Method for manufacturing hermetically sealed polymer capacitors

Abstract

To provide a hermetically sealed polymer capacitor and a method for manufacturing the same.SOLUTION: A method for manufacturing a hermetically sealed polymer capacitor 100 includes contacting a conductive paste 108 with each of a first capacitor element 110 and a second capacitor element 112 to cover the surfaces of the capacitor elements, contacting the conductive paste between the surfaces of the capacitor elements and the inner surfaces of the lateral sides of a housing 102 and with at least a portion of those surfaces and the inner side surfaces, placing a bushing 114 located between an anode side 180 of the capacitor elements and the open anode end of the housing in contact with and adjacent to the first capacitor element and the second capacitor element such that the bushing does not contact the conductive paste, and allowing the conductive paste to harden.SELECTED DRAWING: Figure 3

Description

Related Applications

[0001] This application claims priority to U.S. Nonprovisional Application No. 16 / 115,021, filed August 28, 2018, the contents of which are incorporated by reference. [Technical field]

[0002] The subject matter of the following description relates to improved capacitors and methods of making the same. In particular, the present invention relates to making hermetically sealed capacitors with improved performance. [Background technology]

[0003] Hermetically sealed capacitors are used in applications where environmental conditions have a detrimental effect on capacitor performance. Typically, a hermetically sealed capacitor comprises a capacitive element sealed within a housing, a capacitive element having a valve metal anode with a dielectric, and a conductive layer on the dielectric.

[0004] Wet capacitors can utilize a liquid electrolyte as the cathode conductor, while hermetically sealed solid electrolytic capacitors can use either a solid conductor such as MnO2 as the cathode conductor, or an inherently conductive polymer as the cathode conductor. In recent years, inherently conductive polymers such as poly-3,4-ethylenedioxythiophene (PEDT) have been used as the preferred cathode conductor in electrolytic capacitors, in part due to their high conductivity and benign failure mode. Summary of the Invention

[0005] Disclosed herein is a hermetically sealed polymer capacitor, which preferably includes a conductive paste inside a case or housing. One or more capacitor elements are preferably at least partially surrounded by the conductive paste. The conductive paste may surround a portion of the bottom and sides of the one or more capacitor elements. A cover is preferably welded to the case or housing as a first part of the hermetic seal. One or more GTMS are preferably used to pass through one or more positive leads associated with one or more capacitor elements. One or more metal tubes are preferably insulated from the cover by one or more glasses of GTMS. One or more positive leads are preferably welded to one or more metal tubes to form a second part of the hermetic seal such that the moisture content within the housing is less than approximately 25% relative humidity at approximately 20°C to approximately 30°C.

[0006] Another aspect of the invention relates to a hermetically sealed polymer capacitor. The method includes providing a quantity of conductive paste within a housing. The housing preferably has an anode end, an opposing cathode end, a bottom portion, a first lateral side, a top portion, and a second lateral side. The anode end is preferably formed as an open end or opening. One or more capacitor elements are preferably inserted into the conductive paste through an opening in the housing. The conductive paste preferably surrounds at least a portion of the one or more capacitor elements, for example, surrounding the bottom and a portion of the side of the one or more capacitor elements. A cover is preferably welded over the opening in the housing to seal the anode end of the capacitor assembly. One or more glass to metal seals (GTMS) preferably allow one or more positive leads connected to one or more capacitor elements to pass through the cover while being insulated from the cover. The capacitor assembly is preferably dried to remove moisture from the interior of the capacitor assembly. One or more of the positive leads are preferably welded to one or more of the metal tube sections of the GTMS to seal the capacitor assembly. [Brief description of the drawings]

[0007] The invention may be understood in detail from the following description, illustrated by way of example with reference to the accompanying drawings, in which like reference numerals refer to like elements, and in which:

[0008] [Figure 1] FIG. 1 is an exploded view showing the components of a hermetically sealed polymer capacitor. [Diagram 2] FIG. 2 is a cross-sectional view of the hermetically sealed polymer capacitor taken along line AA of FIG. 4A. [Diagram 3] FIG. 3 is a cross-sectional view of the hermetically sealed polymer capacitor taken along line BB in FIG. 4C. [Figure 4A-4G]4A-4G show multiple views of a hermetically sealed polymer capacitor. [Diagram 5] FIG. 5 is a flow chart illustrating a method for forming a hermetically sealed polymer capacitor. [Figure 6] FIG. 6 is an exploded view showing one embodiment of a hermetically sealed polymer capacitor. [Figure 7] FIG. 7 is a cross-sectional view of the hermetically sealed polymer capacitor of FIG. 6 taken along line CC of FIG. 9A. [Figure 8] FIG. 8 is a cross-sectional view of the hermetically sealed polymer capacitor of FIG. 6 taken along line DD in FIG. 9C. [Figures 9A-9G] 9A-9G show multiple views of the hermetically sealed polymer capacitor of FIG. [Figure 10] FIG. 10 is a flow chart illustrating a method of forming the hermetically sealed polymer capacitor of FIG. [Figure 11] FIG. 11 is an exploded view showing the components of another embodiment of a hermetically sealed polymer capacitor. [Figure 12] FIG. 12 is a cross-sectional view of the hermetically sealed polymer capacitor of FIG. 11 taken along line EE of FIG. 14A. [Figure 13] FIG. 13 is a cross-sectional view of the hermetically sealed polymer capacitor of FIG. 11 taken along line FF of FIG. 14C. [Figures 14A-14G] 14A-14G show multiple views of the hermetically sealed polymer capacitor of FIG. [Figure 15] FIG. 15 is a flow chart illustrating a method of forming the hermetically sealed polymer capacitor of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Different capacitors and their embodiments are described in detail below with reference to the accompanying drawings. The embodiments are not mutually exclusive, and features found in one embodiment may be combined with features found in one or more other embodiments to form separate embodiments. Thus, the embodiments shown in the accompanying drawings are for illustrative purposes only and are not intended to be limiting. Like reference numerals refer to like elements throughout the disclosure.

[0010] In addition, although terms such as first and second are used to indicate various elements, these elements are not limited by these terms. For example, the first element could be replaced with the second element, and similarly the second element could be replaced with the first element, without departing from the scope of the present invention. In addition, "and / or" is a term that refers to an element alone or to all or part of a combination of two or more elements.

[0011] Additionally, when an element, such as a layer, region, or substrate, is referred to as being "on" or extending "on" another element, this means that it is directly on or extending directly from the other element, and may include intervening elements. In contrast, when an element is referred to as being "directly on" or "extending directly" from another element, this means that there are no intervening elements. Additionally, when an element is referred to as being "connected" or "coupled" to another element, this means that it is directly connected or coupled to the other element, and does not exclude intervening elements. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, this means that there are no intervening elements. These terms are intended to encompass different orientations of the elements in addition to the orientation depicted in the drawings.

[0012] Relative terms, such as "top," "bottom" or "lower" or "upper" or "upper" or "lower" or "horizontal" or "vertical," are used to describe the relationship of one element, layer or region to another element, layer or region shown in the figures, and are intended to encompass different orientations in addition to those depicted in the figures.

[0013] The following description relates to a hermetically sealed solid polymer capacitor (HSPC) and a method for making the same. The hermetically sealed solid polymer capacitor is capable of exhibiting high capacitance and low equivalent series resistance (ESR) in harsh environments (e.g., high temperature and / or high humidity). The hermetically sealed solid polymer capacitor of the present invention can have a small footprint, is surface mountable, and has a high capacitance and a low ESR (e.g., tens of mΩ) compared to conventional hermetically sealed capacitors.

