Pacesetter, Inc.

Bruce A Ribble

Ralph Jason Hemphill

David R Bowen

Wallace Ken Hall

Thomas Davis

Thomas Flavian Strange

Xiaofei Jiang

Tearl Stocker

R Jason Hemphill

Gary D Thompson

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.

Method of nano-patterning a foil surface

Method of nano-patterning a foil surce

A method of etching a foil for use in an electrolytic capacitor utilizes a nanoimprinted optic to control the etch pattern. The optic is formed by creating a self-assembled monolayer (SAM) of hemispheres onto the surface of an optical quartz substrate. A laser is directed onto the optic while the foil underlies the optic, and the concentrated light source is used to effectively image an array of submicron spots. The resulting spots allow for controlled initiation of etch tunnels during a subsequent electrochemical etch of the foil, with the purpose of ultimately increasing foil capacitance through the increased surface area.

Nanoimprinting of an optic to control the etch pattern on electrolytic capacitor foil

Disclosed herein is a method for manufacturing a feed thru for use in an electrolytic capacitor case. First, an electrode is inserted into a liquid injection mold. Liquid elastomer is then injected into the mold to surround a portion of the electrode. The elastomer is cured, and the resulting electrode and feed thru combination is inserted into a machined hole in a capacitor case. The machined hole may be located on either the base or the lid of the capacitor case. In other embodiments, a ferrule may also be placed in the liquid injection mold prior to injecting liquid elastomer. When a ferrule is used, the assembly may be welded into a machined hole in a capacitor case.

Electrolytic capacitor case design with insert molded elastomer seals

A method of producing a highly etched electrode for a capacitor from a foil is disclosed. The method comprises first applying a laser beam to the foil to form a plurality of marks on the foil surface and then etching the foil. Preferably, the laser marks facilitate etching of foil surface in areas near the marks and retard etching of foil surface inside the marks. After etching, the foil is further processed in a combination of optional steps such as forming and finishing steps. The laser marking of the foil allows for positional control of tunnel initiation, such that tunnel initiation density and the location of tunnel initiation is controlled. By controlling the position of tunnel initiation, foils are etched more uniformly and have optimum tunnel distributions, thus allows for the production of highly etched foils that maintain high strength and have high capacitance. The present invention further includes an electrolytic capacitor comprising etched aluminum anode foils, which have been prepared using the methods of the present invention.

Laser marking of raw aluminum anode foil to induce uniform patterning etching

This disclosure provides folded anode assemblies, conjoined cathode assemblies, and flat stack capacitor configurations comprising such assemblies, and methods of preparing the various assemblies. The anode assemblies, conjoined cathode assemblies and capacitor configurations disclosed herein can be used in implantable cardioverter defibrillators.

Growing community of inventors

Easley, SC, United States of America

Bruce A Ribble