Method of constructing a capacitor stack for a flat capacitor

CROSS-REFERENCE TO RELATED APPLICATIONS

P-0001[0001] This application is a continuation of U.S. patent application Ser. No. <b>09</b>/<b>705</b>,<b>994</b>, filed on Nov. 3, 2000, the specification of which is incorporated herein by reference.

P-0002[0002] This application is related to application Ser. No. <b>09</b>/<b>706</b>,<b>447</b>, filed on Nov. 3, 2000, entitled FLAT CAPACITOR FOR AN IMPLANTABLE MEDICAL DEVICE, the specification of which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

P-0003[0003] The present invention concerns implantable medical devices, such as defibrillators and cardioverters, and more specifically to a method of manufacturing a capacitor stack for a flat capacitor.

BACKGROUND

P-0004[0004] Since the early <b>1980</b><i>s</i>, thousands of patients prone to irregular and sometimes life-threatening heart rhythms have had miniature heart monitors, particularly defibrillators and cardioverters, implanted in their bodies. These devices detect onset of abnormal heart rhythms and automatically apply corrective electrical therapy, specifically one or more bursts of electric current to the heart. When the bursts of electric current are properly sized and timed, they restore normal heart function without human intervention, sparing patients considerable discomfort and often saving their lives.

P-0005[0005] The typical defibrillator or cardioverter includes a set of electrical leads, which extend from a sealed housing into the wall of a heart after implantation. Within the housing are a battery for supplying power, monitoring circuitry for detecting abnormal heart rhythms, and a capacitor for delivering bursts of electric current through the leads to the heart.

P-0006[0006] Flat capacitors generally include a stack of flat capacitor elements, with each element including a paper separator between two sheets of aluminum foil. One of the foils serves as the anode of the capacitor element, and the other serves as the cathode.

P-0007[0007] One or more of the capacitor elements are often die cut in a shape designed to conform to a capacitor case. The cutting results in undesired residual stresses, and in warpage of the capacitor element. Stacking a plurality of these types of capacitor elements may result in increased height to the assembly. Moreover, the foil strip used to produce the capacitor element may not have the desired flatness prior to processing. Undesired residual stress due to this factor may also result in warpage of the capacitor assembly, enough to add height to the assembly. Moreover, the foils are cut using high-precision dies which are not only expensive, but require repeated sharpening. Another problem that arises is that cutting the foils can produce burrs on the cut edges of the foils. When edge burrs on adjacent anode and cathode foils contact each other, a conductive path results that short circuits the capacitive element.

P-0008[0008] Each anode foil in the stack, and each cathode foil in the stack, is interconnected to the other anodes and cathodes respectively. The anodes and cathodes generally include tabs which are crimped or welded together. Connecting the anodes and cathodes in this way provides a total capacitance equal to the sum of the capacitances of all the capacitor elements. However, the anode and cathode interconnections cause designers to increase the size of the capacitor case to accommodate tabs or to remove a portion of the capacitive elements, which reduces total capacitance or increases the size of the capacitor.

P-0009[0009] Moreover, since defibrillators and cardioverters are typically implanted in the left region of the chest or in the abdomen, a smaller size device, which is still capable of delivering the required level of electrical energy, is desirable.

P-0010[0010] Accordingly, there is a need for capacitor structures and methods of manufacture which provide greater process control, less expensive manufacturing, provide for a design efficiently utilizing space within the capacitor case, and provide for a compact capacitor design capable of providing the required pulse of energy for use within the implantable device.

SUMMARY

P-0011[0011] In one embodiment, a method of manufacturing a capacitor includes disposing one or more conductive layers of a first electrode stack in a recess of an alignment mechanism, where the recess is positioned relative to two or more alignment elements. The method further includes placing a separator over the one or more conductive layers where an outer edge of the separator contacts the two or more alignment elements. In addition, the method includes securing the aligned separator and conductive layers to one another to form an anode or a cathode stack.

P-0012[0012] In one embodiment, a method of manufacturing a capacitor includes providing an alignment mechanism having a plurality of alignment elements and a recess, each alignment element having a position corresponding to a point on the outer edge of either a first electrode stack or second electrode stack. The method further comprises aligning a portion of at least one first electrode stack relative to the recess and the alignment elements, and removing the aligned first electrode stack. In addition, the method further includes aligning a portion of at least one second electrode stack relative to a second alignment mechanism including a second recess and second alignment elements. The method further includes removing the aligned second electrode stack.

P-0013[0013] One aspect provides a multi-tab base foil layer for a flat capacitor. The base tabs of the base foil layer are spaced laterally along a vertical face of the capacitor stack. In addition to the base layer, the capacitor stack of foil layers includes secondary layers. The secondary layers have matching tabs that overlay the base tabs of the base layer. In one embodiment, this arrangement reduces the space required for connecting and routing the tab groups and this allows a reduction in the size of the capacitor, or alternatively an increase in its capacitance, or energy-storage capacity.

P-0014[0014] One aspect provides a capacitor stack structure that is more tolerant of edge burrs in the cut foil layers. In one embodiment, a capacitor with anode and cathode layers having non-overlapping edge portions. The cathode and anode layers are shaped or positioned such that edge portions of the two layers are offset from one another in a layered structure.

P-0015[0015] In one or more embodiments, the above described methods and structures provide for a capacitor making efficient use of space within the case, increased anodic surface area and increased capacitance for a capacitor of a given set of dimensions. Variation in the outer dimensions of one capacitor stack to another capacitor stack is reduced because each is formed within alignment elements positioned the same manner. Dimensional variations in the capacitor stack resulting from variation in the reference points from case to case or alignment apparatus to alignment apparatus are eliminated. This provides improved dimensional consistency in production and allows for reduced tolerances between the capacitor stack and the capacitor case. This allows for more efficient use of space internal to the capacitor case.

P-0016[0016] These and other embodiments, aspects, advantages, and features of the present invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art by reference to the following description of the invention and referenced drawings or by practice of the invention. The aspects, advantages, and features of the invention are realized and attained by means of the instrumentalities, procedures, and combinations particularly pointed out in the appended claims and their equivalents.

BRIEF DESCRIPTION OF DRAWINGS

P-0017[0017]FIG. 1 is a perspective view of a flat capacitor according to one embodiment of the present invention.

P-0018[0018]FIG. 2 is an exploded perspective view of a capacitor stack constructed in accordance with one embodiment.

P-0019[0019]FIG. 3 is an exploded perspective view of an anode stack constructed in accordance with one embodiment.

P-0020[0020]FIG. 4 is a side view of an anode stack and edge connection member constructed in accordance with one embodiment.

P-0021[0021]FIG. 5 is a side view of a separator constructed in accordance with one embodiment;

P-0022[0022]FIG. 6 is an exploded perspective view of a cathode base layer stack constructed in accordance with one embodiment.

P-0023[0023]FIG. 7 is an exploded perspective view of a cathode stack constructed in accordance with one embodiment.

P-0024[0024]FIG. 8 is an exploded perspective view of a cathode stack constructed in accordance with one embodiment.

P-0025[0025]FIG. 9 is an exploded perspective view of a cathode stack constructed in accordance with one embodiment.

P-0026[0026]FIG. 10 is an exploded perspective view of a cathode stack constructed in accordance with one embodiment.

P-0027[0027]FIG. 11A is a perspective view of an alignment mechanism constructed in accordance with one embodiment.

P-0028[0028]FIG. 11B is a perspective view of an alignment mechanism constructed in accordance with one embodiment.

P-0029[0029]FIG. 12 is a perspective view of a capacitor stack in an alignment mechanism constructed in accordance with one embodiment.

P-0030[0030]FIG. 13 is a top view of an anode stack aligned within an external alignment mechanism constructed in accordance with one embodiment.

P-0031[0031]FIG. 14 is a top view of staking locations for a plurality of anode stacks constructed in accordance with one embodiment.

P-0032[0032]FIG. 15 is a cross-sectional view of the staking locations of FIG. 14.

P-0033[0033]FIG. 16 is a top view of a cathode stack within an alignment mechanism constructed in accordance with one embodiment.

