Pacesetter, Inc.

Timothy R Marshall

Thomas Flavian Strange

Ralph Jason Hemphill

Christopher R Feger

David R Bowen

Joseph Beauvais

Thomas V Graham

Tommy Davis

Jason Hemphill

Pete J Fernstrom

Dean F Carson

James L Stevens

Naixiong Jiang

James Brian Smith

Justin King

Melissa A Moore

Jeffrey R LeBold

A method of manufacturing an electrolytic capacitor includes impregnating an electrolytic capacitor with a first electrolyte to form a first impregnated capacitor, aging the first impregnated capacitor using a first aging process to form a first aged capacitor, impregnating the first aged capacitor with a second electrolyte to form a second impregnated capacitor, the second electrolyte being different from the first electrolyte, aging the second impregnated capacitor using a final aging process to form a final aged capacitor, and impregnating the final aged capacitor with a third electrolyte.

Method of aging an electrolytic capacitor

A method of manufacturing an aluminum electrolytic capacitor includes impregnating an aluminum electrolytic capacitor with a first electrolyte to form a first impregnated capacitor, aging the first impregnated capacitor using a first aging process to form a first aged capacitor, impregnating the first aged capacitor with a second electrolyte to form a second impregnated capacitor, the second electrolyte being different from the first electrolyte, aging the second impregnated capacitor using a final aging process to form a final aged capacitor, and impregnating the final aged capacitor with a third electrolyte.

Method of aging an aluminum electrolytic capacitor

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.

Increasing capacitance of a capacitor

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.

Use of nonafluorobutanesulfonic acid in a low PH etch solution to increase aluminum foil capacitance

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.

Process for using persulfate in a low pH etch solution to increase aluminum foil capacitance

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.

Process additives to reduce etch resist undercutting in the manufacture of anode foils

Use of nonafluorobutanesulfonic acid in a low pH etch solution to increase aluminum foil capacitance

A method for manufacturing an electrolytic capacitor with improved deformation qualities includes impregnating an electrolytic capacitor with a first electrolyte, aging the electrolytic capacitor after impregnating and reimpregnating the electrolytic capacitor with a second electrolyte. The water content of the second electrolyte is lower than the water content of the first electrolyte. The second electrolyte may also have a lower viscosity and a higher conductivity than the first electrolyte.

Method for manufacturing an electrolytic capacitor with improved deformation qualities

A conductive electrolyte comprises an indicator dye for facilitating detection of electrolyte leakage in a high voltage electrolytic capacitor as well as for facilitating the determination as to when an electrolyte has reached a desired pH range. In a method for detecting electrolyte leakage, a capacitor comprising a flat stack of anodes enclosed in a housing with a lid and an electrolyte comprising an indicator dye is inspected for the presence of electrolyte leaking out of the capacitor. The indicator dye facilitates viewing leaking electrolyte. The indicator dye can be a coloring agent that changes the color of the electrolyte or can be a fluorescent that fluoresces when exposed to ultraviolet light. The indicator dye is also utilized as a pH indicator during the manufacture of electrolytic capacitors, wherein a base is introduced into an electrolyte having an indicator dye that changes pH when the electrolyte turns basic. The base is introduced into the electrolyte until the indicator dye causes the electrolyte to change color indicating the desired pH has been reached.

Electrolyte with enhanced leakage detection for electrolytic capacitors and method for detecting leakage

This disclosure provides methods for assembling multiple anode stacked capacitor configurations with a temporary adhesive to aide in the alignment of separator materials and electrodes without sacrificing energy density, and electrolytic capacitors comprising such configurations. The temporary adhesive for use in the electrode assemblies will preferably comprise a polymer that is substantially soluble in a solvent-based electrolyte for use in an electrolytic capacitor.

Electrode-separator combination for improved assembly of layered electrolytic capacitors

The present invention is directed to a conductive polyethylenedioxythiophene (PEDOT) polymer coated electrode adapted for use as a cathode electrode of an electrolytic capacitor and a method of manufacturing the same. According to the present invention, a metal foil substrate is placed in an aqueous solution of a doped 3,4-ethylenedioxythiophene (EDOT) monomer and a co-solvent, to dissolve the EDOT monomer, and a current is applied until the desired thickness of the polymer coating is electrochemically deposited. Additionally, an organic acid is added to the aqueous solution to act as an oxidizer. In order to improve the uniformity and adherence of the coating a surfactant may also be added. In a preferred embodiment, the EDOT monomer and cosolvent are first mixed, and then added to a water solution of oxidizer and dopant. The polymer film is deposited electrochemically onto the substrate by applying a DC current between 0.05 mA/cmand 5.0 mA/cmfor 1 to 60 minutes, more preferably between about 0.13 mA/cmto about 0.26 mA/cmfor between 9 and 18 minutes, such that a conductive polyethylenedioxythiophene (PEDOT) coating is formed on the electrode surface. According to the present invention, the increased surface area of the coated cathode results in lower gas generation and, therefore, reduced capacitor swelling, reduced oxide buildup on the cathode and prevention of electrolysis. The present invention results in electrodes with a minimum capacitance of 1 mF/cm. The present invention also makes it possible to use thinner electrodes than conventional aluminum electrodes, thereby reducing the physical dimensions of the capacitor.

