Patent Publication Number: US-2023154688-A1

Title: Hermetically sealed high energy electrolytic capacitor and capacitor assemblies with improved shock and vibration performance

Description:
FIELD OF INVENTION 
     This application relates to the field of electronic components, and more specifically, to capacitors and capacitor assemblies. 
     BACKGROUND 
     Wet capacitors are used in the design of circuits due to their volumetric efficiency, stable electrical parameters, high reliability and long service life. Such capacitors typically have a larger capacitance per unit volume than certain other types of capacitors, making them valuable in high-current, high-power, and low-frequency electrical circuits. One type of wet capacitor is a wet electrolytic capacitor. A wet electrolytic capacitor includes two conducting surfaces (an anode and a cathode) whose function is to store electrical charge, and a fluid electrolyte. An insulating material or dielectric separates the two conducting surfaces. Wet electrolytic capacitors tend to offer a good combination of high capacitance and low leakage current. 
     Wet electrolytic capacitors are basic to various types of electrical equipment from satellites, aerospace, airborne, military group support, oil exploration, power supplies, and the like. In any of these example applications, the capacitor may be exposed to harsh environmental conditions, including extreme temperatures, pressure, moisture, shock, vibration, and the like. 
     The capacitor must be able to withstand these harsh environmental conditions while maintaining its accuracy, service life, and ability to be powered at very high temperatures with no maintenance. Failure of a capacitor due to harsh environmental conditions would necessitate its removal for repairs, which would result in delays and other associated expenses. Additionally, many of these example applications include significant dimensional or layout constraints, as the field of electronics is consistently demanding smaller parts and devices. For example, reductions in both mounting area and component profile (i.e., height) are highly demanded in most current applications. 
     Known wet electrolytic capacitors, such as Tantalum (Ta) electrolytic capacitors, are generally characterized as having a cylindrical shape and axial leaded terminations. Tantalum electrolytic capacitors known in the art may use tantalum for the anode material. The tantalum anode body (also commonly referred to as a “slug” or “pellet”) is usually sintered. A wire (which may also be formed of tantalum) is commonly formed in the anode body in one of two ways: (1) “embedded,” meaning the wire is encased in tantalum powder during a pressing process; or (2) “welded,” meaning after the pellet is pressed and sintered, the wire is welded to the tantalum anode body. The other end of the wire extends outside of the tantalum anode body. The capacitor dielectric material made by anodic oxidation of the anode material to form an oxide layer over the surface of the anode body (e.g., Ta to Ta 2 O 5 ). A capacitor cathode may be formed by coating an inner surface of the body or case of the capacitor that encloses the tantalum anode body. The cathode may be formed of sintered tantalum or electrophoretically deposited tantalum or any other method known in the art, and coupled to a cathode terminal. The cathode may be formed of sintered tantalum, electrophoretically deposited tantalum, graphite, palladium, Ruthenium(IV) oxide (RuO2) or any other acceptable materials known in the art, and coupled to a cathode terminal. A fluid electrolyte separates the cathode and the anode body and provides for electrical communication between the cathode and anode body. Although cylindrical shaped capacitors with axial leaded terminations generally perform reliably in harsh environmental conditions, their provided energy density is limited by their cylindrical shape and limited surface area of their surfaces (anode and cathode), as the surface area of the two surfaces determines the capacitance of the capacitor. Additionally, dimensional constraints often make their application difficult. 
     Other types of known wet electrolytic capacitors are characterized as having a circular or square shaped capacitor body or “can” with radial leaded terminations. While circular or square shaped capacitors with radial leaded terminations may provide higher energy density when compared to cylindrical shaped capacitors with axial leaded terminations, their ability to operate in harsh environmental conditions is limited. Additionally, circular or square shaped capacitors with radial leaded terminations generally have limited ability to survive in high shock or vibration environments. 
     Known wet electrolytic capacitors may have anode wires that are not secured within the capacitor case, can or body. In addition, known wet electrolytic capacitors do not have internal arrangements or components that are configured to secure the anode wires and thereby account for, compensate for, diminish and/or or lessen or prevent damage from shock, high frequency, and vibration. 
     For example, known wet electrolytic capacitors may be used in connection with high energy products. Such products may have difficulty accounting for, by way of example, shock, high-frequency vibration, and random vibration without any damage to the electrical parameters of such products. The capacitors of such products may move, as they are not firmly clamped or secured. This anode movement may lead to anode wire breakage and/or scratches or abrasions to dielectric surfaces of the anodes which may increase the direct leakage current (DCL). 
     At present, therefore, a need exists for an improved wet electrolytic capacitor capable which is configured to account for, compensate for, and/or or lessen or prevent shock, high frequency, and vibration. 
     There further exists a need for an improved wet electrolytic capacitor capable of operating in harsh environmental conditions characterized with a low profile to comply with common dimensional constraints. 
     SUMMARY 
     Capacitor assemblies are provided having increased resistance to shock, high-frequency vibration, and movement. 
     According to an aspect of the invention, a capacitor assembly is provided comprising a case comprising walls defining an interior area and a cover. A plurality of anode plates are provided in the interior area. Each anode plate includes an anode plate wire, having a first portion embedded in the anode plate, and a second portion extending from a wall of the anode plate. At least a portion of the second portion of each anode plate wire is surrounded by an anode wire holder. Each anode wire holder is positioned in a cavity provided between a wall of each anode plate and an inner surface of a wall of the case. 
     According to an aspect of the invention, a wire separator is provided in the interior area, adjacent the cover. The wire separator comprises channels for receiving and guiding portions of the second portions of the anode plate wires. 
     According to an aspect of the invention, an adapter plate is provided on the wire separator. The adapter plate may be received within a recess in the wire separator shaped to receive the adapter plate. The ends of the anode plate wires are electrically connected to the adapter plate. 
     According to an aspect of the invention, a gasket may be provided adjacent the wire separator within the interior area of the case. 