[0014] The hermetically sealed polymer capacitor preferably comprises a hermetically sealed metal package or capacitor assembly with positive and negative terminals on opposite sides of the package. One or more capacitor elements are preferably mounted within the hermetically sealed metal package and electrically connected in parallel. The plurality of capacitor elements preferably comprise one or more sintered tantalum slugs that are electrochemically oxidized to form a tantalum pentoxide dielectric layer which is overlaid with a conductive polymer layer.

[0015] A conductive element, such as a tantalum lead wire, is preferably protruded from the sintered tantalum slug and connected to the anode terminal of the capacitor. One or more capacitor elements are preferably attached to the inside surface of the hermetic metal package using a conductive adhesive. This provides an electrical connection from the one or more capacitor elements to the outside surface of the hermetic metal package and the negative terminal located thereon. To provide a highly stable capacitance and ESR under high temperature and load conditions, the capacitor assembly is preferably dried before the package is finally sealed and the internal capacitor elements are dehumidified.

[0016] 1 is an exploded view of one embodiment of a hermetically sealed polymer capacitor 100. The hermetically sealed polymer capacitor 100 preferably includes a housing 102. The housing 102 is preferably made of a metal such as nickel, nickel-based alloys, copper, copper-based alloys, steel, titanium, and tantalum. The housing 102 is preferably electrically conductive.

[0017] 1 to 4G, the housing 102 preferably includes an open anode end 150, an opposing cathode end 152, a lower portion 154, an upper portion 158, a first lateral side 156, and a second lateral side 160. The upper portion 158 and the lower portion 154 are opposing upper and lower wall portions, respectively, and the first lateral side 156 and the second lateral side 160 are opposing side wall portions. The open anode end 150, the cathode end 152, the lower portion 154, the upper portion 158, the first lateral side 156, and the second lateral side 160 can form an interior region 103 of the housing 102.

[0018] Preferably contained within the interior region 103 of the housing 102 are the conductive paste 108, a first capacitor element 110, a first positive lead 116 connected to and extending from the first capacitor element 110, a second capacitor element 112, and a second positive lead 118 connected to and extending from the second capacitor element 112. Optionally, a bushing 114 can be disposed toward the anode end 150 of the housing 102.

[0019] Each of the first capacitor element 110 and the second capacitor element 112 preferably includes an anode side 180 corresponding to the anode end 150 of the housing, a bottom side 182 corresponding to the cathode end 152 of the housing 102, a bottom side 184 corresponding to the lower side 154 of the housing 102, an upper side 188 corresponding to the upper side 158 of the housing, a first lateral side 186 corresponding to the first lateral side 156 of the housing 102, and a second lateral side 190 corresponding to the second lateral side 160 of the housing 102. Note that the sides may also be considered faces or surfaces of the capacitor elements.

[0020] A quantity of conductive paste 108 is preferably provided within the interior region 103 of the housing 102 and may contact at least a portion of the inner surface of the cathode end 152, the inner surface of the lower portion 154, the inner surface of the upper portion 158, the inner surface of the first lateral side 156, and the inner surface of the second lateral side 160. The conductive paste 108 is preferably initially in an uncured and / or viscous and / or pasty state. In this case, the conductive paste 108 is preferably comprised of a conductive metal such as silver (Ag). In one embodiment, the conductive paste 108 is preferably comprised of Ag flakes in an inorganic silicate water-based composition. In another embodiment, the conductive paste 108 is preferably comprised of Ag epoxy. A quantity of conductive paste 108 is preferably dispensed within the interior region of the housing 102. The first capacitor element 110 and the second capacitor element 112 are preferably inserted into the housing 102 and pressed or otherwise disposed in and contact with the conductive paste 108, such that the conductive paste 108 self-dispenses and fills any gaps that may form between the first capacitor element 110, the second capacitor element 112 and the interior surface of the housing 102. The conductive paste 108 is adapted to be cured and hardened, as described in more detail below.

[0021] The amount of conductive paste 108 should be sufficient to cover at least a portion of the surface of the first capacitor element 110 and the second capacitor element 112. The conductive paste 108 preferably covers all or a portion of the bottom side 182, lower side 184, first lateral side 186, upper side 188, and second lateral side 190 of each capacitor element, for example, from about 5% to about 99%. The conductive paste 108 preferably does not extend to or cover the anode side 180, since contact with the anode wire would result in a short circuit. The surface covered with the conductive paste 108 may be referred to as a silver-plated anode surface.

[0022] The first capacitor element 110 is preferably separated from the second capacitor element 112 by a portion of the conductive paste 108 that fills the gap between the first capacitor element 110 and the second capacitor element 112. The first capacitor element 110 is preferably electrically connected in parallel to the second capacitor element 112 via a silver-plated counter anode portion 120. The conductive paste 108 is preferably cured to provide a reliable electrical connection between the first capacitor element 110 and the second capacitor element 112 and the housing 102. In an exemplary embodiment, the conductive paste 108 may be cured at approximately 80° C. to approximately 200° C. for approximately 0.25 hours to approximately 3 hours. After curing, the conductive paste 108 is preferably substantially cured or substantially solidified.

[0023] First capacitor element 110 and second capacitor element 112 are preferably constructed from sintered tantalum slugs. Each sintered tantalum slug is preferably electrochemically oxidized to form a tantalum pentoxide dielectric layer on each tantalum slug layer, and then covered with one or more conductive polymer layers to form the capacitor elements. Such polymer layers may be constructed from, but are not limited to, polypyrrole, polyaniline, poly(3,4-ethylenedioxythiophene) (PEDOT), or similar materials known to those skilled in the art.

[0024] The first positive lead 116 preferably extends from the anode side 180 of the first capacitor element 110 and extends toward the anode end 150 of the housing 102. The anode end 150 of the housing 102 preferably faces the cathode end 152 of the housing 102. The first positive lead 116 preferably comprises a wire protruding from the sintered tantalum slug. The first positive lead 116 preferably comprises tantalum. The first positive lead 116 is preferably pressed into the tantalum slug during sintering or welded to the tantalum slug after sintering.

[0025] The second positive lead 118 preferably extends from the anode side 180 of the second capacitor element 112 and extends toward the anode end 150 of the housing 102. The second positive lead 118 preferably comprises a wire protruding from a sintered tantalum slug. The second positive lead 118 preferably comprises tantalum. The second positive lead 118 is preferably pressed into the tantalum slug during sintering or welded to the tantalum slug after sintering. The first and second positive leads 116, 118 preferably have a substantially cylindrical cross section and a substantially straight length.

[0026] If the bushing 114 is provided in the housing 102, it is preferably located between the first capacitor element 110, the second capacitor element 112 and the cover 122. The bushing 114 is preferably located toward the anode end 150 of the housing 102. The bushing 114 may be constructed of an insulating material such as rubber or plastic. The bushing 114 may be constructed of one or more of polytetrafluoroethylene (PTFE), Kapton®, polyethylene (PE), and poly(p-phenylene) (PPP). The bushing 114 is preferably configured to allow the first positive lead 116 and the second positive lead 118 to pass through one or more openings in the bushing 114. Alternate embodiments may not use the bushing.

[0027] The cover 122 preferably closes the open anode end 150 of the housing 102 and is preferably constructed of a metal such as steel, nickel, copper, titanium, tantalum, and / or alloys thereof. The cover 122 is preferably shaped as a generally flat panel or wall that fits over and covers the open anode end 150 of the housing 102. Preferably, the cover 122 has a first hole corresponding to the location and dimensions of the first positive lead 116 and a second hole corresponding to the location and dimensions of the second positive lead 118. The housing 102 and cover may be collectively referred to as a capacitor body or a device body.