High surface area cathode for electrolytic capacitors using conductive polymer

The present invention is directed to an electrolytic capacitor having a novel floating anode between the cathode and the powered anode of the capacitor, resulting in a single capacitor having a working voltage double that of the formation voltage of the powered anode. The floating anode acts as cathode to the powered anode and as an anode to the cathode, such that the capacitor according to the present invention supports half the working voltage between the cathode and the floating anode and half the working voltage between the floating anode and the powered anode. The arrangement of the cathode, floating anode and powered anode according to the present invention results in a single capacitor with half the capacitance and twice the voltage of a single anode device.

Floating anode DC electrolytic capacitor

The present invention is directed toward an enhanced very high volt electrolyte for use in electrolytic capacitors. In particular, by the inclusion of a polymer matrix of a hydrogel, preferably of the family of poly(hydroxy alkyl methacrylate) but also including polyvinylalcohol (PVA), polyacrylonitrile (PAN), into a standard fill electrolyte, the breakdown voltage of the enhanced very high volt electrolyte of the present invention is raised to as much as 800 V. An electrolytic capacitor impregnated with the enhanced very high volt electrolyte of the present invention, is capable of operating at a voltage of 700 to 800 volts. The production of a very high volt capacitor capable of operating at a voltage of 700 to 800 volts allows a single high volt electrolytic capacitor to replace the conventional two capacitors-in-series arrangement of an Implantable Cardioverter Defibrillator (ICD). Having a single high voltage capacitor results in savings in cost and in space required, especially where internal volume is at a premium, such as in an ICD and related medical implant devices.

Enhanced very high volt electrolyte

The present invention is directed to a conductive electrolyte for use in high voltage electrolytic capacitors and to an electrolytic capacitor impregnated with the electrolyte of the present invention for use in an implantable cardioverter defibrillator (ICD). The electrolyte according to the present invention is composed of a two solvent mixture of ethylene glycol and a polar organic cosolvent from the group of 2-methoxyethanol, 2-ethoxyethanol, 2-butoxyethanol, hexyl alcohol, or di(ethylene glycol). Dissolved in this mixture is a combination of boric acid with either an aliphatic dicarboxylic acid of carbon chain length from eight to thirteen (C to C ) or a very long chain dicarboxylic acid, where the acid functional groups are separated by 34 carbons (referred to as &ldquo;dimer acid&rdquo;). The solution is then neutralized with an amine. A cathode depolarizer, or degassing agent, from the group of nitro-substituted aromatic compounds (nitroaromatics) can be added to reduce the amount of gas produced during capacitor life. Hypophosphorous acid and/or a colloidal suspension of silica in ethylene glycol may be added to enhance the life characteristics of the electrolyte, resulting in lower leakage currents and better voltage droop characteristics. The water content may be adjusted with deionized water to achieve a Karl Fischer titration (water content) measurement of 1.0-8.0% to achieve proper age characteristics.

Conductive electrolyte for high voltage capacitors

The present invention relates to an improved method of impregnating electrolytic capacitor stacks or wound rolls with a polymer based electrolyte, such as a hydroxyethylmethacrylate (HEMA) or hydroxyethylacrylate (HEA) based electrolyte, to render them suitable for use in electrolytic capacitors, and to such electrolytic capacitors. The initiator to promote the polymerization of the polymer based electrolyte and a surface active wetting agent are deposited on the foil or in the stack or wound roll prior to impregnation of the stack or wound roll with a polymer based electrolyte, allowing the polymer based electrolyte solution to be warmed prior to impregnation to a temperature suitable for easy impregnation into the anode and cathode foil and paper. Polymerization does not begin until impregnation of the capacitor with the polymer based electrolyte and the surfactant allows the polymer based electrolyte to more fully incorporate itself into the microscopic features of the anode foil.

Growing community of inventors

Pickens, SC, United States of America

Timothy R Marshall