     According to an aspect of the invention, a glass-to-metal-seal (GTMS) is provided in the cover. An anode lead wire extends through the glass-to-metal-seal (GTMS) to the interior area of the case. A spacer plate may be provided covering a glass insert of the glass-to-metal-seal (GTMS). The spacer plate may be received in an opening in the wire separator, and positioned adjacent the adapter plate. The anode lead wire may extend through the spacer plate and connect to the adapter plate. 
     According to an aspect of the invention, a plurality of cathode assemblies may be provided. At least some of the cathode assemblies may be positioned between adjacent anode plates. The cathode assemblies may each comprise a cathode foil held between cathode separator sheets. Cathode extensions or tabs may be provided in electrical communication with the cathode foils. The tabs are in electrical communication with the case. The case may further comprise an external cathode lead. 
     According to an aspect of the invention, a fluid electrolyte is introduced into the interior area of the case such as through a fill port through the cover, and a plug is inserted to close the fill port. 
     According to an aspect of the invention, a capacitor assembly may comprise an anode plate having an anode plate wire extending from a surface of the anode plate. An anode wire holder is positioned around at least a portion of the anode plate wire. A wire separator comprising a channel is provided, at least a portion of the anode plate wire received within the channel. The capacitor assembly may further comprise a case defining an interior area, with the anode plate, the anode plate wire, and the wire separator positioned within the interior area. The anode wire holder is positioned between a wall of the anode plate and an inner surface of a wall of the case. The wire separator may further comprise a recessed area, and an an adapter plate may be provided positioned within the recessed area. At least a portion of the anode plate wire is attached to the adapter plate. The case may comprise a cover. A glass-to-metal-seal (GTMS) may be provided in the cover, further comprising an anode lead wire positioned through the glass-to-metal-seal (GTMS). The anode lead wire is in electrical contact with the adapter plate. The anode wire holder may comprise a tube. The anode wire holder may contact the wall of the anode plate at a first position, and contacts the inner wall of the case at a second position. At least one cathode assembly may be positioned within the interior area adjacent to the anode plate and insulated from the anode plate, the cathode assembly in electrical communication with the case. 
     According to an aspect of the invention, a capacitor may comprise a case defining an interior area, the case comprising a cover. A plurality of anode plates may be arranged in a stack, with each of the plurality of anode plates comprising an anode plate wire. Each of the plurality of anode plate wires is surrounded by an anode wire holder. The anode wire holders may be positioned between the plurality of anode plate members and an inner surface of the case. The plurality of anode plates, the anode plate wires, and the anode wire holders are positioned within the interior area. A plurality of cathode assemblies may be positioned within the interior area and insulated from the plurality of anode plates. At least some of the plurality of cathode assemblies are positioned between adjacent anode plates. The plurality of cathode assemblies are in electrical communication with the case. A wire separator is provided positioned in the interior area and comprising a plurality of channels. At least a portion of each of the anode plate wires are received within one of the plurality of channels. An adapter plate is provided positioned on the wire separator. At least a portion of each of the anode plate wires is attached to the adapter plate. An anode lead wire is provided extending through the case and isolated from the case. The anode lead wire is in electrical contact with the adapter plate. A fluid electrolyte is contained within the body. 
     According to an aspect of the invention, a method of forming a cathode assembly. The method comprises: forming an anode plate; forming an anode plate wire extending from a surface of the anode plate; surrounding at least a portion of the anode plate with an anode wire holder; forming a wire separator positioned within the interior area, the wire separator comprising a channel; and positioning at least a portion of the anode plate wire within the channel. 
     These and other objects and advantages of the present invention will be recognized by one skilled in the art after having read the following detailed description, which are illustrated in the various drawing figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more detailed understanding may be had from the following description, given by way of example in conjunction with the accompanying drawings wherein: 
         FIG.  1 A  shows a perspective view of the top of an example of a capacitor according to aspects of the invention; 
         FIG.  1 B  shows a perspective view of the bottom of the capacitor of  FIG.  1 A ; 
         FIG.  1 C  shows a side view of the capacitor of  FIGS.  1 A and  1 B ; 
         FIG.  1 D  shows bottom view of the capacitor of  FIGS.  1 A,  1 B and  1 C ; 
         FIG.  2 A  shows a bottom view of a capacitor according to aspects of the invention; 
         FIG.  2 B  shows a cross-sectional view of the capacitor of  FIG.  2 A , taken along line B-B of  FIG.  2 A ; 
         FIG.  2 C  shows a cross-sectional view of the capacitor of  FIG.  2 B , taken along line C-C of  FIG.  2 A ; 
         FIG.  2 D  shows a cross-sectional view of the capacitor of  FIG.  2 B , taken along line A-A of  FIG.  2 A ; 
         FIG.  3    shows an example of an internal arrangement of a capacitor according to an aspect of the invention, showing anode plates, a wire separator, and a cover, from a top perspective view; 
         FIG.  4    shows an example of an internal arrangement of a capacitor according to an aspect of the invention, showing anode plate, cathode assemblies, and a wire separator, from a bottom perspective view; 
         FIG.  5    shows an example of an internal arrangement of a capacitor according to an aspect of the invention, showing anode plate members, cathode assemblies, a wire separator, and a cover from a bottom perspective view; 
         FIG.  6    shows an example of an internal arrangement of a capacitor according to an aspect of the invention, showing anode plate members, cathode assemblies, and a wire separator, from a bottom perspective view; 
         FIG.  7 A  shows an exploded view of a capacitor according to an aspect of the invention; 
         FIG.  7 B  shows an exploded view of a capacitor according to an aspect of the invention; 
         FIG.  8 A  shows example arrangement of anode plates connected to a wire separator and adapter plate according to an aspect of the invention; 
         FIG.  8 B  shows a cross-sectional view of the arrangement of  FIG.  8 A , taken along line  8 B- 8 B of  FIG.  8 A ; 
         FIG.  9 A  shows an example arrangement of a single anode plate design connected to a wire separator and adapter plate according to an aspect of the invention; 