[0028] The cover 122 preferably includes a glass to metal seal (individually or collectively designated GTMS) 124. The one or more GTMS 124 preferably include a first glass insulator 126 and a first metal tube 128, and a second glass insulator 134 and a second metal tube 136. The first glass insulator 126 is preferably located in a first hole in the cover 122, and the second glass insulator 134 is preferably located in a second hole in the cover 122. The first positive lead 116 preferably extends through the first glass insulator 126 to insulate it from the cover 122, and the second positive lead 118 preferably extends through the second glass insulator 134 to insulate it from the cover 122. The first metal tube 128 and the second metal tube 136 may be constructed of one or more of nickel, copper, steel, titanium, tantalum, and / or alloys thereof. The first positive lead 116 preferably extends through a first metal tube 128 and is secured by a clip of the same length, and the second positive lead 118 preferably extends through a second metal tube 136 and is secured by a clip of the same length. The cover 122 is preferably seam welded to the housing 102.

[0029] Prior to sealing one or more GTMS 124 by welding metal tubes to the leads, the capacitor body is preferably thoroughly dried to dehumidify the interior region 103, the first capacitor element 110, the second capacitor element 112, and the conductive paste 108. The drying temperature for dehumidifying the capacitor body may be from about 120° C. to about 180° C., and the drying time may be from about 2 hours to about 8 hours.

[0030] After drying, the cover 122 is preferably sealed by welding it onto the open anode end 150 of the housing 102, welding the first metal tube 128 to the first positive lead 116, and welding the second metal tube 136 to the second positive lead 118 to form a package. The package is preferably hermetically sealed. The final moisture content inside the package is preferably less than approximately 25% relative humidity at 20°C to 30°C. As shown in Figures 1-3, the first positive lead 116 and the second positive lead 118 extend from the sintered tantalum slug through one or more GTMS 124 to the exterior of the housing 102 as a single piece.

[0031] The housing 102 is preferably sheathed with an insulator 104, which may be an insulating sleeve. The insulator 104 need only cover the lower side 154, the first lateral side 156, the upper side 158, and the second lateral side 160 of the housing 102, leaving the cathode end 152 and the cover 122 of the housing 102 exposed. The insulator 104 may be made of a polyimide film, PTFE, fluorinated ethylene propylene (FEP), VITON, or other suitable materials. TM , polyvinyl chloride (PVC), polyurethane, etc. are preferably used.

[0032] The anode insulator 130 is preferably formed as an insulating shim on the cover 122. The anode insulator 130 is preferably generally L-shaped with an upstanding first portion 131 on the cover 122 and a generally horizontal lower portion 133 that extends along the underside 154 of the housing 102 across the insulator 104, although other shapes are possible. The upstanding first portion 131 extends upwardly along the cover 122 above the portion of the cover 122 carrying the GTMS 124. The generally horizontal lower portion 133 of the anode insulator 130 preferably extends along at least a portion of the underside 154 of the housing 102.

[0033] Regarding the anode insulator 130, the first hole 135 may correspond to the position and dimensions of the first positive lead 116, and the second hole 137 may correspond to the position and dimensions of the second positive lead 118. The first hole 135 and the second hole 137 allow not only the first positive lead 116 and the first metal tube 128 but also the second positive lead 118 and the second metal tube 136 to pass through, which is preferable since it facilitates alignment of not only the first positive lead 116 and the first metal tube 128 but also the second positive lead 118 and the second metal tube 136. The anode insulator 130 may be made of an insulating material such as rubber, plastic, or Teflon, and may be made of one or more of PTFE, polyimide, PE, and PPP.

[0034] The anode terminal 132 is preferably disposed entirely over the anode insulator 130 and is in electrical communication with the first positive lead 116 and the second positive lead 118 through the metal tube of the GTMS 124. The anode terminal 132 is preferably generally L-shaped with an upstanding first portion 139 above the anode insulator 130 and a generally horizontal lower portion 141 extending along the underside 154 of the housing 102 above the anode insulator 130, although other shapes may be used. The upstanding first portion 139 of the anode terminal 132 is preferably smaller in size than the first portion 131 of the anode insulator 130, allowing the first portion 139 of the anode terminal 132 to be completely insulated from the cover 122 by the first portion 131 of the anode insulator 130. A generally horizontal lower portion 141 of the anode terminal 132 preferably extends along at least a portion of the horizontal lower portion 133 of the anode insulator 130 and preferably extends toward the cathode end 152 of the housing 102. The anode terminal 132 is preferably constructed of a metal such as nickel, nickel-based alloys, copper, and copper-based alloys. The anode terminal 132 may be soldered / plated with tin, lead, palladium, gold, and / or alloys thereof. The anode terminal 132 forms the surface mount terminal of the hermetically sealed capacitor 100.

[0035] For the anode terminal 132, it is preferable that the first hole 143 corresponds to the position and dimensions of the first positive lead 116, and the second hole 145 corresponds to the position and dimensions of the second positive lead 118. The first hole 143 and the second hole 145 are preferable because they allow not only the first positive lead 116 and the first metal tube 128 but also the second positive lead 118 and the second metal tube 136 to pass through, and facilitate the alignment of not only the first metal tube 128 but also the second positive lead 118 and the second metal tube 136. The edge of the first hole 143 is preferably welded to the first metal tube 128 to form an electrical connection. The edge of the second hole 145 is also preferably welded to the second metal tube 136 to form an electrical connection.

[0036] The cathode terminal 106 is preferably welded to the cathode end of the housing 102 to form an electrical connection. The cathode terminal 106 is preferably generally L-shaped with an upstanding first portion 147 overlying the cathode end of the housing 102 and a generally horizontal lower portion 149 extending along the underside 154 of the housing 102 above the cathode insulator 130, although other shapes may be used. The upstanding first portion 147 of the cathode terminal 106 preferably extends along at least a portion of the cathode end 152 of the housing 102. The generally horizontal lower portion 149 of the cathode terminal 106 preferably extends along at least a portion of the horizontal lower portion 133 of the cathode insulator 130 and is separated from the anode terminal 132 by a gap. The cathode terminal 106 is preferably constructed of a metal such as nickel, nickel-based alloys, copper, and copper-based alloys. Cathode terminal 106 may be soldered / plated with tin, lead, palladium, gold, and / or alloys thereof. The cathode terminal 106 forms the surface mount terminal of the hermetically sealed capacitor 100.

[0037] Reference is now made to Figure 2, which is a vertical cross-sectional view of the hermetically sealed poly capacitor 100. The vertical cross-sectional view is taken along line AA shown in Figure 4A. Figure 2 shows the interior of the hermetically sealed capacitor 100 in greater detail. As shown in Figure 2, the conductive paste 108 preferably contacts the inner surface of the lower portion 154 of the housing 102, the inner surface of the cathode end 152 of the housing 102, the inner surface of the upper portion 158 of the housing 102, the bottom side 182 of the first capacitor element 110, the upper portion 188 of the first capacitor element 110, and the lower portion 184 of the first capacitor element 110. The conductive paste 108 preferably does not extend to the anode end 180 of the first capacitor element 110.

[0038] The first positive lead 116 preferably extends from the anode end 180 of the first capacitor element 110 and preferably extends through an optional bushing 114. The first positive lead 116 also preferably extends through a first metal tube 128 to which it is welded. The first metal tube 128 is preferably disposed within a first glass insulator 126 of the GTMS 124 and the cover 122 is preferably welded to the housing 102.