P-0034[0034]FIG. 17 is a perspective view of a cathode stack in an alignment mechanism constructed in accordance with one embodiment.

P-0035[0035]FIG. 18 is a top view of a capacitor stack according to one embodiment.

P-0036[0036]FIG. 19 is a side schematic view of the capacitor stack of FIG. 18.

P-0037[0037]FIG. 20 is a side schematic view of a capacitor stack according to one embodiment.

P-0038[0038]FIG. 21 is a cross-sectional view of a capacitor stack constructed in accordance with one embodiment.

P-0039[0039]FIG. 22 is an exploded view of an anode stack constructed in accordance with one embodiment.

P-0040[0040]FIG. 23 is an exploded view of a modified anode stack constructed in accordance with one embodiment.

P-0041[0041]FIG. 24 is an exploded view of a mixed anode stack constructed in accordance with one embodiment.

P-0042[0042]FIG. 25 is a cross-sectional view of a capacitor stack constructed in accordance with one embodiment.

P-0043[0043]FIG. 26 is a perspective view of a capacitor stack according to one embodiment.

P-0044[0044]FIG. 27 is a perspective view of the capacitor stack of FIG. 26.

P-0045[0045]FIG. 28 is a perspective view of the capacitor stack of FIG. 26 with a plurality of tab groups positioned on the top surface of the capacitor stack.

P-0046[0046]FIG. 29 is a partial exploded side view of the capacitor stack of FIG. 26.

P-0047[0047]FIG. 30 is a partial side view of a capacitor stack according to one embodiment.

P-0048[0048]FIG. 31 is a flow chart of a method for manufacturing a capacitor in accordance with one embodiment.

P-0049[0049]FIG. 32 is a block diagram of a implantable medical device system constructed in accordance with one embodiment.

DESCRIPTION OF EMBODIMENTS

P-0050[0050] In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the present invention. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.

P-0051[0051]FIG. 1 shows a partially exploded view of an exemplary embodiment of capacitor <b>18</b>. The present embodiment shows a D-shaped capacitor. In other embodiments, capacitor <b>18</b> may be designed in a variety of flat shapes to conform to various housing shapes. The capacitor includes a metallic case <b>20</b> defining a chamber <b>22</b>, in which is placed a capacitor stack <b>24</b>. In one embodiment, case <b>20</b> is manufactured from a conductive material, such as aluminum. In another option, the case <b>20</b> is manufactured using a nonconductive material, such as a ceramic or a plastic.

P-0052[0052] Case <b>20</b> includes a base <b>26</b> and a lid <b>28</b> overlying and resting on an upper rim of base <b>26</b>. Stack <b>24</b> has a face <b>30</b> and a top surface <b>32</b>. Stack <b>24</b> has a cutout region <b>34</b> at its periphery, with cutout region <b>34</b> being positioned when the stack <b>24</b> is installed in case <b>20</b> to provide space for electrical connections. An anode feedthrough post <b>36</b> passes through to stack <b>24</b> and is electrically insulated from case <b>20</b>. The capacitor stack <b>24</b> is covered with insulating tape <b>38</b>. A space <b>40</b> exists between the lid <b>28</b> and the top surface <b>32</b> of the stack <b>24</b> and between the face <b>30</b> of the stack <b>24</b> and a lateral wall of the base <b>26</b> of the case <b>20</b>. In some embodiments, space <b>40</b> is a line-to-line interference fit between portions of stack <b>24</b> and case <b>20</b>. In other embodiments, space <b>40</b> is a gap or opening within the case and between the stack and the case.

P-0053[0053] Capacitor stack <b>24</b> includes anode assemblies and cathode assemblies, with separator layers interposed therebetween.

P-0054[0054]FIG. 2 illustrates an exploded view of capacitor stack <b>24</b> according to one embodiment. Stack <b>24</b> includes a plurality of layers <b>120</b> which include at least one first electrode comprised of an anode stack <b>100</b>, at least one separator <b>200</b>, and at least one second electrode comprised of one of cathode stacks <b>300</b>. The separator <b>200</b> separates each anode stack <b>100</b> from each cathode stack <b>300</b>.

P-0055[0055]FIG. 3 illustrates an exploded view of one example of an anode stack <b>100</b>. The anode stack <b>100</b> includes a plurality of anode layers including conductive layers <b>115</b> consisting of an upper conductive layer <b>110</b>, a middle conductive layer <b>114</b>, and a lower conductive layer <b>116</b> as well as an anode-separator layer <b>90</b>. Each conductive anode layer has a first edge <b>111</b>, <b>121</b>, <b>131</b>, and <b>141</b>, respectively. Each anode layer also includes a clearance area defined by a second edge <b>112</b>, <b>122</b>, <b>132</b>, <b>142</b>. Each anode layer also includes an optional second edge <b>113</b>, <b>123</b>, <b>133</b>, <b>143</b>, respectively. The anode stack <b>100</b> further includes an edge connection member such as edge clip <b>150</b> for use in interconnecting the anode layers in adjacent layers of the capacitor stack <b>24</b>.

P-0056[0056]FIG. 4 illustrates a portion of an assembled anode stack <b>100</b>. The clearance area defined by the second edge <b>142</b> of the anode-separator <b>90</b> leaves the upper surface <b>154</b> of the edge clip <b>150</b> exposed for contact with an adjacent edge clip <b>150</b> of an adjacent layer <b>120</b>.

P-0057[0057]FIG. 5 illustrates a separator <b>200</b> which separates the anode stack <b>100</b> from the cathode stack <b>300</b> (FIG. 2). The separator <b>200</b> includes a first edge <b>251</b> a clearance area defined by a second edge <b>252</b> and a flat edge <b>253</b>. The clearance area of the separator <b>200</b> allows a side portion of the edge clip <b>150</b> (FIG. 3) to extend past the separator to reach an edge clip of an adjacent anode stack <b>100</b> (FIG. 2). The separator <b>200</b> is, in one option, made from a roll or sheet of separator material. Suitable materials for the separator material include, but are not limited to, pure cellulose or Kraft paper. Other chemically inert materials are suitable as well, such as porous polymeric materials. The separator <b>200</b> is cut slightly larger than the anode layers (or cathode layers) to accommodate misalignment during the stacking of layers, to prevent subsequent shorting between electrodes of opposite polarity, and to act as an outermost edge for alignment.

P-0058[0058]FIG. 6 illustrates an exploded view of an embodiment of a cathode base stack <b>50</b> including a cathode conductive layer <b>60</b> and a cathode-separator layer <b>70</b>. In this embodiment, cathode conductive layer <b>60</b> includes one or more legs <b>54</b><i>a</i>, <b>54</b><i>b</i>, <b>54</b><i>c</i>, <b>54</b><i>d </i>extending from the flat edge <b>363</b>. The cathode conductive layer <b>60</b> also includes a cathode extension member <b>62</b> for coupling the capacitor stack <b>24</b> to the case <b>20</b> (FIG. 1). Cathode legs <b>54</b><i>a</i>, <b>54</b><i>b</i>, <b>54</b><i>c</i>, <b>54</b><i>d </i>and cathode extension leg <b>62</b> extend beyond the dimensions defined by the inside of the case <b>20</b> during intermediate steps in the manufacturing process and are later formed to fit within the case. The cathode conductive layer <b>60</b> includes a first edge <b>361</b> inset from the first edges of the anode layers <b>110</b>, <b>114</b>, <b>116</b>, and <b>90</b> (FIG. 3) and inset from the second edges of the anode layers <b>110</b>, <b>114</b>, <b>116</b>, and <b>90</b>. The conductive layer <b>60</b> also includes a flat edge <b>363</b> inset from the flat edges of the anode layers <b>110</b>, <b>114</b>, <b>116</b>, and <b>90</b>.