         FIG.  9 B  shows an example arrangement of a double anode plate design connected to a wire separator and adapter plate according to an aspect of the invention; 
         FIG.  9 C  shows an example arrangement of a triple anode plate design connected to a wire separator and adapter plate according to an aspect of the invention; 
         FIG.  9 D  shows an example arrangement of a quadruple anode plate design connected to a wire separator and adapter plate according to an aspect of the invention; 
         FIG.  10    shows an exploded view of an example arrangement of a first anode plate, a second anode plate, and a third anode plate connected, a wire separator, an adapter plate, a spacer plate, and a cover according to an aspect of the invention, 
         FIG.  11    shows an arrangement of a wire separator according to an aspect of the invention arranged with a cover of a capacitor according to aspects of the invention; 
         FIG.  12    shows an arrangement of anode plate members, anode plate wires, and anode wire holders, according to aspects of the invention; 
         FIG.  13    shows an arrangement of anode plate members according to aspects of the invention connected to adapter plate, positioned for alignment with a wire separator according to aspects of the invention; 
         FIG.  14    shows an arrangement of a wire separator of the invention arranged with a cover of a capacitor according to aspects of the invention, showing a spacer plate in position on the wire separator; 
         FIG.  15    shows an arrangement of anode plate members connected to an adapter plate according to aspects of the invention; 
         FIG.  16    shows an arrangement of anode plate members connected to an adapter plate, positioned on the wire separator as shown in  FIG.  15   , according to aspects of the invention; 
         FIG.  17 A  shows the arrangement of  FIG.  16   , with the anode plates bent for positioning, and with a gasket positioned on a wire separator; 
         FIG.  17 B  shows the arrangement of  FIG.  16   , with a cathode assembly positioned for assembly; 
         FIG.  17 C  shows the arrangement of a cathode stack assembly according to aspects of the invention, with cathode assemblies inserted between the anode plates, showing an arrangement of cathode tabs; 
         FIG.  18 A  shows a stack assembly separator according to an aspect of the invention and a cathode assembly positioned for arrangement with the stack assembly separator; 
         FIG.  18 B  shows a stack assembly separator according to an aspect of the invention with a cathode assembly arranged with the stack assembly separator, and positioned for further assembly with a cathode stack assembly according to aspects of the invention; 
         FIG.  18 C  shows a stack assembly separator according to an aspect of the invention arranged over a cathode stack assembly according to aspects of the invention, with cathode assembly tabs arranged through slots in the stack assembly separator; 
         FIG.  18 D  shows a first portion of a capacitor case according to aspect of the invention positioned for arrangement over a cathode stack assembly; 
         FIG.  18 E  shows a sealed capacitor case with capacitor assembly tabs extending from the case; and, 
         FIG.  19    shows a flow chart with an example of a process of forming a capacitor according to aspects of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to various aspects and/or embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with these aspects and/or embodiments, it is understood that they are not intended to limit the invention to these aspects and/or embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims. Furthermore, in the following detailed description of the invention, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be recognized by one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure aspects of the invention. 
     Certain terminology is used in the following description for convenience only and is not limiting. The words “right,” “left,” “top,” “bottom,” “upper,” and/or “lower” designate directions in the drawings to which reference is made. The words “a” and “one,” as used in the claims and in the corresponding portions of the specification, are defined as including one or more of the referenced item unless specifically stated otherwise. This terminology includes the words above specifically mentioned, derivatives thereof, and words of similar import. The phrase “at least one” followed by a list of two or more items, such as “A, B, or C,” means any individual one of A, B, or C, as well as any combination thereof. 
       FIGS.  1 A- 2 A  illustrate an example of a capacitor  10  according to an aspect of the invention, which may also be referred to as a “device” or “component.” Various arrangements of component parts or sub-assemblies of the capacitor  10  assembled according to aspects of the invention may be referred to each as a “capacitor assembly,” or together as “capacitor assemblies.” 
     The capacitor  10  is preferably a self-contained unit housing a plurality of plate members that are stacked with one another and filled with an electrolyte fluid. The outer arrangement of the capacitor  10  can be seen in  FIGS.  1 A- 2 A . As shown in  FIGS.  1 A- 2 A , the capacitor  10  includes a case  12  which may also be referred to as a “body.” The case  12  may have an overall generally rectangular shape, although other shapes, including square, circular, and oblong, are also contemplated. The case  12  may generally include a first surface  24  (or “top” or “upper surface” or “upper side”) as shown in the orientation of the capacitor  10  in the Figures, although the capacitor may be mounted in a different orientation in use. The case  12  may generally include a wall  14  extending downwardly from the first surface  24 , thereby forming sides or sidewalls of the case  12 . The wall  14  is preferably a continuous component or uninterrupted wall. In a generally rectangular arrangement, the wall  14  may comprise a first side  16 , and opposite second side  18 , a third side  20  extending between the first side  14  and the second side  16 , and an opposite fourth side  22  extending between the first side  14  and the second side  16 . The case comprises a conductive metal such as tantalum and/or another suitable material, such as niobium, titanium, or alloys of those. 
     A first portion  23  of the case  12  includes the first surface and the extending wall  14 , and may be generally formed having an initially open end  28  opposite the first surface  24  that is covered by a cover  30 . The cover  30  is provided covering and extending across the open end  28 , and forming a second surface  26  (or “lower surface” or “bottom surface” or “lower side”) of the case  12 . The cover  30  may comprise a conductive metal such as tantalum and/or another suitable material, such as niobium, titanium, or alloys of those. The case  12  including the cover  30  thus form or define an interior area  32  configured to house internal components of the capacitor  10 . The cover  30  may be welded to the wall  14  to seal the case  12 . The case  12  may sometimes be referred to as a “body” or “can.” 