[0039] The upstanding first portion 131 of the anode insulator is preferably disposed on the cover 122, and the generally horizontal lower portion 133 preferably extends along the underside 154 of the housing 102 over the entire insulator 104. The upstanding first portion 131 preferably extends along the cover 122 over the portion of the cover 122 carrying the GTMS 124. The generally horizontal lower portion 133 of the anode insulator 130 preferably extends along at least a portion of the underside 154 of the housing 102.

[0040] The anode terminal 132 is preferably mounted to the anode insulator 130 and is preferably in electrical communication with the first positive lead 116 via the first metallic tube 128. The upstanding first portion 130 of the anode terminal 132 preferably extends along the lower side 154 of the anode insulator 130 and the generally horizontal lower portion 141 preferably extends along the lower side 154 of the housing 102 entirely above the anode insulator 130. The dimensions of the upstanding first portion 139 of the anode terminal 132 are preferably smaller than the dimensions of the first portion 131 of the anode insulator 130, which in turn completely insulates the first portion 139 of the anode terminal 132 from the cover 122. A generally horizontal lower portion 141 of the anode terminal 132 preferably extends along the horizontal lower portion 133 of the anode insulator 130 and preferably extends toward the cathode end 152 of the housing 102 .

[0041] The cathode terminal 106 is preferably welded to the cathode end of the housing 102 to form an electrical connection. The upstanding first portion 147 of the cathode terminal 106 is preferably located at the cathode end 152 of the housing 102, and the generally horizontal lower portion 149 of the cathode terminal 106 preferably extends to the underside 154 of the housing 102 all over the anode insulator 130. The upstanding first portion 147 of the cathode terminal 106 preferably extends along at least a portion of the cathode end 152 of the housing 102, and the generally horizontal lower portion 149 of the cathode terminal 106 preferably extends along at least a portion of the horizontal lower portion 133 of the anode insulator 130, and is separated from the anode terminal 132 by a gap.

[0042] Reference is now made to Figure 3, which is a horizontal cross-sectional view of the hermetically sealed poly capacitor 100. The horizontal cross-sectional view is taken along line BB in Figure 4C. Figure 3 is a detailed view of the interior of the hermetically sealed capacitor 100. As shown in Figure 3, the conductive paste 108 preferably contacts the inner surface of the bottom portion 156 of the housing 102, the inner surface of the cathode end 152 of the housing 102, the inner surface of the second lateral side 160 of the housing 102, the bottom sides 182 of the first capacitor element 110 and the second capacitor element 112, the first lateral side 186 of the second capacitor element 112, and the second lateral side 190 of the first capacitor element 110. The conductive paste 108 preferably does not extend to the anode end 180 of the first capacitor element 110 and the second capacitor element 112.

[0043] The first and second positive leads 116, 118 preferably extend from the anode end 180 of the first capacitor element 110 and the second capacitor element 112, and preferably extend through an optional bushing 114. The first and second positive leads 116, 118 also preferably extend through a first and second metal tube 128, 136 to which they are welded. The first and second metal tubes 128, 136 are preferably disposed within the first and second glass insulators 126, 134 of the GTMS 124, and the cover 122 is preferably welded to the housing 102.

[0044] An upstanding first portion 131 of the anode insulator is preferably disposed on the cover 122 and preferably extends upwardly along the cover 122 above the portion of the cover 122 carrying the GTMS 124 .

[0045] The anode terminal 132 is preferably provided on the anode insulator 130 and is preferably in electrical communication with the first and second positive leads 116, 118 by the first and second metallic tubes 128, 136. The upstanding first portion 139 of the anode terminal 132 is preferably provided on the anode insulator 130 and is preferably smaller in size than the first portion 131 of the anode insulator 130, such that the first portion 131 of the anode insulator 130 allows the first portion 139 of the anode terminal 132 to be completely separated from the cover 122.

[0046] The cathode terminal 106 is preferably welded to the cathode end of the housing 102 to form an electrical connection. The upstanding first portion 147 of the cathode terminal 106 is preferably located at and preferably extends along at least a portion of the cathode end 152 of the housing 102. The insulator 104 is preferably located at a first lateral side 156 of the housing 102 and a second lateral side 160 of the housing 102.

[0047] The inset in Figure 3 shows the gap between the first capacitor element 110 and the second capacitor element 112, which is preferably filled with conductive paste 108. As shown in this close-up, the silver plated anode portions 120 of the first capacitor element 110 and the second capacitor element 112 face each other.

[0048] The description will now continue with reference to Figures 4A-4G, which are different perspective and plan views of the hermetically sealed polymer capacitor 100. Figure 4A is a front view of the hermetically sealed polymer capacitor 100 showing the anode end. Figure 4B is a rear view of the hermetically sealed polymer capacitor 100 showing the cathode end. Figure 4C is a side view of the hermetically sealed polymer capacitor 100. Figure 4D is a top view of the hermetically sealed polymer capacitor 100 showing the upper portion 158 of the housing 102. Figure 4E is a bottom view of the hermetically sealed polymer capacitor 100 showing the lower portion 154 of said housing 102. Figure 4F is a front perspective view of the hermetically sealed polymer capacitor 100 showing the anode end. Figure 4G is a rear perspective view of the hermetically sealed polymer capacitor 100 showing the cathode end.

[0049] 5 illustrates a method of assembly of the hermetically sealed polymer capacitor 100. In step 502, a predetermined amount of conductive paste 108 is preferably dispensed inside the housing 102.

[0050] In step 504, the first capacitor element 110 and the second capacitor element 112 are inserted into the housing 102 and press-fit into the conductive paste 108. The first positive lead 116 and the second positive lead 118 extend toward the anode end 150 of the housing 102.

[0051] An optional step 506 preferably includes providing the first capacitor element 110 and the second capacitor element 112 with a bushing 114. The first positive lead 116 and the second positive lead 118 are preferably threaded into holes in the bushing 114.

[0052] The cover 122 is preferably applied to the anode end 150 of the housing 102. The first and second positive leads 116, 118 are threaded onto the first and second metal tubes 128, 136 of the one or more GTMS 124. In step 508, the conductive paste 108 is preferably allowed to cure. In step 510, the cover 122 is preferably seam welded to the housing 102.

[0053] In step 512, the first positive lead 116 and the second positive lead 118 are clipped to the first metal tube 128 and the second metal tube 136 by the same length clips.

[0054] At step 514, the capacitor assembly is preferably dried and the package is dehumidified. At step 516, after drying, the capacitor assembly is preferably sealed by welding the first positive lead 116 to a first metal tube 128 of the one or more GTMS 124 and the second positive lead 118 to a second metal tube 136 of the one or more GTMS 124.

[0055] At step 518, insulator 104 is preferably applied to the sides of housing 102. At step 520, anode insulator 130 is preferably applied to cover 122 with holes aligned with first metal tube 128 and second metal tube 136. At step 522, anode terminal 132 is preferably applied to anode insulator 130 and the edges of its opening are preferably welded to first metal tube 128 and second metal tube 136. At step 524, cathode terminal 106 is preferably welded to the cathode end of housing 102.

[0056] 6, which is an exploded view of the components of another embodiment of a surface mount hermetically sealed polymer capacitor 600. The hermetically sealed polymer capacitor 600 includes a housing 602 similar in design to the housing 102 described above. The housing 602 is preferably constructed from a metal such as nickel, nickel-based alloys, copper, copper-based alloys, steel, titanium, and tantalum, and is preferably electrically conductive.

