Cathode subassembly with integrated separator for electrolytic capacitor, and method of manufacture thereof

A device, comprising:

• a conductive anode;
• a dielectric material disposed on a surface of the conductive anode;
• a cathode subassembly, wherein the cathode subassembly includes:
• a first separator sheet including a surface having a first region and a second region, wherein the second region extends from a perimeter of the first region to a first peripheral edge of the first separator sheet;
• a cathode;
• and
• a second separator sheet having a second peripheral edge, wherein the second peripheral edge is substantially aligned with the first peripheral edge, and wherein the cathode is sandwiched between the first and second separator sheets and disposed within the first region, and
• wherein the first and second separator sheets are adhered to each other in a sealing region extending from the second region of the first separator sheet to a region of a surface of the second separator sheet facing the second region, and
• wherein the first separator 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 separator sheet;
• and
• an electrolyte disposed between the anode and the cathode subassembly, wherein the first and second peripheral edges respectively of the first and second separator sheets are aligned with a peripheral edge of the anode;
• wherein the cathode includes a cathode tail that extends through the sealing region,
• a peripheral edge of the cathode includes multiple third recessed portions and the sealing region is positioned in an interior of each of the third recessed portions, and
• the tail is positioned between two of the third recessed portions;
• and
• wherein another one of the third recessed portions is positioned on a side of the peripheral edge of the cathode that is opposite from the two third recessed portions.

A device, comprising:

• a conductive anode;
• a dielectric material disposed on a surface of the conductive anode;
• a cathode subassembly, wherein the cathode subassembly includes:
• a first separator sheet including a surface having a first region and a second region, wherein the second region extends from a perimeter of the first region to a first peripheral edge of the first separator sheet;
• a cathode;
• and
• a second separator sheet having a second peripheral edge, wherein the second peripheral edge is substantially aligned with the first peripheral edge, and wherein the cathode is sandwiched between the first and second separator sheets and disposed within the first region, and
• wherein the first and second separator sheets are adhered to each other in a sealing region extending from the second region of the first separator sheet to a region of a surface of the second separator sheet facing the second region, and
• wherein the first separator 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 separator sheet;
• and
• an electrolyte disposed between the anode and the cathode subassembly, wherein the first and second peripheral edges respectively of the first and second separator sheets are aligned with a peripheral edge of the anode;
• wherein the cathode includes a cathode tail that extends through the sealing region,
• a peripheral edge of the cathode includes a third recessed portion and the sealing region is positioned in an interior of the third recessed portion, and
• the third recessed portion is positioned on a side of the peripheral edge of the cathode that is opposite from the cathode tail.