P-0059[0059] Cathode-separator layer <b>70</b> is also provided and includes a first edge <b>371</b>, a clearance area defined by a second edge <b>372</b>, a flat edge <b>373</b> and an extension edge <b>374</b>. The cathode conductive layer <b>60</b> includes a first edge <b>361</b> inset from the first edge <b>371</b> of the cathode-separator and inset from the second edges of the cathode-separator layer <b>70</b>. The cathode conductive layer <b>60</b> also includes a flat edge <b>363</b> inset from the flat edges of the cathode-separator layer <b>70</b>. The inset edge <b>361</b> of the cathode conductive layer <b>60</b> and the clearance area of the cathode-separator layer <b>70</b> allows a portion of the edge clip <b>150</b> (FIG. 3) to extend past the cathode conductive layer <b>60</b> and the cathode-separator layer <b>70</b> to reach an edge clip <b>150</b> (FIG. 3) of an adjacent anode stack.

P-0060[0060] Referring to FIGS. <b>7</b>-<b>10</b>, examples of cathode stacks <b>300</b> are shown. Cathode stacks <b>300</b> include in one embodiment, cathode stacks <b>301</b>, <b>302</b>, <b>303</b>, <b>304</b>. Each cathode stack <b>301</b>, <b>302</b>, <b>303</b>, <b>304</b> includes cathode layers comprising a cathode conductive layer <b>60</b> and a cathode-separator layer <b>70</b>. In this embodiment, each cathode stack <b>301</b>, <b>302</b>, <b>303</b>, <b>304</b> conductive layer <b>60</b> includes an extension member such as a leg <b>60</b><i>a</i>, <b>60</b><i>b</i>, <b>60</b><i>c</i>, or <b>60</b><i>d </i>respectively. Cathode legs <b>60</b><i>a</i>-<b>60</b><i>d </i>on each cathode stack <b>301</b>, <b>302</b>, <b>303</b>, <b>304</b> extend beyond the dimensions defined by the case <b>20</b> (FIG. 1) during intermediate steps in the manufacturing process and are later formed to fit within the case. In one embodiment, each leg <b>60</b><i>a</i>-<b>60</b><i>d </i>corresponds to leg <b>54</b><i>a</i>, <b>54</b><i>b</i>, <b>54</b><i>c</i>, <b>54</b><i>d</i>, respectively, on the cathode base layer stack <b>50</b>, as will be discussed further below. Each cathode stack <b>301</b>, <b>302</b>, <b>303</b>, <b>304</b> includes a cathode conductive layer <b>60</b> having a first edge <b>361</b>, which when stacked, is inset from the first edge <b>141</b> of the anode separator <b>90</b> (FIG. 3) and inset from the second edge <b>142</b> of the anode separator. Further details of cathode stacks <b>300</b> will be described below.

P-0061[0061] In one embodiment of the present invention, the capacitor stack <b>24</b> described above is aligned to provide for optimal surface area of the capacitor.

P-0062[0062]FIGS. 11A, 11B, and <b>12</b> illustrate external alignment mechanisms <b>408</b>, <b>406</b>, <b>400</b> used to assemble anode stack <b>100</b>, cathode stack <b>300</b>, and capacitor stack <b>24</b>, respectively, in accordance with one embodiment. Each of the external alignment mechanisms <b>408</b>, <b>406</b>, <b>400</b> includes a plurality of precisely placed alignment elements <b>500</b>.

P-0063[0063] The alignment elements <b>500</b> in this embodiment, are vertically placed alignment elements <b>501</b>, <b>502</b>, <b>503</b>, <b>504</b>, which extend from a base <b>402</b>. The base <b>402</b> supports components thereon, while the alignment elements <b>501</b>, <b>502</b>, <b>503</b>, <b>504</b> align the components while the components are being stacked therein. The external alignment mechanism <b>400</b> optionally includes a first recess <b>520</b>, which is sized and positioned to receive a clip, as further discussed below. In another option, the external alignment mechanisms <b>406</b>, <b>408</b> each include a second recess <b>506</b>, <b>508</b>, respectively, in the base <b>402</b>, as further discussed below.

P-0064[0064] Referring to FIG. 12, a capacitor stack <b>24</b> is assembled within the alignment apparatus <b>400</b>. The capacitor stack <b>24</b> includes the plurality of layers <b>120</b>. Each layer <b>122</b> of the plurality of layers <b>120</b> includes at least one first electrode stack, at least one separator <b>200</b> (FIG. 2) and at least one second electrode stack. Each first electrode stack, second electrode stack and each separator <b>200</b> is aligned relative to the position of the alignment elements <b>501</b>, <b>502</b>, <b>503</b>, and <b>504</b>. Optionally positioned within the optional channel <b>600</b> is a fastener <b>610</b>, which is for wrapping around a portion of the capacitor stack <b>24</b> once the first electrode stacks, separators <b>200</b> and second electrode stacks have been stacked and aligned. Placing the fastener <b>610</b> in the channel <b>600</b> of the external alignment mechanism <b>400</b> positions the fastener <b>610</b> below the aligned capacitor stack <b>24</b> to maintain flatness of the capacitor stack <b>250</b>, for example, for further processing. Alternatively, or in addition to, the optional channel <b>600</b> allows for a gripping device such as pliers to be slipped under the capacitor stack <b>250</b>. In addition, precise alignment of the capacitor stack <b>250</b> is maintained by the alignment elements <b>500</b> when wrapping the capacitor stack <b>250</b>.

P-0065[0065]FIG. 13 illustrates a top view of anode stack <b>100</b> within the anode external alignment mechanism <b>408</b>, as described in FIG. 11A. To align the anode stack <b>100</b>, each conductive layer <b>110</b>, <b>114</b>, <b>116</b>, (FIG. 3) is placed in the recess <b>508</b>. The anode separator <b>90</b> (FIG. 3) is placed over the conductive layers <b>110</b>, <b>114</b>, <b>116</b> and is aligned relative to the alignment elements <b>501</b>, <b>502</b>, <b>503</b>, <b>504</b> by positioning the separator such that the first edge <b>141</b> and the flat edge <b>143</b> extend to contact each of the alignment elements <b>501</b>, <b>502</b>, <b>503</b>, <b>504</b>. The second recess <b>508</b> allows the anode separator <b>90</b> to be aligned relative to the conductive layers <b>110</b>, <b>114</b>, <b>116</b>. The alignment elements <b>501</b>, <b>502</b>, <b>503</b>, <b>504</b> concentrically align the separator <b>90</b> (FIG. 3) relative to the conductive layers <b>110</b>, <b>114</b>, <b>116</b> (FIG. 3).

P-0066[0066] In one embodiment, the anode external alignment mechanism <b>408</b> includes a recess <b>520</b>. The recess <b>520</b> receives a portion of the edge clip <b>150</b> (FIG. 3) that extends beyond the anode stack <b>100</b> and allows the conductive layers <b>115</b> of the anode stack <b>100</b> to lay flat, one on top of the other within the anode external alignment mechanism <b>408</b>. In one embodiment, the anode stack <b>100</b> is staked after being aligned in this manner.

P-0067[0067]FIG. 14 illustrates one embodiment in which the anode stack <b>100</b> is removed from the anode external alignment mechanism <b>408</b> (FIG. 13) and staked so that the conductive layers of the anode stack <b>100</b> form an anode chip. In one embodiment, the anode stack is staked as described in co-pending U.S. patent application Ser. No. 09/706,518, filed on Nov. 3, 2000, entitled FLAT CAPACITOR HAVING STAKED FOILS AND EDGE-CONNECTED CONNECTION MEMBERS, and incorporated herein by reference in its entirety.

P-0068[0068] In one embodiment, the staking locations <b>102</b> of the anode stacks <b>100</b> in the capacitor stack <b>24</b> (FIG. 1) are distributed so that anode stacks <b>100</b> in adjacent layers have staking locations that are offset from one another, as shown in FIG. 15 In one embodiment, the anode stack <b>100</b> is pressed after being staked to help reduce warpage and to reduce the overall height of the anode stack <b>100</b>. In one embodiment, the anode stack <b>100</b> is pressed to a specific, predetermined height.