     As shown for example in  FIGS.  1 B and  1 D , the cover  30  may include mounting elements formed as an extending first screw weld stud  34  and an extending second screw weld stud  36 . These may be employed to secure the case  12  to a mounting surface. A fill port  38  may be provided through the cover  30 , allowing for the introduction of a fluid electrolyte. The fill port  38  may be positioned through the wall  14  or top surface  24  in other contemplated arrangements. The fill port  38  may be sealed using a plug  40  and/or a tantalum ball. A cathode lead  44  may be provided as a pin or post extending from or otherwise attached to or welded to the cover  30 . 
     As shown for example in  FIGS.  1 B and  1 D , the cover  30  is further preferably provided with a glass-to-metal-seal (GTMS)  46 . The glass-to-metal-seal (GTMS)  46  preferably includes an anode lead wire  48  therethrough that will form the external anode connection for the capacitor  10 . The anode lead wire  48  is generally formed from tantalum. An anode lead tube  50 , which may be formed from nickel, nickel alloy, or any other solderable material, or another conductive metal, coaxially surrounds and electrically, directly contacts the anode lead wire  48 . A performed glass insert  52  formed from a pressed glass surrounds the anode lead tube  50 , insulating and isolating the anode lead tube  50  from the case  12 . A portion of the cover is formed, such as by punching or stamping, as an extended lip  53  or annular wall surrounding the glass insert  52 . A compression seal  54  formed from stainless steel may be provided surrounding the lip  54  and sealing the glass-to-metal-seal (GTMS)  46  in place. The glass-to-metal-seal (GTMS)  46  acts to isolate the anode lead wire  48  from the case  12 . 
     In the area surrounding an outer perimeter of the extended lip, the cover may have a recessed area  55 , having portions extending toward the interior of the case  12 . The compression seal  54  may be positioned in the recessed area  55 , thereby allowing the compression seal  54  to rest in the recessed area and not extend beyond overall capacitor height. 
     The case  12  may be formed of tantalum and/or any other suitable type of conductive material such as a metal. The wall  14  and the cover  30  are preferably hermetically welded together to form an enclosure or interior area of the capacitor  10 . 
     A capacitor according to aspects of the invention preferably includes various internal components configured to provide improved shock and vibration resistance, as will be described in further detail. 
       FIGS.  2 B- 2 D, and  3 - 9 D  show examples of anode plates, or anode plate members, or simply anodes, generally referenced as  58 . In an example of a capacitor having multiple anode plates  58 , a capacitor according to an aspect of the invention may include three anode plates, shown as a first anode plate  58   a , a second anode plate  58   b , and a third anode plate  58   c , in  FIGS.  2 B- 2 D and  3 - 8 A . Thus, a capacitor  10  according to an aspect of the invention provided a multi-anode plate arrangement. 
     The anode plates  58  may be formed using sintered tantalum powder. An anode of sintered tantalum powder is sometimes referred to in the relevant art as an anode “pellet” or “slug.” Such anode of sintered tantalum powder forms a porous “slug” with a large surface area. An oxide layer may form over the surface of the anode plates  58  to function as an anode of the capacitor  10 . A dielectric layer may be formed on the anode plates  58  by an anodization process, whereby anodic oxidation of the anode material may form an oxide layer over the surface, and preferably the entire surface, of the anode plates  58 . 
     Each anode plate  58  may be formed having a generally rectangular shape as shown in  FIGS.  3 - 9 D . Each anode plate  58 , may include a first, top or upper surface generally designated as  60 , and a second, bottom or lower surface generally designated as  62 . 
     Each anode plate  58  further includes a perimeter wall generally designated as  64 . Each side of the perimeter wall  64  preferably includes an indentation generally designated as  66 . The indentations  66  provide a decreased diameter portion of the anode plates  58 . Each anode plate  58  further preferably includes a cut-out or angled or sloped or beveled corner portion generally designated as  68 . These corner portions  68  provide a decreased diameter portion of the anode plates  58 , allowing for the passage of anode plate wires  70  as further described. 
     In an arrangement of a capacitor  10  according to aspects of the invention as shown in  FIGS.  2 B- 2 D , the first anode plate  58   a  preferably includes a first surface  60   a  arranged to be positioned adjacent the first surface  24  of the case  12 , and a second surface  62   a  arranged to face the second surface  26  of the case  12 . The first anode plate  58   a  preferably includes perimeter walls  64   a.    
     As shown for example in  FIGS.  8 A and  10   , the first anode plate  58   a  preferably includes indentations  66   a ,  66   a ′,  66   a ″, and  66   a ′″. The first anode plate  58   a  preferably includes cut-out corner portions  68   a ,  68   a ′,  68   a ″, and  68   a′″.    
     In an arrangement of a capacitor  10  according to aspects of the invention as shown in  FIGS.  2 B- 2 D , the second anode plate  58   b  preferably includes a first surface  60   b  arranged to be positioned adjacent the second surface  62   a  of the first anode plate  58   a , and a second surface  62   b  arranged to face the second surface  26  of the case  12 . 
     As shown for example in  FIGS.  8 A and  10   , the second anode plate  58   b  preferably includes perimeter walls  64   b . The second anode plate  58   b  preferably includes indentations  66   b ,  66   b ′,  66   b ″, and  66   b ′″. The second anode plate  58   a  preferably includes cut-out corner portions  68   b ,  68   b ′,  68   b ″, and  68   b′″.    
     In an arrangement of a capacitor  10  according to aspects of the invention as shown in  FIGS.  2 B- 2 D , the third anode plate  58   c  preferably includes a first surface  60   c  arranged to be positioned adjacent the second surface  62   b  of the second anode plate  58   b , and a second surface  62   c  arranged adjacent to and/or facing the second surface  26  of the case  12 . The third anode plate  58   c  preferably includes perimeter walls  64   c.    
     As shown for example in  FIGS.  8 A and  10   , the third anode plate  58   c  preferably includes indentations  66   c ,  66   c ′,  66   c ″, and  66   c ′″. The second anode plate  58   c  preferably includes cut-out corner portions  68   c ,  68   c ′,  68   c ″, and  68   c′″.    