[0057] 6-9G, the housing 602 preferably includes an open anode end 650, an opposing cathode end 652, a lower portion 654, a first lateral side 656, an upper portion 658, and a second lateral side 660. The upper portion 658 and the lower portion 654 are opposing top and bottom walls, and the first lateral side 656 and the second lateral side 660 are opposing side walls. The open anode end 650, the cathode end 652, the lower portion 654, the upper portion 658, the first lateral side 656, and the second lateral side 660 can form an interior region 603 of the housing 602.

[0058] The housing 602 preferably contains within its interior region 603 a conductive paste 608, a first capacitor element 610 having a first anode wire 634 and a first positive lead 616, and a second capacitor element 612 having a second anode wire 636 and a second positive lead 618. Optionally, a bushing 114 can be provided towards the anode end 650 of the housing 602.

[0059] Each of the first capacitor element 610 and the second capacitor element 612 preferably has an anode side 680 corresponding to the anode end 650 of the housing, a bottom side 682 corresponding to the cathode end 620 of the housing 602, a lower side 684 corresponding to the lower side 654 of the housing 602, a first lateral side 686 corresponding to the first lateral side 656 of the housing 602, an upper side 688 corresponding to the upper side 658 of the housing 602, and a second lateral side 690 corresponding to the second lateral side 660 of the housing 602.

[0060] A quantity of conductive paste 608 is preferably provided in the interior region 603 of the housing 602 and is capable of contacting at least a portion of the inner surface of the cathode end 652, the inner surface of the lower portion 654, the inner surface of the upper portion 658, the inner surface of the first lateral side 656, and the inner surface of the second lateral side 660. The conductive paste 608 is preferably initially in an uncured and / or viscous and / or paste state. The conductive paste 608 is then preferably comprised of a conductive metal such as silver (Ag). In one embodiment, the conductive paste 608 is preferably comprised of Ag flakes in an inorganic silicate aqueous solution. In another embodiment, the conductive paste 608 is preferably comprised of Ag epoxy. A quantity of conductive paste 608 is preferably dispensed into the housing 602. The first capacitor element 610 and the second capacitor element 612 are preferably inserted into the housing 602 and pressed or otherwise disposed in and contact with the conductive paste 608, such that the conductive paste 608 self-dispenses and fills any gaps that may form between the first capacitor element 610, the second capacitor element 612, and the interior surface of the housing 602. The conductive paste 608 is adapted to be cured and hardened, as described in more detail below.

[0061] The amount of conductive paste 608 should be sufficient to cover at least a portion of the surface of the first capacitor element 610 and the second capacitor element 612. The conductive paste 608 preferably covers the bottom side 682 of the first capacitor element 610 and the second capacitor element 612, and preferably covers from about 5% to about 99% of the first lateral side 686, the top side 688, the second lateral side 690, and the lower side 684 of the first capacitor element 610 and the second capacitor element 612. The conductive paste 608 preferably does not extend to or cover the anode side 680, since contact with the anode wire would result in a short circuit. The surface covered with the conductive paste 608 may be referred to as a silver plated anode surface.

[0062] The first capacitor element 610 and the second capacitor element 612 are preferably surrounded by the conductive paste 608. The first capacitor element 610 is preferably separated from the second capacitor element 612 by a portion of the conductive paste 608. The first capacitor element 610 is preferably electrically connected in parallel to the second capacitor element 612 via the opposing silver-plated anode portion 620. The conductive paste 608 is preferably cured to provide a reliable electrical connection between the first capacitor element 610 and the second capacitor element 612 and the housing 602. In the illustrated embodiment, the conductive paste 608 is preferably cured at approximately 80° C. to approximately 200° C. for approximately 0.25 hours to approximately 3 hours. After curing, the conductive paste 608 is preferably substantially solidified.

[0063] First capacitor element 610 and second capacitor element 612 are preferably constructed from sintered tantalum slugs that are preferably electrochemically oxidized to form a tantalum pentoxide dielectric layer on each tantalum slug layer and then covered with one or more conductive polymer layers to form the capacitor elements. Such polymer layers may be constructed from, but are not limited to, polypyrrole, polyaniline, PEDOT, or similar materials known to those skilled in the art.

[0064] The first anode wire 634 preferably extends from the anode side 680 of the first capacitor element 610 and extends toward the anode end 650 of the housing 602, which preferably faces the cathode end of the housing 602. The first anode wire 634 also preferably comprises a wire protruding from a sintered tantalum slug. The first anode wire 634 is preferably comprised of tantalum. The first anode wire 634 is preferably pressed into the tantalum slug during sintering or welded to the tantalum slug after sintering.

[0065] The second anode wire 636 preferably extends from the anode side 680 of the second capacitor element 612 and extends toward the anode end 650 of the housing 602. The second anode wire 636 preferably comprises a wire protruding from a sintered tantalum slug. The second anode wire 636 is preferably comprised of tantalum and is preferably pressed into the tantalum slug during sintering or welded to the tantalum slug after sintering. The first and second anode wires 634, 636 preferably have a substantially cylindrical cross section and a substantially straight length.

[0066] The first positive lead 616 is preferably welded to the first anode wire 634 and is preferably constructed from one or more of nickel, copper, steel, titanium, tantalum, and / or alloys thereof. The second positive lead 618 is preferably welded to the second anode wire 636 and is preferably constructed from one or more of nickel, copper, steel, titanium, tantalum, and / or alloys thereof. The first positive lead 616 and the second positive lead 618 are preferably substantially cylindrical in cross section and have a substantially straight length.

[0067] If a bushing 614 is provided in the housing 602, it is preferably located between the first capacitor element 610, the second capacitor element 612 and the cover 622. The bushing 614 is preferably located toward the anode end 650 of the housing 602. The bushing 614 may be constructed of an insulating material such as rubber or plastic. The bushing 614 may be constructed of one or more of PTFE, Kapton®, PE, and PPP. The bushing 614 is preferably configured to allow the first positive lead 616 and the second positive lead 618 to pass through one or more openings in the bushing 614. In an alternative embodiment, the bushing is not used.

[0068] The cover 622 preferably seals the open anode end 650 of the housing 602 and is preferably constructed of a metal such as steel, nickel, copper, titanium, tantalum, and / or alloys thereof. The cover 622 is preferably shaped as a generally flat panel or wall that fits over and covers the open anode end 650 of the housing 602. Preferably, the cover 622 has a first hole corresponding to the location and dimensions of the first positive lead 616 and a second hole corresponding to the location and dimensions of the second positive lead 618. The housing 602 and cover 622 may be collectively referred to as a capacitor body or a device body.

[0069] The cover 622 preferably includes one or more seals, i.e., one or more GTMS 624, that insulate the cover 622. The one or more GTMS 624 preferably include a first glass insulator 626 and a first metal tube 628, and a second glass insulator 635 and a second metal tube 637. The first glass insulator 626 is preferably located in a first hole in the cover 622, and the second glass insulator 635 is preferably located in a second hole in the cover 622. The first positive lead 616 preferably extends through the first glass insulator 626 to insulate it from the cover 622, and the second positive lead 618 preferably extends through the second glass insulator 634 to insulate it from the cover 622. The first metal tube 628 and the second metal tube 637 may be comprised of one or more of nickel, copper, steel, titanium, tantalum, and / or alloys thereof. The first positive lead 616 preferably extends through a first metal tube 628 and is secured by a clip of the same length, and the second positive lead 618 preferably extends through a second metal tube 637 and is secured by a clip of the same length. The cover 622 is preferably seam welded to the housing 602 to close the opening at the anode end 650 of the housing 602.