P-0069[0069]FIG. 16 illustrates a cathode stack <b>300</b> within a cathode external alignment mechanism <b>406</b>. The same method is used to align the cathode conductive layer <b>60</b> and cathode separator layer <b>70</b> of the cathode stacks <b>50</b>, <b>301</b>, <b>302</b>, <b>303</b> and <b>304</b>, as was used to align the anode stack <b>100</b> (FIG. 13). The cathode conductive layer <b>60</b> is disposed within the recess <b>506</b>, and the cathode separator layer <b>70</b> is aligned relative to the alignment elements <b>501</b>, <b>502</b>, <b>503</b>, <b>504</b>. Since the alignment elements <b>501</b>, <b>502</b>, <b>503</b>, and <b>504</b> are placed in the same location for the anode external alignment mechanism <b>408</b>, the cathode external alignment mechanism <b>406</b>, and the external alignment mechanism <b>400</b> (FIG. 12), allows for the stacks <b>100</b>, <b>300</b> to be better aligned to one another. This helps to reduce variances in alignment which may result from varying tolerance stack ups between layers of the assembly and the alignment mechanism used.

P-0070[0070] In one embodiment, the cathode separator layer <b>70</b> is aligned relative to the plurality of alignment elements <b>500</b> by stacking the cathode separator layer <b>70</b> so that edge <b>371</b> and flat edge <b>373</b> extend to contact each of the alignment elements <b>501</b>, <b>502</b>, <b>503</b>, and <b>504</b>. While aligned, the cathode separator layer <b>70</b> is coupled to the cathode conductive layer <b>60</b>, for example, with adhesive. In one embodiment, each cathode stack <b>300</b> is pressed to help reduce warpage and thus to reduce the overall height of the capacitor stack <b>24</b> (FIG. 1).

P-0071[0071]FIG. 17 illustrates a capacitor stack <b>24</b> within an external alignment mechanism <b>400</b>. In this embodiment, the capacitor stack <b>24</b> includes a plurality of layers <b>120</b>, including anode stacks <b>100</b> (FIG. 3), and cathode stacks <b>300</b> (such as cathode stacks <b>50</b>, <b>301</b>-<b>304</b> in FIGS. <b>6</b>-<b>10</b>), which were each individually aligned with the anode external alignment mechanism <b>408</b> and the cathode external alignment mechanism <b>406</b>, respectively. The anode stacks <b>100</b> and the cathode stacks <b>50</b>, <b>301</b>-<b>304</b> are aligned relative to the alignment elements <b>500</b> using one or more outer edges of the cathode separators <b>70</b> (FIGS. <b>6</b>-<b>10</b>) and one or more outer edges of the anode separators <b>90</b> (FIG. 3). In one embodiment, capacitor stack <b>24</b> includes separators <b>200</b> (FIG. 5) and the alignment elements <b>501</b>, <b>502</b>, <b>503</b>, <b>504</b> further align each separator <b>200</b> relative to the anode stacks <b>100</b> and the capacitor stacks <b>300</b> using an outer edge of the separator <b>200</b> (FIG. 5). In some embodiments, separators <b>200</b> are omitted and capacitor stack <b>24</b> is aligned relative to the alignment elements <b>500</b> using only one or more outer edges of the cathode separators <b>70</b> (FIGS. <b>6</b>-<b>10</b>) and one or more outer edges of the anode separators <b>90</b> (FIG. 3).

P-0072[0072] In one embodiment, a fastener <b>610</b> is wrapped around a portion of the stack <b>24</b> to retain the alignment of the layers <b>120</b> relative to one another. In one embodiment, fastener <b>610</b> comprises tape that is wrapped around a central portion of the capacitor stack <b>24</b>. Optionally, the capacitor stack <b>24</b> is then clamped and annealed, with or without the fastener <b>610</b>. The channel <b>600</b> optionally allows for a tool and/or a robot to be disposed under the stack <b>24</b>.

P-0073[0073] In some embodiments, the anode stack <b>100</b> and the cathode stacks <b>50</b>, <b>301304</b> are aligned relative to one another within the case <b>20</b>, instead of using the external alignment mechanism <b>400</b>, and then are coupled to one another in the aligned position. For instance, an outer edge of a separator of the anode stack <b>100</b> (FIG. 3) and an outer edge of a separator of the cathode stacks <b>50</b>, <b>301</b>-<b>304</b> (FIGS. <b>6</b>-<b>10</b>) would contact an interior surface of the case <b>20</b>, and would be aligned therein.

P-0074[0074] Among other advantages, one or more embodiments of the alignment mechanism described provide for a capacitor making efficient use of space within the case, permit increased anodic surface area, and increased capacitance for a capacitor of a given set of dimensions. Variation in the outer dimensions of one capacitor stack to another capacitor stack is reduced because each is formed within alignment elements positioned the same manner. Dimensional variations in the capacitor stack resulting from variation in the reference points from case to case or alignment apparatus to alignment apparatus are eliminated. This provides improved dimensional consistency in production and allows for reduced tolerances between the capacitor stack and the capacitor case. This allows for more efficient use of space internal to the capacitor case. Each first electrode stack, second electrode stack and each separator is aligned relative to the position of the alignment elements.

P-0075[0075] Moreover, the capacitor stack structure described above provides for greater anodic surface area since, by aligning to the separator, the anode surface area is optimized by not having to provide extraneous alignment notches or other alignment features on the anode foil itself which decrease the anode surface area.

P-0076[0076] Since the external alignment mechanism is exterior to the case, better visual observation of the alignment of each electrode stack and separator is provided. Furthermore, multiple points are used to make the alignment, reducing the effect of the tolerance stack up between the conductive layer or separator being aligned and the alignment element at any one position. This also facilitates for alignment of components which during certain steps in the manufacturing process have portions which extend beyond the dimensions defined by the case and are later formed to fit within the case.

P-0077[0077] In some embodiments, the edges of the cathodes and anodes described above are generally co-extensive or aligned with each other within stack <b>24</b>. In other embodiments, capacitor stack <b>24</b> includes anode and cathode layers having at least partially offset edges.

P-0078[0078]FIG. 18 shows a planar view of a cathode stack <b>1800</b> according to one embodiment. The capacitor stack <b>1800</b> includes an anode layer <b>1801</b>, a separator <b>1802</b>, and a cathode layer <b>1803</b> that are configured in a layered structure analogous to capacitor stack <b>24</b> described above. The bottom surface in the figure is the anode layer, and the top surface is the cathode layer with the paper separator interposed therebetween. The separator includes two paper separators impregnated with an electrolyte that conducts current between the anode and cathode layers.

P-0079[0079] Some cutting processes used to make anode and cathode foil layers can produce burrs on the foils that can result in a short circuit if a burr on an anode layer edge portion makes contact with an adjacent cathode layer or vice-versa. When the dimensions of the cathode and anode layers are the same so that the edges of each layer are aligned, a burr on a cathode layer edge portion can then contact a burr on an anode layer edge portion. Burrs on overlapping edge portions of the anode and cathode layers may then make contact and cause a short circuit by traversing only half of the thickness of the paper separator between the two layers.

P-0080[0080] Accordingly, in one embodiment, the capacitor stack is constructed with layers having edge portions that are offset from one another. In one embodiment, this is done by having a cathode layer with a different dimension than the anode layer so that portions of their edges are offset in the layered structure (i.e., either the anode layer or the cathode layer is smaller than the other). The anode and cathode layers may be of the same general shape, for example, but of different surface areas so that the perimeter of one layer is circumscribed by the perimeter of the other layer.

P-0081[0081] The capacitance of an electrolytic capacitor results from the charge separation between the electrolyte and the anode layer so that altering the surface area of the cathode layer does not appreciably affect the capacitance of the device. Such an arrangement is shown in FIG. 18 where the cathode layer <b>1803</b> is of the same general shape as the anode layer <b>1801</b> but with a smaller surface area such that the edge portions of the cathode layer are inwardly offset from the anode layer edges. In this structure, only an edge burr on the cathode layer that traverses the entire thickness of the paper separator can produce a short circuit. This is in contrast to the case where the edge portions of the two layers are aligned rather than being offset. Offsetting the edge portions results in a greater tolerance for edge burrs and allows a less constrained manufacturing process.

