is assembled such that at least one electrode in the capacitor includes at least a portion of the sheet of material.

Abstract: A process for creating an anode foil for use in an electrolytic capacitor of an implantable cardioverter defibrillator is provided. The process includes placing a partially masked bulk metal foil in an etch electrolyte solution to etch exposed area of the bulk metal foil, removing the etch-resistant mask to expose the unetched areas, widening the bulk metal foil, and partially cutting the bulk metal foil between a plurality of unetched areas to form a partially detached etched foil anode, such that the unetched areas are not cut and the unetched areas serve as attachment tabs to keep the partially detached etched foil anode attached to the bulk metal foil. Additionally, the process may include an oxide formation step, wherein the step of partially cutting the bulk metal foil is performed after the etching and widening steps, and before the oxide formation step.

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.