[0070] Prior to sealing one or more GTMS 624 by welding metal tubes to the leads, the capacitor body is preferably thoroughly dried to dehumidify the interior region 603, the first capacitor element 610, the second capacitor element 612, and the conductive paste 608. The drying temperature of the unfinished package to dehumidify the capacitor body is preferably about 120° C. to about 180° C., and the drying time is preferably about 2 hours to about 8 hours.

[0071] After drying, the package is preferably sealed by welding a cover 622 onto the open anode end 650 of the housing 602, welding a first metal tube 628 to the first positive lead 616, and welding a second metal tube 637 to the second positive lead 618 to form a package. The package is preferably hermetically sealed. The final moisture content inside the package is preferably less than approximately 25% relative humidity at 20°C-30°C.

[0072] The housing 602 is preferably sheathed with an insulator 604, which may be an insulating sleeve. The insulator 604 may cover the lower side 654, the first lateral side 656, the upper side 658, and the second lateral side 660 of the housing 602, leaving the cathode end 652 of the housing 602 and the cover 622 exposed. The insulator 104 may be made of a material such as polyimide film, PTFE, FEP, VITON, etc. TM , PVC, polyurethane, etc. are preferably used.

[0073] The anode insulator 630 is preferably formed as an insulating shim on the cover 622. The anode insulator 630 is preferably generally L-shaped with an upright first portion 631 extending along the cover 622 and a generally horizontal lower portion 633 extending along the underside 654 of the housing 602 across the insulator 604, although other shapes can be used. The upright first portion 631 extends upwardly along the cover 622 over the portion of the cover 622 having the GTMS 124. The generally horizontal lower portion 633 of the anode insulator 630 preferably extends along at least a portion of the underside 654 of the housing 602.

[0074] Regarding the anode insulator 630, the first hole 638 may correspond to the position and dimensions of the first positive lead 616, and the second hole 670 may correspond to the position and dimensions of the second positive lead 618. The first hole 638 and the second hole 670 allow not only the first positive lead 616 and the first metal tube 628 but also the second positive lead 618 and the second metal tube 637 to pass through, which is preferable since it facilitates alignment of not only the first positive lead 616 and the first metal tube 628 but also the second positive lead 618 and the second metal tube 637. The anode insulator 630 may be made of an insulating material such as rubber, plastic, or Teflon, and may be preferably made of one or more of PTFE, polyimide, PE, and PPP.

[0075] The anode terminal 632 is preferably disposed entirely over the anode insulator 630 and is in electrical communication with the first positive lead 616 and the second positive lead 618 through the metal tube of the GTMS 624. The anode terminal 632 is preferably generally L-shaped with an upstanding first portion 639 above the anode insulator 630 and a generally horizontal lower portion 641 extending along the lower side 654 of the housing 602 above the anode insulator 630, although other shapes may be used. The upstanding first portion 639 of the anode terminal 632 is preferably smaller in size than the first portion 631 of the anode insulator 630, such that the first portion 639 of the anode terminal 632 is completely insulated from the cover 622 by the first portion 631 of the anode insulator 630. A generally horizontal lower portion 641 of the anode terminal 632 preferably extends along at least a portion of the horizontal lower portion 633 of the anode insulator 630 and preferably extends toward the cathode end 652 of the housing 602. The anode terminal 632 is preferably constructed of a metal such as nickel, nickel-based alloys, copper, and copper-based alloys. The anode terminal 632 may be soldered / plated with tin, lead, palladium, gold, and / or alloys thereof. The anode terminal 632 forms the surface mount terminal of the hermetically sealed capacitor 600.

[0076] For the anode terminal 632, the first hole 643 preferably corresponds to the position and dimensions of the first positive lead 616, and the second hole 645 preferably corresponds to the position and dimensions of the second positive lead 618. The first hole 643 and the second hole 645 allow passage of not only the first positive lead 616 and the first metal tube 628, but also the second positive lead 618 and the second metal tube 637. The edge of the first hole 643 of the anode terminal 632 is preferably welded to the first metal tube 628 to form an electrical connection. The edge of the second hole 645 of the anode terminal 632 is preferably welded to the second metal tube 637 to form an electrical connection.

[0077] The cathode terminal 606 is preferably welded to the cathode end of the housing 602 to form an electrical connection. The cathode terminal 606 is preferably generally L-shaped with an upstanding first portion 647 overlying the cathode end 652 of the housing 602 and a generally horizontal lower portion 649 extending along at least the lower side 654 of the housing 602 over the cathode insulator 630, although other shapes may be used. The generally horizontal lower portion 649 of the cathode terminal 606 preferably extends along at least a portion of the horizontal lower portion 649 of the cathode insulator and is separated from the anode terminal 632 by a gap. The cathode terminal 606 is preferably constructed of metals such as nickel, nickel-based alloys, copper, and copper-based alloys. The cathode terminal 606 may be soldered / plated with tin, lead, palladium, gold, and / or alloys thereof. The cathode terminal 606 forms the surface mount terminal of the hermetically sealed capacitor 600.

[0078] Continuing with the description, reference is now made to FIG. 7, which is a vertical cross-sectional view of the hermetically sealed polymer capacitor 600. The vertical cross-sectional view is taken along line CC shown in FIG. 9A. FIG. 7 shows the interior of the hermetically sealed polymer capacitor 600 in detail. As shown in FIG. 7, the conductive paste 608 contacts the inner surface of the lower portion 654 of the housing 602, the inner surface of the cathode terminal 652, the inner surface of the upper portion 658, the bottom side 682 of the first capacitor element 610, the upper side 688 of the first capacitor element 610, and the lower side 684 of the first capacitor element 610. The conductive paste 608 does not extend to the anode end 680 of the first capacitor element 610.

[0079] The first anode wire 634 preferably extends from the anode end 680 of the first capacitor element 610. The first anode wire 634 and first positive lead 616 preferably extend through an optional bushing 614. The first positive lead 616 also preferably extends through a first metal tube 628 to which it is welded. The first metal tube 628 is preferably disposed within a first glass insulator 626 of the GTMS 624, and the cover 622 is preferably welded to the housing 602.

[0080] The upright first portion 631 of the anode insulator 630 is preferably disposed on the cover 622 and the generally horizontal lower portion 633 preferably extends along the underside 654 of the housing 602 over the entirety of the insulator 604. The upright first portion 631 of the anode insulator 630 preferably extends along the cover 622 over the portion of the cover 622 carrying the GTMS 624. The generally horizontal lower portion 633 of the anode insulator 630 preferably extends along at least a portion of the underside 654 of the housing 602.

[0081] The anode terminal 632 is preferably mounted to the anode insulator 630 and is preferably in electrical communication with the first positive lead 616 via the first metallic tube 628. The upstanding first portion 639 of the anode terminal 632 is preferably mounted to the anode insulator 630 and has a generally horizontal lower portion 641 that preferably extends along the lower side 654 of the housing 602 over the entire anode insulator 630. The upstanding first portion 639 of the anode terminal 632 is preferably smaller in size than the first portion 631 of the anode insulator 630 such that the first portion 631 of the anode insulator 630 completely insulates the first portion 639 of the anode terminal 632 from the cover 622. A generally horizontal lower portion 641 of the anode terminal 632 preferably extends along at least a portion of the horizontal lower portion 633 of the anode insulator 630 and preferably extends toward the cathode end 652 of the housing 602 .