P-0082[0082]FIG. 19 shows a cross-sectional schematic of capacitor stack <b>1800</b>. The capacitor is made up of a plurality of capacitive elements that are stacked on one another with each capacitive element being a layered structure capacitor such as shown in FIG. 18. The anode layers <b>1801</b> are stacked on cathode layers <b>1803</b> in alternate fashion with paper separator <b>1802</b> interposed between each anode layer and each cathode layer.

P-0083[0083]FIG. 20 shows a capacitor stack <b>2000</b> according to one embodiment. Capacitor stack <b>2000</b> includes multiple porous anode layers <b>1901</b>. The multiple layers result in a greater surface area exposed to the liquid electrolyte and a greater capacitance for each element. Three anode layers <b>1901</b><i>a</i>-<b>1901</b><i>c </i>are shown in the figure which are stacked together with a paper separator <b>1902</b> and cathode layer <b>1903</b> on each side of the stack. The liquid electrolyte flows through perforations in the anode layers to reach the oxide layers of each layer. The edge portions of each cathode layer <b>1903</b> are inwardly offset from the edge portions of each overlying and underlying anode layer <b>1901</b>.

P-0084[0084] In one embodiment, the offset structure described above can be incorporated into a cylindrical capacitor. For instance, the anode and cathode layers are cut from a sheet in a desired width and length. The cathode layer is made narrower than the anode layer so that the edges of the cathode layer are inwardly offset from the anode layer edges. The cylinder configuration is then produced by rolling the layers into concentric anode and cathode layers that are separated by electrolyte.

P-0085[0085] Offsetting of anode layer and cathode layer edge portions may be accomplished by using a variety of differently shaped and/or dimensioned cathode or anode layers.

P-0086[0086] In some embodiments, the cathode layer reduction ratio relative to the anode layer is limited. The electrical equivalent circuit of an electrolytic capacitor is the series connection of an anodic capacitance due to the charge separation that occurs between the anode layer and the electrolyte across the dielectric layer, an equivalent series resistance of the capacitor or ESR, and a cathodic capacitance due to the charge separation that occurs between the cathode layer and the electrolyte. When a capacitor is charged to its rated voltage, the voltage is divided and dropped across between the cathodic capacitance Cc and the anodic capacitance Ca. Since the charge stored on cathode layer Qc must equal the charge stored on the anode layer Qa, then:

P-0087[0087] Qa=Qc

P-0088[0088] CcVc=CaVa

P-0089[0089] where Vc is the voltage dropped across the cathodic capacitance and Va is the voltage dropped across the anodic capacitance.

P-0090[0090] The voltage Vc is thus inversely proportional to the cathodic capacitance. The cathodic capacitance should be large enough so that only a small voltage drop occurs across it when a voltage is applied to the capacitor, with most of an applied voltage being dropped across the anodic capacitance. If the cathode layer is made small enough relative to the anode layer, the cathode layer's capacitance may be reduced to such an extent that when the capacitor's rated voltage is applied an overvoltage condition occurs at the cathode layer with the creation of oxide and evolution of hydrogen gas.

P-0091[0091] Accordingly, in one embodiment the cathode layer is limited to the degree of decrease in surface area relative to the anode layer. In one embodiment, the cathode layer is kept to a size that keeps the overvoltage at tolerable levels when a rated voltage is applied to the capacitor. Such a minimum size for a cathode layer will vary, of course, with the capacitor's geometry and its rated operating voltage, but the size limit can easily be determined empirically.

P-0092[0092] In one embodiment, for example, a flat capacitors used in implantable defibrillators and designed to operate at a rated voltage of 400 volts, includes a ratio of the cathode layer surface area to the anode layer surface area of approximately 0.75 or greater. In some embodiments, the ratio is approximately 0.75 to approximately 0.93. In some embodiments, the ratio is approximately 0.93.

P-0093[0093] In some embodiments, capacitor stack <b>24</b> includes a uniform level of anode foils in each anode stack <b>200</b>. In other embodiments, the number of anode foils varies.

P-0094[0094] For instance, FIG. 21 illustrates a cross-section of a capacitor stack <b>2100</b> according to one embodiment. One example of mixed anode stacks <b>2102</b> is shown, which includes an anode stack <b>2100</b> and a modified anode stack <b>2101</b>. The anode stack <b>2100</b> includes at least one conductive layer <b>2115</b> having a height <b>2146</b>. The modified anode stack <b>2101</b> includes a plurality of conductive layers <b>2118</b> such that the modified anode stack <b>2101</b> includes at least one more conductive layer than included in the anode stack <b>2100</b>. The anode stack <b>2100</b> and the modified anode stack <b>2101</b> differ in the quantity of conductive layers in each. In addition, the anode stack <b>2100</b> and the modified anode stack <b>2101</b> differ in the total surface area of each.

P-0095[0095] The anode stack <b>2100</b>, also shown in FIG. 22 includes a first conductive element <b>2110</b>, a second conductive element <b>2112</b>, and a third conductive element <b>2114</b>, and an anode separator <b>2140</b>. In one embodiment, as shown in FIG. 23, a modified anode stack <b>2101</b> includes a first conductive element <b>2110</b>, a second conductive element <b>2112</b>, a third conductive element <b>2114</b>, and a fourth conductive element <b>2116</b>, and an anode separator <b>2140</b>, where the modified anode stack <b>2101</b> includes at least one more conductive element than the anode stack <b>2100</b>. In another option, the modified anode stack <b>2101</b> includes one or more less conductive elements than the anode stack <b>2100</b>.

P-0096[0096]FIG. 24 illustrates another example of mixed anode stacks <b>2202</b>, which includes a first anode stack <b>2204</b>, a second anode stack <b>2206</b>, and a third anode stack <b>2208</b>. The first anode stack <b>2204</b> has a plurality of conductive layers <b>2215</b> including a first conductive element <b>2210</b>, a second conductive element <b>2212</b>, and a third conductive element <b>2214</b>. In one option, the second anode stack <b>2206</b> includes a first conductive element <b>2210</b>, a second conductive element <b>2212</b>, a third conductive element <b>2214</b>, and a fourth conductive element <b>2216</b>. The third anode stack <b>2208</b> includes a first conductive element <b>2210</b>, a second conductive element <b>2212</b>, a third conductive element <b>2214</b>, a fourth conductive element <b>2216</b>, and a fifth conductive element <b>2218</b>, where the second and third anode stacks <b>2206</b>, <b>2208</b> include a different number of conductive elements than the first anode stack <b>2204</b>. In another option, the modified anode stack <b>2201</b> includes one or more less conductive elements than the anode stack <b>2200</b>.

P-0097[0097] In one embodiment, the first anode stack <b>2204</b> has a first surface area, and the second anode stack <b>2206</b> has a second surface area, and the first surface area is different than the second surface area, for example the second surface area is greater than the first surface area. In a further option, the first anode stack <b>2204</b> has a first surface area, the second anode stack <b>2206</b> has a second surface area, and the third anode stack <b>2208</b> has a third surface area. The third surface area is different than the first surface area and/or the second surface area, for example the third surface area is greater than the first surface area and/or the second surface area. The surface areas can be modified by modifying the surface of the conductive elements, for example, by etching. It should be noted that additional combinations of conductive layers and/or surface areas are contemplated and are considered within the scope of one or more embodiments of the present invention.

P-0098[0098] Referring to FIG. 25 the anode stack <b>2100</b> is coupled with the modified anode stack <b>2101</b>, where there are a variety of ways to couple the modified anode stack <b>2101</b> with the anode stack <b>2100</b>. In one example, the stack <b>2160</b> includes an edge clip <b>2150</b> and a modified edge clip <b>2170</b>, which interconnect the modified anode stack <b>2101</b> with the anode stack <b>2100</b>. The modified edge clip <b>2170</b>, which is coupled with the modified anode stack <b>2101</b>, has a height <b>2142</b> that is extended for a slightly higher height of the modified anode stack <b>2101</b>. The edge clip <b>2150</b> coupled with the anode stack <b>2100</b> has a height <b>2144</b> suitable for use with the anode stack <b>2100</b>. The edge clips <b>2150</b>, <b>2170</b> permit taller anode stacks to be reliably combined. The edge clips <b>2150</b>, <b>2170</b> are anodic and are optionally used to increase anodic surface area of the conductive layers <b>2115</b> as the edge clips <b>2150</b>, <b>2170</b> require little space within the capacitor stack <b>2160</b>. The composition of cells <b>290</b> and modified cells <b>292</b> as further discussed below, can be modified without requiring changes to other components in the capacitor stack <b>2160</b> resulting in greater design flexibility.