     The anode plates  58  may preferably be arranged such that the indentations  66  and corner portions  68  are aligned. Such arrangements are shown for example in the  FIGS.  8 A and  10   , showing how respective indentations  66   a - 66   b - 66   c ,  66   a ′- 66   b ′- 66   c ′,  66   a ″- 66   b ″- 66   c ″, and  66   a ′″,  66   b ′″, and  66   c ′″, and corner portions  68   a - 68   b - 68   c ,  68   a ′- 68   b ′- 68   c ′,  68   a ″- 68   b ″- 68   c ″, and  68   a ′″- 68   b ′″- 68   c ′″, will align. The other parts of the respective perimeter walls  64  of each anode plate  58  are also aligned in this arrangement. 
     When arranged accordingly, the anode plate members, along cathode assemblies  76  as will be described, may form a capacitor stack assembly  200 , or capacitor stack, or capacitor assembly stack. This capacitor stack assembly  200  can be seen, for example, in  FIGS.  3 ,  4 ,  5 ,  6 ,  17 C,  18 B, and  18 D . A capacitor stack assembly arrangement is shown for example in U.S. Patent Publication No. US 2020/0020486 A1, “LOW PROFILE WET ELECTROLYTIC TANTALUM CAPACITOR,” the entire contents of which is incorporated by reference as if fully set forth herein. When aligned as shown and described, for example in  FIGS.  3 - 6 , and  17 C , the aligned corner portions  68  may form an angled sidewall  73  at corners of the capacitor stack assembly  200 , and the aligned indentations may form an indentation channel  71  along the sidewalls  64  of the anode plates  58 . As described herein, the anode plate wires may be positioned having portions extending along the angled sidewalls  73 , and tabs  84  of the cathode assemblies  76  may extend along the indentation channels  71 . 
     When the anode plates  58  of the capacitor  10  are assembled, the corner portions  68  and inner surface of the wall  14  of the case  12  may define cavities  67  providing space within the interior area of the capacitor  10 . The anode plate wires  70  may extend along the spaces of the cavities  67 . 
     While three anode plates  58  are shown and described in certain examples, it is contemplated that any number of anode plates  58  may be used for a capacitor according to aspects of the invention. For example,  FIGS.  9 A- 9 D , show arrangements of anode plates including one anode plate  58   d , two anode plates  58   e ,  58   f , three anode plates  58   g ,  58   h ,  58   i , and four anode plates  58   j ,  58   k ,  58   l , and  58   m.    
     Each anode plate  58  preferable includes an anode plate wire generally designated as  70 . The anode plate wire  70  may include a first portion  72  embedded in a respective anode plate  58 , and a second portion  74  that is external to the anode plate  58  and extends from a wall  64  of the anode plate  58 , as shown for example in  FIGS.  2 B- 2 D,  4 ,  6 ,  7 A and  7 B . Each anode plate wire  70  may be formed of any suitable type of material, such as tantalum, niobium, and titanium, or a suitable conductive metal. Although the anode plate wire  70  is shown with a circular cross-section, alternative implementations are possible in which the anode plate wire  70  may have another type of cross-section, such as a rectangular cross-section. 
     As shown for example in  FIGS.  2 B,  7 A,  7 B,  8 A,  8 B,  10 ,  12  and  13   , the first anode plate  58   a  preferably includes first anode wire  70   a , having a first portion  72   a  embedded in the first anode plate  58   a , and a second portion  74   a  that is external to the first anode plate  58   a . In a preferred arrangement, as shown for example in  FIGS.  8 A,  10 ,  12 ,  13 , and  15   , the second portion  74   a  of the first anode wire  70   a  extends from the corner portion  68   a.    
     As shown for example in  FIGS.  2 B,  7 A,  7 B,  8 A,  8 B,  10 ,  12  and  13   , the second anode plate  58   b  preferably includes second anode wire  70   b , having a first portion  72   b  embedded in the second anode plate  58   b , and a second portion  74   b  that is external to the second anode plate  58   b . In a preferred arrangement, as shown for example in  FIGS.  8 A,  10 ,  12 ,  13 , and  15   , the second portion  74   b  of the second anode wire  70   b  extends from the corner portion  68   b′.    
     As shown for example in  FIGS.  2 B,  7 A,  7 B,  8 A,  8 B,  10 ,  12  and  13   , the third anode plate  58   c  preferably includes third anode wire  70   c , having a first portion  72   b  embedded in the second anode plate  58   b , and a second portion  74   b  that is external to the second anode plate  58   b . In a preferred arrangement, as shown for example in  FIGS.  8 A,  10 ,  12 ,  13 , and  15   , the second portion  74   b  of the second anode wire  70   b  extends from corner portion  68   c″.    
     The second portions  74  of the anode plate wires  70  are preferably bent toward the cover  30  direction to run vertically along the height of the case  12 , and then further bent to run horizontally across the width of the case  12 . Thus, the second portions  74  of the anode plate wires  70  may have an L-shape when assembled, extending along the height of the capacitor, and along the wire separator  90 , as will be described further. The entireties of the anode plate wires  70 , including the first portions  72  embedded in the anode plates  58 , may have a C-shape when assembled, as shown for example in  FIGS.  2 B and  2 D . 
     In the arrangement of the anode plates  58  and anode wires  70  as described, each anode wire  70  have an alternating position, such that only one anode wire  70  is positioned along each set of corner portions  68 , such as when forming an angled sidewall  73 . Therefore, only one of the anode wires  70  is positioned along a respective corner of the cathode stack assembly  200 , such that no anode plate wires  70  overlap or extend in a same part of the cavity  67 . 