[0082] The cathode terminal 606 is preferably welded to the cathode end of the housing 602 to form an electrical connection. An upstanding first portion 647 of the cathode terminal 606 is located at the cathode end 652 of the housing 602 and a generally horizontal lower portion 649 extends to the underside 654 of the housing 602 entirely above the anode insulator 630. The upstanding first portion 647 of the cathode terminal 606 preferably extends along at least a portion of the cathode end 652 of the housing 602 and the generally horizontal lower portion 649 of the cathode terminal 606 preferably extends along at least a portion of the horizontal lower portion 633 of the anode insulator 630 and is separated from the anode terminal 632 by a gap.

[0083] Reference will now be made to Figure 8, which is a horizontal cross-sectional view of the hermetically sealed polymer capacitor 600. The horizontal cross-sectional view is taken from line DD shown in Figure 9C. As shown in Figure 8, the conductive paste 608 preferably contacts the inner surface of the first lateral side 656 of the housing 602, the inner surface of the cathode end 652 of the housing 602, the inner surface of the second lateral side 660 of the housing 602, the bottom sides 682 of the first and second capacitor elements 610 and 612, the first lateral side 686 of the second capacitor element 612, and the second lateral side 690 of the first capacitor element 610. The conductive paste 608 preferably does not extend to the anode ends 680 of the first and second capacitor elements 610 and 612.

[0084] The first and second anode wires 634, 636 preferably extend from the anode ends 680 of the first and second capacitor elements 610, 612. The first and second anode wires 634, 636, the first and second positive leads 616, 618 preferably extend through an optional bushing 614. The first and second positive leads 616, 618 preferably extend through a first and second metal tube 628, 636 to which they are welded. The first and second metal tubes 628, 636 are preferably located within the first and second glass insulators 626, 634 of the GTMS 624. The cover 622 is preferably welded to the housing 602.

[0085] The upstanding first portion 631 of the anode insulator is preferably disposed on the cover 622. The upstanding first portion 631 preferably extends upwardly along the cover 622 above the portion of the cover 622 carrying the GTMS 624.

[0086] The anode terminal 632 is preferably provided on the anode insulator 630 and is preferably in electrical communication with the first positive lead 616 and the second positive lead 618 via the first metal tube 628 and the second metal tube 636. The upstanding first portion 639 of the anode terminal 632 is preferably provided on the anode insulator 630 and is preferably smaller in size than the first portion 631 of the anode insulator 630 such that the first portion 639 of the anode terminal 632 is completely insulated from the cover 622 by the first portion 631 of the anode insulator 630.

[0087] The cathode terminal 606 is preferably welded to the cathode end of the housing 602 to form an electrical connection. The upstanding first portion 647 of the cathode terminal 606 is preferably provided at the cathode end 652 of the housing 602. The upstanding first portion 647 of the cathode terminal 606 preferably extends along at least a portion of the cathode end 652 of the housing 602, and the insulator 604 is preferably provided at a first lateral side 656 of the housing 602 and a second lateral side 660 of the housing 602.

[0088] 8 shows the gap between a first capacitor element 610 and a second capacitor element 612 which is preferably filled with conductive paste 608. As shown, the silver plated anode portions 620 of the first capacitor element 610 and the second capacitor element 612 face each other.

[0089] The description will now continue with reference to Figures 9A-9G, which are different views of the hermetically sealed polymer capacitor 600. Figure 9A is a front view of the hermetically sealed polymer capacitor 600, showing the anode end. Figure 9B is a rear view of the hermetically sealed polymer capacitor 600, showing the cathode end. Figure 9C is a side view of the hermetically sealed polymer capacitor 600. Figure 9D is a top view of the hermetically sealed polymer capacitor 600, showing the upper portion 658 of the housing 602. Figure 9E is a bottom view of the hermetically sealed capacitor 600, showing the lower portion 654 of said housing 602. Figure 9F is a perspective view of the hermetically sealed polymer capacitor 600, showing the anode end. Figure 9G is a rear perspective view of the hermetically sealed polymer capacitor 600, showing the cathode end.

[0090] 10 is a flow chart illustrating a method for assembling a hermetically sealed polymer capacitor 600. In step 1002, a quantity of conductive paste 608 is preferably dispensed inside the housing 602.

[0091] In step 1004 , the first positive lead 616 is preferably welded to the first anode wire 634 , and the second positive lead 618 is preferably welded to the second anode wire 636 .

[0092] In step 1006, the first capacitor element 610 and the second capacitor element 612 are inserted into the housing 602 and press-fit into the conductive paste 608. A first positive lead 616 and a second positive lead 618 can extend toward the anode end 650 of the housing 602.

[0093] An optional step 1008 preferably includes providing a bushing 614 for the first capacitor element 610 and the second capacitor element 612. A first positive lead 616 and a second positive lead 618 are preferably threaded into holes in the bushing 614.

[0094] A cover 622 is preferably applied to the anode end 650 of the housing 602. A first positive lead 616 and a second positive lead 618 are threaded onto a first metal tube 628 and a second metal tube 637 of one or more GTMS 624. In step 1010, the conductive paste 608 is preferably allowed to cure. In step 1012, the cover 622 is preferably seam welded to the housing 602.

[0095] In step 1014, the first positive lead 616 and the second positive lead 618 are clipped to the first metal tube 628 and the second metal tube 637 by the same length.

[0096] At step 1016, the capacitor assembly is preferably dried and the package is dehumidified. At step 1018, after drying, the capacitor assembly is preferably sealed by welding the first positive lead 616 to a first metal tube 628 of one or more GTMS 124 and the second positive lead 618 to a second metal tube 637 of one or more GTMS 624.

[0097] At step 1020, insulator 604 is preferably applied to the sides of housing 602. At step 1022, anode insulator 630 is preferably applied to cover 622 with holes aligned with first metal tube 628 and second metal tube 637. At step 1024, anode terminal 632 is preferably applied to anode insulator 630 and the edges of its holes are preferably welded to first metal tube 628 and second metal tube 637. At step 1026, cathode terminal 606 is preferably welded to the cathode end of housing 602.

[0098] Continuing with the description, reference is now made to Figure 11, which is an exploded view of the components of another embodiment of a surface mount hermetically sealed polymer capacitor 1100. The hermetically sealed polymer capacitor 1100 preferably includes a housing 1102. The housing 1102 is preferably constructed from a metal such as nickel, nickel-based alloys, copper, copper-based alloys, steel, titanium, and tantalum, and is preferably electrically conductive.

[0099] 11-14G, the housing 1102 preferably includes an open anode end 1150, an opposing cathode end 1152, a lower portion 1154, a first lateral side 1156, an upper portion 1158, and a second lateral side 1160. The upper portion 1158 and the lower portion 1154 are opposing top and bottom walls, and the first lateral side 1156 and the second lateral side 1160 are opposing side walls. The open anode end 1150, the cathode end 1152, the lower portion 1154, the upper portion 1158, the first lateral side 1156, and the second lateral side 1160 can form an interior region 1103 of the housing 1102.

[0100] The housing 1102 preferably contains within its interior region 1103 a conductive paste 1108, a first capacitor element 1110 having a first anode wire 1134, and a second capacitor element 1112 having a second anode wire 1136. The first anode wire 1134 is preferably connected to a second anode wire 1138 by a cross wire 1138. The positive lead 1116 is preferably welded to the cross wire 1138. An optional bushing 1114 may be provided toward the anode end 1150 of the housing 1102.