P-0099[0099] Referring again to FIG. 21, the capacitor stack <b>2160</b> includes at least one cell <b>290</b>, where each cell <b>290</b> includes an anode stack <b>2100</b>, an anode separator <b>2140</b>, a cathode stack <b>2300</b>, and a cathode separator <b>2200</b>. In addition, the capacitor stack <b>2160</b> includes at least one modified cell <b>292</b>, where each modified cell <b>292</b> includes a modified anode stack <b>2101</b>, an anode separator <b>2140</b>, a cathode stack <b>2300</b>, and a cathode separator <b>2200</b>. In one option, the cathode stack <b>2300</b> and the cathode separator <b>2200</b> are substantially the same as included in the cell <b>290</b> and the modified cell <b>292</b>, such that the difference in height between the anode stack <b>2100</b> and the modified anode stack <b>2101</b> is due to the increase in height of the modified anode stack <b>2101</b> resulting from the modified anode stack <b>2101</b> having a greater number of conductive layers <b>2115</b> than included in the anode stack <b>2100</b>. In another option, the modified anode stack <b>2101</b> of the modified cell <b>292</b> has fewer conductive layers <b>2115</b> than the anode stack <b>2100</b>.

P-0100[0100] In one embodiment, a plurality of modified cells <b>292</b> are distributed throughout the capacitor stack <b>2160</b> in a manner to optimize use of existing cathodic area. In one example, the capacitor stack <b>2160</b> includes fifteen cells, where at otherwise would be every fifth cell <b>290</b>, a modified cell <b>292</b> is disposed instead. Since the modified anode stack <b>2101</b> of the modified cell <b>292</b> includes at least one more conductive layer than the anode stack <b>2100</b>, the resulting example of capacitor stack <b>2160</b> includes at least three additional conductive anode layers within the case <b>20</b> (FIG. 1), without a substantial increase in the height of the components therein. For instance, for the capacitor stack <b>2160</b>, instead of adding an additional anode stack <b>2100</b>, which would have a height of three conductive layers <b>2115</b> (FIG. 21), and the height of an anode separator <b>2140</b> (FIG. 21), and the height of a separator <b>2200</b>, and the height of a cathode stack and an additional separator, only the height of the additional conductive layers <b>2115</b> in the modified anode stack <b>2101</b> is added to the height of the capacitor stack <b>2160</b>.

P-0101[0101] In other embodiments the modified anode stack <b>2101</b> contains one, two, three, four, five, six or more conductive layers <b>2115</b> than is included in each anode stack <b>2100</b>. Alternatively, more than one type of modified anode stack <b>2101</b> is included with the capacitor stack <b>2160</b>.

P-0102[0102] Referring again to FIG. 25, a stack <b>2160</b> is shown which includes cell <b>290</b>, and modified cell <b>292</b>. An edge clip <b>2150</b> is adjacent the edge clip <b>2170</b> of an adjacent modified cell <b>292</b>. The edge clip <b>2150</b> is coupled to adjacent modified edge clip <b>2170</b>. For example, the edge clip <b>2150</b> is welded to the modified edge clip <b>2170</b>. Where a plurality of cells <b>290</b> and modified cells <b>292</b> are provided, a plurality of edge clips <b>2150</b>, <b>2170</b> are also provided. The plurality of edge clips <b>2150</b>, <b>2170</b> stack one on the other such that the bottom surface <b>2157</b> of an edge clip <b>2150</b> or modified edge clip <b>2170</b> contacts the upper surface <b>2154</b> of an adjacent modified edge clip <b>2170</b>, or edge clip <b>2150</b>. The stacked edge clips <b>2150</b>, <b>2170</b> provide a larger contact surface <b>2158</b> increasing ease of attachment thereto. Each anode stack <b>2100</b> and modified anode stack <b>2101</b> remain essentially flat and do not require the ductility required of other designs to make an electrical connection. The stacked edge clips <b>2150</b>, <b>2170</b> provide for layer designs having higher stack composed of less ductile materials previously used, and further provide for interconnections in less space.

P-0103[0103] In one option, an upper portion <b>2153</b> of the edge clip <b>2150</b> or modified edge clip <b>2170</b> is positioned within a clearance area <b>2112</b> of the first conductive element <b>2110</b>. A side portion <b>2152</b> of the edge clip <b>2150</b> extends along the edges <b>2122</b>, <b>2132</b> of the second <b>2112</b> and third <b>2114</b> conductive elements, and extends along the edges of separators <b>2200</b>, and further along the edge of the anode separator <b>2140</b> of an adjacent modified anode stack <b>2101</b>. The edge clip <b>2150</b> remains separate from the cathode stack <b>2300</b>. The side portion <b>2152</b> of the modified edge clip <b>2170</b> extends along the edges <b>2122</b>, <b>2132</b>, <b>2182</b> of the second <b>2112</b>, third <b>2114</b>, and fourth <b>2116</b> conductive elements. The side portion <b>2152</b> also extends along the edges of separators <b>2200</b>, as well as along the edge of the anode separator <b>2140</b> of an adjacent anode stack <b>2100</b> or modified anode stack <b>2101</b>. The edge clip <b>2170</b> remains separate from the cathode stack <b>2300</b>.

P-0104[0104] In one or more embodiments, edge clips are utilized such as one or more connection members described in co-pending U.S. patent application Ser. No. 09/706,518, filed on Nov. 3, 2000, entitled FLAT CAPACITOR HAVING STAKED FOILS AND EDGE-CONNECTED CONNECTION MEMBERS, and cited above.

P-0105[0105] In one embodiment, a method is also provided, the method involving aligning an anode stack, including aligning at least one conductive layer having a surface and an edge, and aligning a first separator between the anode stack and a modified anode stack. The method further includes aligning at least one modified anode stack with the anode stack, which includes aligning a plurality of conductive layers, wherein the plurality of conductive layers includes at least one more conductive layer than included in the anode stack and one of the plurality of conductive layers having a surface and an edge, and electrically coupling the anode stack with the modified anode stack.

P-0106[0106] Several variations for the method are as follows. The method further including welding an edge clip to the modified anode stack. In another option, the method further includes aligning a first modified anode stack and a second modified anode stack, each having a plurality of conductive layers. In yet another option, the method further includes stacking a first number of layers to form the first modified anode stack, and stacking a second number of layers to form the second modified anode stack, and the first number of layers is different than the second number of layers. In yet another option, the method further includes aligning a second separator between the first modified anode stack and the second modified anode stack.

P-0107[0107] Advantageously, the mixed-anode capacitor stacks described above allow for a reduction in the volume, thickness, and the mass of the stack without a reduction in the deliverable energy, which provides for a smaller overall device size. This results in increased patient comfort, and reduces tissue erosion surrounding the implantable device. In addition, reducing the size of the capacitor allows for other critical component sizes to be increased, for example, the battery, or for other components to be added. A further benefit is that anodic surface area is increased without requiring additional cathodic area to support the added anode conductive layers. This allows a boost in capacitance with a minimal increase in thickness of the capacitor. In empirical studies, capacitors that included the modified anode stack showed capacitance values of 186 μF, 185 μF, and 186 μF, compared to standard devices without the modified anode stack which had capacitance values of 172 μF, 172 μF, and 173 μF.

P-0108[0108] Referring again to FIG. 17, once stack <b>24</b> is stacked as shown, the anode and cathode layers are interconnected. In one embodiment, the cathode layers are constructed and connected as described following.