     According to aspects of the invention, in order to assist in reducing detrimental shock and vibration damage, anode wire holders, or anode wire separators, separation tubes, wire separator, or simply tubes, are provided, generally designated as  124 . The anode wire holders  124  are preferably formed of polytetrafluoroethylene (PTFE), or another acceptable non-conductive material, such as a plastic or polymer. Anode wire holders  124 , are preferably provided around portions of the anode plate wires  70 . The anode plate wires  70  are positioned through the anode wire holders  124 , such that the anode wire holders coaxially surround portions of the second portions of the anode plate wires  70 , as shown for example in  FIGS.  2 B- 2 D,  8 A- 10 , and  12 - 13   . 
     The anode wire holders  124  are positioned and sized such that, when the anode plates  58  are assembled and the anode plate wires  70  are connection to the wire separator  90 , the anode wire holders  124  will be positioned in the interior space or cavity  67  between the corner portions  68  of the anode plates  58  and an adjacent inner surface  130  of the wall  14  of the case  12 . Preferably the anode wire holders  124  are sized having a diameter such that the outer walls of the anode wire holders  124  will be held against or contact the anode plates  58  and the inner surface  130  of the wall  14  of the case  12 , as shown for example in  FIGS.  2 B- 2 D . This arrangement will securely and/or firmly hold and position the anode wire holders  124 , and the portions of the anode plate wires  70  surrounding by the anode wire holders  124 , preventing movement or shifting. It is appreciated that the anode wire holders may have other than a tubular shape, and may have flat walls, or a combination of round and flat walls. The anode wire holders may act as a protective sheath around portions of the anode plate wires  70 . 
     The anode wire holders  124  are preferably sized and dimensioned such that each anode wire holder  124  will cover at least a part of the second portion  74  of each anode plate wire  70 . In addition, the anode wire holders  124  are preferably sized and dimensioned such that the anode wire holder  124  surrounding the anode plate wire  70  of the anode plate  58  positioned further from the wire separator  90  will have the greatest length, and the anode wire holders  124  surrounding the anode plate wires  70  of the anode plates  58  positioned closer to the wire separator  90  will have progressively shorter lengths. Thus, as shown for example in  FIGS.  2 A,  2 D,  7 A, and  8 A , the first anode wire holder  124   a  has a longest length that is greater than the length of second anode wire holder  124   b  and third anode wire holder  124   c , and the second anode wire holder  124   b  may have a length that is greater than the third anode wire holder  124   c . In this manner, the portions of the anode wire holders that extend along the side, or height, of the capacitor, are surrounded and protected by the anode wire holders. 
     Cathode assemblies are further provided and generally designated as  76 . Each cathode assembly  76  preferably includes a cathode foil  82 . The cathode foil  82  preferably comprises tantalum. The cathode foil  82  may be formed by stamping a tantalum foil and applying, for example, a palladium cathode layer thereto. However, alternative implementations are possible in which the cathode foil  82  may be formed of another suitable material such as platinum, rhodium, or their oxides, sintered tantalum, electrophoretically deposited tantalum, graphite, palladium, Ruthenium(IV) oxide (RuO2), or carbon, or any other cathode material. Further, surfaces of the cathode foil  82  and/or tabs  84  and portions of the inner surface of the case  12  may form various cathode layers. The cathode foil  82  and portions of the inner surface of the case  12  may include sintered tantalum, as described in U.S. Pat. No. 9,947,479 and U.S. Published Patent Application No. 2017/0207031 A1, the entire contents of each of which are incorporated by reference herein. The cathode foil  82  and portions of the inner surface of the case  12  may include electrophoretically deposited tantalum, as described in U.S. Pat. No. 9,070,512, the entire contents of which is incorporated by reference herein. 
     Each cathode assembly may further include a first separator sheet  78  and a second cathode separator sheet  80 , with a cathode foil  82  sandwiched between the first separator sheet  78  and a second cathode separator sheet  80 . The cathode sheets  78 ,  80  may be formed of polytetrafluoroethylene (PTFE) or another non-conductive and/or insulative material permeable by electrolyte. The cathode sheets  78 ,  80  insulate the cathode foil  82  from adjacent anode plates  58 . 
     Each cathode assembly  76  further includes a cathode foil extension or tab  84  extending from and in electrical communication with the cathode foil  82 , and extending beyond the first separator sheet  78  and a second cathode separator sheet  80 . Each cathode assembly  76  may be shaped having a generally rectangular shape, with cut-out, beveled or angled corners  86 . These corner portions  86  are configured to align with the corner portions  68  of the anode plates  58 . The cathode tabs  84  are positioned along the side walls  88  of the cathode assemblies  76 , but are preferably not positioned extending from the corners  86  or at locations where the anode plate wires  70  extend. 
     In an aspect of the invention, as shown for example in  FIGS.  7 A and  7 B , a first cathode assembly  76   a  having a cathode tab  84   a  may be positioned adjacent the first surface  60   a  of the first anode plate  58   a . A second cathode assembly  76   b  may be positioned between the first anode plate  58   a  and the second anode plate  58   b . A third cathode assembly  58   c  may be positioned between the second anode plate  58   b  and the third anode plate  58   c . A fourth cathode assembly  58   d  may be positioned between the second surface  60   c  of the third anode plate  58   c  and the cover  30 . 
     It is noted that alternative implementations are possible in which the cathode assembly  76  may have any selected shape, such as a rectangular shape or a circular shape. In addition, tabs  84  may have various shapes and may extend from any selected portion of the cathode foil  82 . 
     According to aspects of the invention, as shown for example in  FIGS.  4 ,  6 ,  7 A- 7 B,  8 A,  8 B,  9 A- 9 D,  10 ,  11 ,  13   , a wire separator  90  is provided. The wire separator  90  is arranged so as to gather, guide, organize and/or assemble the second portions  74  of the anode plate wires  70  to provide a collective contact area providing electrical communication with the anode lead wire  48 . Further, the wire separator  90  provides for shock and vibration resistance, by preventing the anode wires from moving during shock and/or vibration, or decreasing such movement. 
