US 2003/0199942 A1 · Implantable medical device having flat electrolytic capacitor fabricated with expansion riveted anode sheets

Abstract

Implantable medical devices (IMDs) and their various components, including flat electrolytic capacitors for same, and methods of making and using same, particularly an improved electrolytic capacitor fabricated of an electrode stack assembly comprising a plurality of capacitor layers stacked in registration upon one another. Each capacitor layer comprises a cathode layer having a cathode tab, an anode layer having an anode tab, and a separator layer located between adjacent anode and cathode layers. The anode layer is fabricated of side-by-side stacked anode sheets joined together by at least one malleable member that is fitted into substantially aligned anode sheet bores extending through each sheet and expanded therein to bear against the valve metal core layer of the anode sheets exposed by the bores to effect electrical and mechanical connection of the anode sheets and the anode tab.

Claims40

Dependent claims

An electrode stack assembly of an electrolytic capacitor comprising:

an anode layer comprising:
a first anode sheet fabricated of a valve metal having first and second sheet sides that are bounded by a first sheet edge, the first anode sheet having a first anode sheet bore extending through the valve metal from the first sheet side to the second sheet side;
at least one second anode sheet fabricated of a valve metal having first and second sheet sides that are bounded by a second sheet edge, the second anode sheet having a second anode sheet bore extending through the valve metal from the first sheet side to the second sheet side;
and
a first malleable conductive member expansion riveted within the first and second anode sheet bores into physical and electrical contact with the valve metals of the first and second anode sheets, whereby the valve metal of the second sheet is electrically connected to the valve metal of the first anode sheet;
a cathode layer;
and
a separator between the anode layer and the cathode layer, the separator carrying an electrolyte.

5 more elements

An electrode stack assembly of an electrolytic capacitor comprising:

an anode layer comprising:
a first anode sheet fabricated of a valve metal having first and second sheet sides that are anodized and bounded by a sheet edge, the first anode sheet having a plurality of first anode sheet bores extending through the valve metal from the first sheet side to the second sheet side;
at least one second anode sheet fabricated of a valve metal having first and second sheet sides that are anodized and bounded by a sheet edge, the second anode sheet having a plurality of second anode sheet bores extending through the valve metal from the first sheet side to the second sheet side;
and
a plurality of malleable conductive members expansion riveted within a respective plurality of anode layer bores each comprising a first anode sheet bore substantially aligned with a second anode sheet bore, the malleable conductive members making physical and electrical contact between the valve metals of the first and second anode sheets;
a cathode layer;
and
a separator between the anode layer and the cathode layer, the separator carrying an electrolyte.

5 more elements

An electrode stack assembly of a capacitor comprising:

a plurality of anode layers, each anode layer comprising:
a first anode sheet fabricated of a valve metal having first and second sheet sides that are bounded by a sheet edge, the first anode sheet having a first anode sheet bore extending from the first sheet side to the second sheet side;
at least one second anode sheet fabricated of a valve metal having first and second sheet sides that are bounded by a sheet edge, the second anode sheet having a second anode sheet bore extending from the first sheet side to the second sheet side;
and
a malleable conductive member expansion riveted through the first and second anode sheet bores and into physical and electrical contact with the valve metals of the first and second anode sheets, whereby the valve metal of the first and second anode sheets are electrically and mechanically connected together;
a plurality of cathode layers;
and
a plurality of separators positioned between the anode layers and the cathode layers, the separators carrying an electrolyte.

5 more elements

A method of fabricating an electrode stack assembly of an electrolytic capacitor comprising the steps of:

assembling an anode layer by:
providing first and second anode sheets fabricated of a valve metal having first and second sheet sides bounded by a sheet edge
boring a first anode sheet bore through the first anode sheet from the first sheet side to the second sheet side;
boring a second anode sheet bore through the second anode sheet from the first sheet side to the second sheet side;
substantially aligning the first and second anode sheet bore;
and
expansion riveting a malleable conductive member within the first and second anode sheet bores into physical and electrical contact with the valve metals of the first and second anode sheets;
providing a cathode layer;
and
interposing a separator between the anode layer and the cathode layer, the separator carrying an electrolyte.

7 more elements

A method of forming an electrode stack assembly of an electrolytic capacitor comprising:

forming an anode layer by:
providing first and second anode sheets fabricated of a valve metal having first and second etched and anodized sheet sides bounded by a sheet edge
boring a plurality of first anode sheet bores through the first anode sheet from the first sheet side to the second sheet side;
boring a plurality of second anode sheet bores through the second anode sheet from the first sheet side to the second sheet side;
and
expansion riveting a plurality of malleable conductive members within the plurality of aligned first and second anode sheet bores into physical and electrical contact with the valve metals of the first and second anode sheets;
providing a cathode layer;
and
interposing a separator between the anode layer and the cathode layer, the separator carrying an electrolyte.

6 more elements

A method of forming an electrode stack assembly of an electrolytic capacitor comprising:

forming a plurality of anode layers by, for each anode layer:
providing first and second anode sheets fabricated of a valve metal having first and second etched and anodized sheet sides bounded by a sheet edge
boring a first anode sheet bore through the first anode sheet from the first sheet side to the second sheet side;
boring a second anode sheet bore through the second anode sheet from the first sheet side to the second sheet side;
and
expansion riveting a malleable conductive member within the first and second anode sheet bores into physical and electrical contact with the valve metals of the first and second anode sheets;
providing a plurality of cathode layers;
and
interposing a separator between each anode layer and each cathode layer, the separator carrying an electrolyte.

6 more elements

Dependencies are inferred from the claim text.

Implantable medical device having flat electrolytic capacitor fabricated with expansion riveted anode sheets

Life of this patent

Implantable medical device having flat electrolytic capacitor fabricated with expansion riveted anode sheets

Life of this patent

Abstract

Claims40