P-0109[0109]FIG. 26 shows further details of capacitor stack <b>24</b> according to one embodiment of the present invention. As described above, the cathode layers <b>300</b> include base foil layer <b>50</b> and a plurality of secondary foil layers <b>301</b>-<b>304</b>, here denoted generally as layers <b>52</b>. The base layer has a plurality of base tabs <b>54</b><i>a</i>-<b>54</b><i>d </i>including a first base tab <b>54</b><i>a </i>in a first tab position <b>56</b><i>a</i>, a second base tab <b>54</b><i>b </i>in a second tab position <b>56</b><i>b</i>, a third base tab <b>54</b><i>c </i>in a third tab position <b>56</b><i>c</i>, and a fourth base tab <b>54</b><i>d </i>in a fourth tab position <b>56</b><i>d</i>. The present description is an example. Other embodiments include more tabs and less tabs with varying numbers of tab positions. Each tab <b>54</b><i>a</i>-<b>54</b><i>d </i>is electrically coupled to the other tabs <b>54</b><i>a</i>-<b>54</b><i>d </i>through base layer <b>50</b>, which includes at least one tab at each tab location. Each secondary layer <b>52</b> has at least one extension member or leg <b>60</b><i>a</i>-<b>60</b><i>d </i>positioned to overlay, be co-extensive with, or match with one of the plurality of tab positions <b>56</b><i>a</i>-<b>56</b><i>c. </i>

P-0110[0110] In this embodiment, the cathode layers are positioned to include a first layer group <b>60</b><i>a</i>, a second layer group <b>60</b><i>b</i>, a third layer group <b>60</b><i>c </i>and a fourth layer group <b>60</b><i>d</i>. Other embodiments have more layers or less layers. The layer groups are in electrical contact with each other, but spaced apart from the anode tabs <b>49</b> to allow separate connection of anode layers <b>46</b> without shorting. The layer groups electrically connect to an external cathode connection or cathode lead <b>62</b> which provides an external electrical connection to the case.

P-0111[0111] Each group of extension members <b>60</b><i>a</i>-<b>60</b><i>c </i>is positioned to overlay one of a plurality of tab positions <b>56</b><i>a</i>-<b>56</b><i>d</i>. The plurality of secondary layers are portioned into the plurality of the layer groups. The matching tabs of each layer group are located in the same position. For example, each of the matching tabs <b>60</b><i>a </i>of first layer group <b>60</b><i>a </i>are located in first tab position <b>56</b><i>a </i>so that the matching tabs <b>60</b><i>a </i>overlay first base tab <b>54</b><i>a</i>, which is also in first tab position <b>56</b><i>a</i>. In other words, from a top view perspective, tabs <b>60</b><i>a </i>are commonly positioned or co-extensive with base tab <b>54</b><i>a</i>. Secondary layers in each layer group are shown as located in adjacent layers. Alternatively, the layer groups may comprise secondary layers from non-adjacent layers.

P-0112[0112]FIG. 27 shows another view of the capacitor stack <b>24</b> having matching tabs of each secondary layer group <b>60</b> folded and welded to the corresponding tab <b>54</b> of the base layer, forming a plurality of tab groups <b>64</b>. The tab groups <b>64</b> electrically connect to an external cathode connection or cathode lead <b>62</b> which provides an external electrical connection to the case.

P-0113[0113] The cathode layers <b>44</b> include a first tab group <b>64</b><i>a</i>, a second tab group <b>64</b><i>b</i>, a third tab group <b>64</b><i>c </i>and a fourth tab group <b>64</b><i>d</i>. The tab groups <b>64</b> are also in electrical contact with each other, but spaced apart from the anode tabs <b>49</b> to allow separate connection from the anode layers <b>46</b> without shorting. The tab groups <b>64</b> are electrically connected to the capacitor case <b>20</b> or alternatively may be insulated from the case <b>20</b>.

P-0114[0114]FIG. 28 shows another view of capacitor stack <b>24</b> showing tab groups <b>64</b> folded into position on the top surface <b>32</b> of capacitor stack <b>24</b>. The tab groups have a reduced thickness and are folded onto the top of the stack and taped. Alternatively, the tab groups are cut just beyond the weld and taped against the face <b>30</b> of the stack. Each tab group <b>64</b> has a thickness that is less than the sum of the base layer and all the secondary layers.

P-0115[0115] The thickness of the tab groups are approximately equal to or less than space <b>40</b> as previously shown in FIG. 1. As noted above, in some embodiments, space <b>40</b> is merely a line-to-line interference fit. The present cathode structure provides that the cathode interconnections fit within the limited room available. Alternatively, the tab groups are located in space <b>40</b> between the face <b>30</b> of stack <b>24</b> and the case <b>20</b> or base <b>26</b>.

P-0116[0116] In this embodiment, base layer <b>50</b> has four base tabs <b>54</b><i>a</i>-<b>54</b><i>d </i>and each secondary layer <b>52</b> has at least one tab <b>58</b> that matches one of the base tabs <b>54</b><i>a</i>-<b>54</b><i>d</i>. The base tabs and matching tabs may be staked to the foil layer or the tabs may be integral with the foil layer. The layers <b>50</b>, <b>52</b> may have two or more tabs. The base tabs are shown with four tabs and the secondary tabs are shown with one tab. In some embodiments, the secondary layers include two or more tabs to create redundancy.

P-0117[0117] The embodiment described above show the base layer and secondary layer as cathode layers. However, the anode layers may also be arranged in a similar fashion. The anode layers may include a base layer with base tabs and secondary layers with matching tabs either alternatively or in addition to the cathode layers. The anode layers and cathode layers may be separated into tab groups and positioned in the space between the top of the stack and the housing and the face of the stack and the housing. The anode layers and cathode layers remain separated from each other such as with paper layers. Insulation may also be required between the anode and cathode layers and the case.

P-0118[0118]FIG. 29 shows a side view of base layer <b>50</b> and secondary layers <b>52</b> of a capacitor stack including layer groups such as non-adjacent layer group <b>66</b><i>d</i>. The matching tabs <b>58</b> of secondary layers <b>52</b> of non-adjacent layer group <b>66</b><i>d </i>are shown mating with base tab <b>54</b><i>d </i>to form non-adjacent tab group <b>68</b><i>d. </i>

P-0119[0119]FIG. 30 shows a side view of the foil layers of a capacitor stack <b>24</b> according to one embodiment where both one or more anode layers <b>46</b> and one or more cathode layers <b>44</b> are portioned into cathode tab groups <b>70</b> and anode tab groups <b>72</b>.

P-0120[0120] Capacitor stack <b>24</b> comprises separators <b>48</b> between foil layers of alternating cathode layers <b>44</b> and anode layers <b>46</b>. The anode layers and cathode layers form capacitive elements <b>42</b>. The cathode layers include a base layer <b>50</b> and secondary layers <b>52</b>. The base layer <b>50</b> has base tabs <b>54</b><i>a</i>-<b>54</b><i>d </i>and the secondary layers <b>52</b> have matching tabs <b>58</b>. Each matching tab <b>58</b> overlays one of the base tabs <b>54</b><i>a</i>-<b>54</b><i>d </i>of the base layer <b>50</b>. The cathode layers <b>44</b> connect to the base layer <b>50</b>.

P-0121[0121] The anode layers <b>46</b> include a secondary base layer <b>76</b> with secondary base tabs <b>78</b><i>a</i>-<b>78</b><i>d </i>and additional secondary layers <b>80</b>. Each of the additional secondary layers <b>80</b> has a secondary matching tab <b>82</b> with each secondary matching tab <b>82</b> overlaying one of the secondary base tabs <b>78</b><i>a</i>-<b>78</b><i>d </i>of the secondary base layer <b>76</b>. For example, secondary matching tab <b>82</b><i>c </i>vertically matches or overlays secondary base tab <b>78</b><i>c</i>. Each of the anode layers <b>46</b> connect to the secondary base layer <b>76</b>.