     According to an aspect of the invention, the wire separator  90  may comprise a plate formed from polytetrafluoroethylene (PTFE). In a preferred embodiment, the wire separator includes grooves or channels  92  in a first (or upper or top) surface  98 . The channels  92  are preferably positioned so as to extend or run from the wire separator  92  corners toward a central portion  96  of the wire separator  94 , such corners generally designated as  94 . Thus, the channels  92  may be considered as running diagonally across the first surface  98  of the wire separator  90 . 
     As shown in  FIGS.  7 A- 7 B,  8 A,  8 B,  9 A- 9 D,  10 ,  11 ,  13   , each channel  92  is sized so as to receive at least part of a second portion  74  an anode plate wire  70 , and to engage and hold such second portion  74  an anode plate wire  70  in alignment and/or position. Preferably, the end or terminal portions of the anode plate wires are received in the channels  92 . The channels  92  may thus be sized to be at least slightly larger than a diameter of a cross-section of the anode plate wires  70 . 
     At least one channel  92  may preferably be provided corresponding to each of the second portions  74  of the anode plate wires  70 . Accordingly, as shown for example in in  FIGS.  8 A,  13 ,  16   , first channel  92   a  is configured to receive at least a part of the second portion  74   a  of first anode plate wire  70   a , second channel  92   b  is configured to receive at least a part of the second portion  74   b  of second anode plate wire  70   b , and third channel  92   c  is configured to receive at least a part of the second portion  74   c  or third anode plate wire  70   c.    
     The wire separator  90  is further formed with an opening  102  through the central portion  96  of the first surface  98 . The opening  102  is depicted as circular, but may be another shape such as oblong, semi-circular, rectangular, or another shape. The opening  102  is further configured to receive a portion of the glass-to-metal-seal (GTMS)  46  as shown for example in  FIG.  11   . 
     Surrounding the opening  102  is a recessed area  104 . As shown for example in  FIGS.  10 ,  11  and  13   , the recessed area  104  forms a step or indentation having a decreased depth adjacent the first surface  98  of the wire separator  90  and around the perimeter of the opening  102 . 
     An adapter plate  106  formed from a conductive material is provided, preferably formed from tantalum, which may be oxidized or anodized. The recessed area  104  is sized and shaped so as to receive the adapter plate  106 , as shown for example in  FIGS.  7 B,  8 B,  10 ,  13  and  16   . The adapter plate  106  may clamp, snap or press into or otherwise mechanically engage the wire separator  90 . As shown for example in  FIGS.  8 A,  8 B,  9 A- 9 D, and  16   , parts of the second portions  74  of each anode plate wire  70  are positioned within the channels  92 . The terminal ends  108  of the anode plate wires are connected or otherwise attached to the adapter plate  106 , such as by welding. In a preferred embodiment, as shown for example in  FIG.  15   , the terminal ends  108  of the anode plate wires are connected or otherwise attached to the adapter plate  106  on a second (or bottom or lower) surface of the adapter plate  106 . 
     It is appreciated that the adapter plate  106  may be formed in any shape and may be sized as a circular plate, rectangular plate, a square plate, a triangular plate, an oblong plate, or any selected shape, so long as the anode plate wires  70  can be electrically connected to such a plate configuration in order to provide electrical communication between the anode plate wires  70  and the anode lead wire  44 . When provided as a circulate plate, as shown in the Figures, the adapter plate  106  may be referred to as a “disk adapter” or “disk adapter plate.” The recessed area  104  in the wire separator  90  can have a shape complimentary to any shape selected for the adapter plate  106 . 
     A spacer plate  116  is provided. The spacer plate  116  if preferably formed from polytetrafluoroethylene (PTFE). The spacer plate  116  is sized to be received within the opening  102 , and to cover and protect the glass insert  52  of the glass-to-metal-seal (GTMS)  46  as shown for example in  FIGS.  2 B- 2 D,  7 A,  7 B, and  10   . When provided in a disk shape as shown in the Figures, the spacer may be referred to as a “spacer disk.” However, it is appreciated that the spacer plate  116  may be formed in any shape and may be sized as a circular plate, rectangular plate, a square plate, a triangular plate, an oblong plate, or any selected shape, so long as the spacer plate  116  can provide a cover for the glass insert  52  of the glass-to-metal-seal (GTMS)  46 . When provided as a circulate plate, as shown in the Figures, the adapter plate  106  may be referred to as a “spacer disk” or “spacer disk plate.” The opening  102  in the wire separator  90  can have a shape complimentary to any shape selected for the spacer plate  116 . 
     The spacer plate  116  preferable has a central opening  118  therethrough. A portion of the anode lead wire  48  passes through the spacer plate  116 . A terminal end  120  of the anode lead wire  48  may be received in an opening  122  in the adapter plate  106  and welded to the adapter plate  106  at this position. The adapter plate  106  thereby provided the electrical connection of the anode plates wires  70  and the anode lead wire  48 , so as to provide an external electrical connection to the anode plates  58 . 
     A stack assembly separator  132  is provided configured to be placed over and around the anode plates  58  and cathode assemblies  76  that have been arranged in a capacitor stack assembly  200 , a shown for example in  FIGS.  7 A,  7 B,  18 A,  18 B,  18 C , and  18 D. The stack assembly separator  132  may be formed of polytetrafluoroethylene (PTFE) or some other non-conductive material that is permeable by an electrolyte. The stack assembly separator  132  may have a shape that is the same, similar to, or complementary to the shape of the capacitor stack assembly  200  and/or the case  12  and fits inside the case  12 . The sidewalls  136  of the stack assembly separator  132  may have a height allowing the sidewalls  136  to entirely cover the sides of the capacitor stack assembly  200  to prevent the case  12  from short-circuiting the capacitor stack assembly  200 . The stack assembly separator  132  preferably includes one or more slots  134  configured to receive the cathode extensions  84  and allow the cathode extensions  84  to pass through the slots  134 . 
     Between the anode plate  58  closest to the wire separator  90  and the wire separator  90 , a spacer  140  may be provided. The spacer  140  may be formed of polytetrafluoroethylene (PTFE). The spacer  140  may include an adhesive such as a tape on a surface of the spacer  140 , for attachment to surfaces of adjacent components. 
     Between the spacer  140  and the wire separator, a gasket  142  is preferably provided. The gasket  142  may preferably be formed from Viton™ fluoroelastomer or a similar material, and may assist in providing anti-vibration, shock absorption and stability properties to the capacitor  10 . The gasket  142  may also be formed with an opening to receive a portion of the anode lead wire  48  which may be referred to as a riser wire, to provide further stability to this attachment. 
     Forming and/or manufacturing a capacitor  10  according to aspects of the invention will not be described, with reference to the flow chart of  FIG.  19   , and the additional Figures indicated depicting various stages of the manufacturing process. It is noted that one or more steps may be combined, that certain steps may be omitted, and that the steps may be performed in any preferred order as desired. 
     At step  700 , anode plates  58  are formed. As shown in  FIG.  12   , in an example arrangement, a first anode plate  58   a  is formed having an embedded first anode plate wire  70   a , a second anode plate  58   b  is formed having an embedded second anode plate wire  70   b , and a third anode plate  58   c  is formed having an embedded third anode plate wire  70   c.    
     It should be noted that the lengths of the anode plate wires  70  are formed and/or otherwise sized such that the anode plate wire  70  extending from an anode plate  58  to be positioned furthest from the wire separator  90  when assembled will have a longest length, so as to reach the wire separator  90 , while those anode plates  58  to be positioned closer to the wire separator  90  will have progressively shorter anode plate wires  70 . 
     For example, as shown in  FIGS.  2 B,  2 D,  7 A, and  8 A , in order to reach and contact the adapter plate  106 , anode plate wire  70   a , being furthest from the adapter plate  106 , has a length greater than the length of anode plate wire  70   b  and anode plate wire  70   c , and anode plate wire  70   b  has a length greater than anode plate wire  70   c.    
     At step  710 , the anode wire holders  124  are placed around parts of the second portions  74  of the anode plate wires  70 . This is shown for example in  FIGS.  12 ,  13 ,  15 , and  16   . 
     At step  720  the anode plate wires are connected to the wire separator  90 , such as by welding. As shown in  FIG.  15   , the second portion  74   a  of the first anode plate wire  70   a  is welded to a surface of the wire separator  90 , the second portion  74   b  of the second anode plate wire  70   b  is welded to a same surface of the wire separator  90 , and the second portion  74   c  of the third anode plate wire  70   c  is welded to a same surface of the wire separator  90 . Preferably, the surface of the wire separator  90  to which the anode plate wires  70  are attached is the surface that will ultimately face the cover  30 . This is shown for example in  FIGS.  10 ,  13 ,  15 , and  16   . 
     At step  730 , and as shown for example in  FIGS.  8 A,  8 B, and  16   , parts of the second portions  74  of the anode plate wires  70  are inserted into the channels  92  of the wire separator  90 . 
     At step  740 , the anode lead wire  48  is positioned through the adapter plate  106  and inserted into the opening  102  in the wire separator  90 , and connected, such as by welding, to the wire separator  90 . This is shown for example in  FIGS.  14  and  16   . 
     At this stage, the capacitor assembly according to aspects of the invention as shown for example in  FIG.  16   , including the cover  30 , anode plates  58 , anode wires  70 , and wire separator  90 , is a unique and novel arrangement that can be used with various capacitor arrangements and cases, in a manner so as to prevent shock and vibration. 
     At step  750 , the cathode assemblies  76  are positioned so as to be interleaved or placed between adjacent anode plates  58 , forming the capacitor stack assembly  200 . The cathode extensions or cathode tabs  84  are positioned so as to align with the indentations  66  of the anode plates  58 . The cathode tabs  84  are electrically coupled to the cover  30  and/or the case  12 . When the cover  30  and case  12  are connected, the case  12  may form part of the cathode of the capacitor  10 . The cathode tabs  84  may be spot welded to the cover  30  via a weld. It may be appreciated that the description of elements in contact with or directly coupled does not preclude the presence of solder or some other form of adhesive or attachment element between the elements that are described as in direct contact or directly coupled. This is shown for example in  FIGS.  17 A,  17 B, and  17 C . 
     Additional cathode assemblies  76  may be positioned between the wire separator and the second surface  26  of the lower-most anode plate  58   c , and/or between the first surface  24  of the upper-most anode plate  58   a  and the first side  16  of the case  12 . 
     As the cathode assemblies  76  are positioned, and as shown for example in  FIGS.  18 A,  18 B and  18 C , the cathode tabs  84  are positioned through the slots  134  in the sidewalls  136  of the stack assembly separator  132 . In this manner, the cathode tabs  84  cannot contact the capacitor stack assembly  200  and short out the device. The cathode tabs  84  are bent toward the cover  30 . 
     At step  760 , the first portion  23  of the first portion  23  of the case  12  is placed over the internal components of the capacitor  10 , and attached to the cover  30 , such as via welding. This is shown for example in  FIGS.  18 D and  18 E . The external portions of the tabs  84  may preferably be trimmed. The first portion  23  of the case  12  and tabs  84  may all be attached via welding. 
     At step  770 , a fluid electrolyte is introduced into the interior area of the case through the fill port  38 . 
     At step  780 , the fill port  38  is sealed, such as by a plug  40  or tantalum ball. 
     Although the features and elements of the present invention are described in the example aspects and/or embodiments in particular combinations, each feature may be used alone without the other features and elements of the example aspects and/or embodiments or in various combinations with or without other features and elements of the present invention. The foregoing descriptions of specific aspects and/or embodiments of the present technology have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The aspects and/or embodiments were chosen and described in order to best explain the principles of the present technology and its practical application, to thereby enable others skilled in the art to best utilize the present technology and various aspects and/or embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents. 
     It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the scope of the present invention includes both combinations and sub-combinations of various features described herein as well as modifications thereof which are not in the prior art.