P-0122[0122] In one or more of the embodiments described above, the foil layers are spread out or distributed over multiple locations. For example, the cathode layers may be spread out over four locations with four tab groups, with the thickness of each tab group at each location being about 0.006 inch (assuming that 5 layers at 0.00118 inch per layer are at each location). This thinness of the tab group allows the stacked unit to be placed into the housing with the tab groups occupying the space between the housing and the edge of the stack or the clearance space between the lid and the top of the stack. These clearance spaces are allowed for inserting the stack into the housing. As a comparison, if the cathode tabs were all brought out at one location, the thickness would be greater than 0.020 inch and make it difficult, if not practically impossible, to fold the tabs collectively over the stack as in FIGS. 27 and 28. Thus, this thickness would require that part of the stack be removed or the case enlarged to allow space for routing and connecting the cathode layer connections, thereby reducing the packing efficiency of the capacitor.

P-0123[0123] One embodiment of a method to cut foil layers out of etched and unetched aluminum foil using a laser is described below. In one embodiment, the method of preparing aluminum foil layers for electrolytic capacitors includes cutting a capacitor foil layer out of a sheet of aluminum foil with a laser, removing the foil layer from the sheet of aluminum foil, and inserting the foil layer shape in a capacitor. The foil layer may be used as a cathode layer or as an anode layer. In some embodiments, the foil layer includes a plurality of tabs.

P-0124[0124] In various embodiments, the cutting may be partially through the sheet, the method may include cutting multiple sheets at one time, the method may include cutting multiple layers of sheets including paper separators, and/or the method may include cutting a portion or an entire capacitor stack at one time.

P-0125[0125] In some embodiments, the method includes laying out a pattern of capacitor foil layer shapes, delivering the aluminum foil to the laser in a roll, cutting different shapes out of the sheet of aluminum foil, and cutting through multiple layered sheets of aluminum foil. The method is used to cut out the intricate shapes of a multi-leg or multi-tab foil layer.

P-0126[0126] Using the above laser cutting method has one or more of the following advantages: a) rapid prototyping, b) the cut out shape does not drop out of the foil until needed, making for easier handling, c) the method eliminates the need for constant sharpening of expensive dies, d) the method does not produce burrs or particulates. Thus, allowing the use of thinner separators, e) the method allows for optimal pattern layout on the foil reducing the amount of generated waste, f) the foil may be delivered to the laser in several ways including rolls, sheets or small pieces, and g) the laser can be set up to cut out different shapes out of the shame sheet. The method has the advantage of cutting out the intricate shapes of the multiple tab cathode described above without tearing the closely spaced tabs. In addition, the intricate shapes can be formed without developing an expensive die that requires sharpening.

P-0127[0127] In one embodiment, the foil is cut using a Signature <b>75</b> laser manufactured by Control Laser Corporation. In various embodiments, the laser was set at the following setting: current 18-23, 5-8 kHz, and a speed of 0.35 to 1.5 inches/second.

P-0128[0128]FIG. 31 illustrates an example of a process flow for a method for manufacturing a capacitor <b>18</b> having a capacitor stack <b>24</b> with one or more of the features described above. The method of FIG. 31 is an example of one embodiment and it is understood that different steps may be omitted, combined, and/or the order changed within the scope of one or more embodiments of the present invention.

P-0129[0129] The method includes, at <b>410</b>, stacking the anode conductive layers within an external alignment mechanism <b>408</b> and aligning them therein. In some embodiments, the anode stack is pressed <b>412</b>, as further described below. The separator is aligned with the anode layers <b>414</b>, and the separator is coupled with the anode stack <b>416</b>, for example, by bonding using, for example, an adhesive. The cathode layer is aligned with the cathode separator at <b>420</b>, and the cathode separator is coupled with the cathode layer at <b>422</b>, for example, by bonding the cathode separator with the cathode layer using, for example, an adhesive.

P-0130[0130] In one embodiment, the anode stack and cathode stack are individually pressed to improve the flatness of each stack and to reduce or eliminate warpage, and are optionally are pressed to a specific, predetermined height. In another option, the capacitor stack <b>24</b> is pressed to improve the flatness and to reduce or eliminate warpage. In one embodiment, the capacitor stack <b>24</b> is pressed to a specific height to improve the flatness and to reduce or eliminate warpage. Pressing to a specific height helps to maintain consistency in the manufacturing process. Each anode stack <b>100</b>, each cathode stack <b>300</b>-<b>304</b>, each layer set, the capacitor stack <b>24</b> of all of the layer sets form, in effect, a spring. The spring rate will vary from capacitor stack <b>24</b> to capacitor stack <b>24</b> due, in part, to variations in the foil supplied and/or in the manufacturing processes associated with cutting the foil as well as the general handling of the part. Pressing the anode stack <b>100</b>, the cathode stacks <b>300</b>-<b>304</b>, the layer set, or the capacitor stack <b>24</b> to a controlled height maintains consistency in the assembly process in that each stack <b>100</b>, <b>300</b>-<b>304</b>, layer set or capacitor stack <b>24</b> will be maintained at the same height regardless of initial spring rate. Among other things, this assures a consistent fit between the capacitor stack <b>24</b> and the case <b>20</b> (FIG. 1).

P-0131[0131] Referring again to FIG. 18, at <b>430</b>, the cathode, anode, and separator layers are stacked and aligned by the outer edges of the separators using the external alignment mechanism <b>400</b> to form a capacitor stack <b>24</b>. The capacitor stack <b>24</b> is optionally partially taped at <b>432</b>. Optionally, at <b>434</b> the capacitor stack is clamped and annealed. For example, an anode stack is pressed to a specified height, then assembled into the capacitor stack <b>24</b>. The capacitor stack <b>24</b> is clamped to a specified height and annealed. In one example, annealing includes heating to a temperature of about 85° C., soaking for about 12 hours, and cooling to 23° C. degrees for about 1 hour.

P-0132[0132] In another option, the components are individually annealed. Annealing reduces or eliminates undesired residual stresses which contribute to warpage and can help to provide improved flatness of the overall capacitor stack <b>24</b>. Annealing can also be performed after a portion of an electrode has been deformed to retain the deformed shape and reduce effect of material relaxation. In applications where the anode conductive layers are deformed annealing after deforming can also reduce creation of discontinuities of the dielectric layer on the deformed portion of an anode stack. Annealing reduces stresses, increases softness and ductility and produces a specific microstructure. A variety of annealing heat treatments can be applied to the components of the capacitor to accomplish the desired result.

P-0133[0133] Further processing includes welding the cathode legs <b>436</b>, taping the capacitor stack <b>438</b>, welding the anode stack <b>440</b>, and welding the feedthrough <b>442</b>, and finish taping the capacitor stack <b>444</b>. In addition, the capacitor stack is inserted into the capacitor case <b>446</b>, the case cover and the cathode ribbon are welded to the case at <b>448</b>. The feedthrough opening is sealed at <b>452</b>. The process further includes a vacuum bake and backfill at <b>454</b>, clamping the capacitor at <b>456</b>, and an aging process at <b>458</b>.

P-0134[0134]FIG. 32 illustrates one of the many applications for the capacitor. For example, one application includes an implantable medical device <b>550</b> which provides therapeutic stimulus to a heart muscle, for instance, a defibrillator. The medical device <b>550</b> is coupled with a lead system <b>552</b>. The lead system <b>552</b> is implanted in a patient and electrically contacts strategic portions of a patient's heart. The medical device <b>550</b> further includes a monitoring circuit <b>554</b> for monitoring heart activity through one or more of the leads of the lead system <b>552</b>. The medical device <b>550</b> further includes a therapy circuit <b>556</b> which includes one or more capacitors <b>350</b> having one or more of the features of the capacitors discussed above. The therapy circuit <b>556</b> delivers a pulse of energy through one or more of the leads of lead system <b>552</b> to the heart, where the medical device <b>550</b> operates according to well known and understood principles.

P-0135[0135] In addition to implantable defibrillators, the capacitor can be incorporated into other cardiac rhythm management systems, such as heart pacers, combination pacer-defibrillators, congestive heart failure devices, and drug-delivery devices for diagnosing or treating cardiac arrhythmias. Moreover, the capacitor can be incorporated also into non-medical applications, for example, photographic flash equipment. Alternatively, one or more teachings of the present discussion can be incorporated into cylindrical capacitors.

P-0136[0136] It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. It should be noted that embodiments discussed in different portions of the description or referred to in different drawings can be combined to form additional embodiments of the present invention. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.