[0101] Each of the first capacitor element 1110 and the second capacitor element 1112 preferably has an anode side 1180 corresponding to the anode end 1150 of the housing 1102, a bottom side 1182 corresponding to the cathode end 1152 of the housing 1102, a bottom side 1184 corresponding to the lower side 1154 of the housing 1102, a first lateral side 1186 corresponding to the first lateral side 1156 of the housing 1102, an upper side 1188 corresponding to the upper side 1158 of the housing 1102, and a second lateral side 1190 corresponding to the second lateral side 1160 of the housing 1102. It should be noted that these sides may be considered faces or surfaces of the capacitor elements.

[0102] A quantity of conductive paste 1108 is preferably provided or dispensed into the interior region 1103 of the housing 1102, and is capable of contacting at least a portion of the inner surface of the cathode end 1152, the inner surface of the lower portion 1154, the inner surface of the upper portion 1158, the inner surface of the first lateral side 1156, and the inner surface of the second lateral side 1160. The conductive paste 1108 is preferably initially in an uncured and / or viscous and / or paste state. The conductive paste 1108 is then preferably comprised of a conductive metal such as silver (Ag). In one embodiment, the conductive paste 1108 is preferably comprised of Ag flakes in an inorganic silicate water-based composition. In another embodiment, the conductive paste 1108 is preferably comprised of Ag epoxy. A quantity of conductive paste 1108 is preferably dispensed into the interior region of the housing 1102. The first capacitor element 1110 and the second capacitor element 1112 are preferably inserted into the housing 1102 and pressed or otherwise disposed in and contact with the conductive paste 1108, such that the conductive paste 1108 self-dispenses and fills any gaps that may form between the first capacitor element 1110, the second capacitor element 1112, and the interior surface of the housing 1102. The conductive paste 1108 is allowed to harden, as described in more detail below.

[0103] The amount of conductive paste 1108 should be sufficient to cover at least a portion of the surface of the first capacitor element 1110 and the second capacitor element 1112. The conductive paste 1108 preferably covers the bottom side 1182 of the first capacitor element 1110 and the second capacitor element 1112, and also covers all or a portion of the lower side 1184, the first lateral side 1186, the upper side 1188, and the second lateral side 1190, for example, by approximately 5% to approximately 90%. The conductive paste 1108 preferably does not extend to or cover the anode side 1180, since contact with the anode wire would result in a short circuit. The surface coated with the conductive paste 1108 may be referred to as a silver plated anode surface.

[0104] The first capacitor element 1110 is preferably coupled to the second capacitor element 1112 as previously described. The first capacitor element 1110 is preferably electrically connected in parallel to the second capacitor element 1112 by a cross wire 1138 welded to the first anode wire 1134 and the second anode wire 1136. The first capacitor element 1110 is preferably separated from the second capacitor element 1112 by a portion of the conductive paste 1108 that fills the gap between the first capacitor element 1110 and the second capacitor element 1112. The first capacitor element 1110 is also preferably electrically connected to the second capacitor element 1112 through the opposing silver plated anode portion 1120. The conductive paste 1108 is preferably cured to provide a reliable mechanical and electrical parallel connection between the exterior surfaces of the first capacitor element 1110 and the second capacitor element 1112 and the housing 1102. In the illustrated embodiment, the conductive paste 108 may be cured for approximately 0.25 hours to approximately 3 hours at approximately 80° C. to approximately 200° C. After curing, the conductive paste 1108 is preferably substantially solidified.

[0105] The first capacitor element 1110 and the second capacitor element 1112 are preferably constructed from sintered tantalum slugs which are preferably electrochemically oxidized to form a tantalum pentoxide dielectric layer on each tantalum slug layer and then covered with one or more conductive polymer layers to form the capacitor elements. Such polymer layers may be constructed from, but are not limited to, polypyrrole, polyaniline, PEDOT, or similar materials known to those skilled in the art.

[0106] The first anode wire 1134 preferably protrudes from the anode side 1180 of the first capacitor element 1110 and extends toward the anode end 1150 of the housing 1102, which preferably faces the cathode end 1152 of the housing 1102. The first anode wire 1134 is preferably comprised of a wire protruding from a sintered tantalum slug. The first anode wire 1134 is preferably comprised of tantalum. The first anode wire 1134 is preferably pressed into the tantalum slug during sintering or welded to the tantalum slug after sintering. The second anode wire 1136 preferably protrudes from the anode side 1180 of the second capacitor element 1112 and extends toward the anode end 1150 of the housing 1102. The second anode wire 1136 is preferably comprised of a wire protruding from a sintered tantalum slug. The second anode wire 1136 is preferably constructed of tantalum and is preferably pressed into a tantalum slug during sintering or welded to a tantalum slug after sintering. The first and second anode wires 1134, 1136 are preferably substantially cylindrical in cross section and have a substantially straight length.

[0107] The cross wire 1138 is preferably constructed from one or more of nickel, copper, steel, titanium, tantalum, and / or alloys thereof. The cross wire 1138 is preferably welded to the first anode wire 1134 and the second anode wire 1136. The positive lead 1116 is preferably constructed from one or more of nickel, copper, steel, titanium, tantalum, and / or alloys thereof. The cross wire 1138 and positive lead 1116 are preferably substantially cylindrical in cross section and have a substantially straight length.

[0108] If a bushing 1114 is provided in the housing 1102, it is preferably located between the first and second capacitor elements 1110, 1112 and a cover 1122 located at the anode end 1150 of the housing 1102. The bushing 1114 may be made of an insulating material such as rubber or plastic. The bushing 1114 may be made of one or more of PTFE, Kapton®, PE, and PPP. The bushing 1114 is preferably shaped to allow the first positive lead 1116 to pass through one or more openings in the bushing 1114. In an alternative embodiment, the bushing is not used.

[0109] The cover 1122 preferably closes the open anode end 1150 of the housing 1102 and is preferably constructed from a metal such as steel, nickel, copper, titanium, tantalum, and / or alloys thereof. The cover 1122 is preferably shaped as a generally flat panel or wall that fits over and covers the open anode end 1150 of the housing 1102. The cover 1122 preferably has a first hole that corresponds to the location and size of the first positive lead 1116. The housing 1102 and cover 1122 may be collectively referred to as the capacitor body or device body.

[0110] The cover 1122 preferably includes a GTMS 1124. The GTMS 1124 preferably includes a glass insulator 1126 and a metal tube 1128. The glass insulator 1126 is preferably located in a hole in the cover 1122. The metal tube 1128 is preferably made of one or more of nickel, copper, steel, titanium, tantalum, and / or alloys thereof. The positive lead 1116 preferably extends through the glass insulator 1126 to insulate it from the cover 1122. The positive lead 1116 preferably extends through the metal tube 1128 and is secured by a clip of the same length. The cover 1122 is preferably seam welded to the housing 1102.

[0111] Prior to sealing the GTMS 1124 by welding the metal tube 1128 to the positive lead 1116, the capacitor body is preferably thoroughly dried to dehumidify the interior region 1103, the first capacitor element 1110, the second capacitor element 1112, and the conductive paste 1108. The drying temperature for dehumidifying the capacitor body is preferably from about 120° C. to about 180° C., and the drying time is preferably from about 2 hours to about 8 hours.

[0112] After drying, a cover 1122 is preferably sealed by welding it over the open anode end of the housing 1102 and welding a metal tube 1128 to the positive lead 1116 to form a package. The package is preferably hermetically sealed. The final moisture content inside the package is preferably less than approximately 25% relative humidity at approximately 20°C to 30°C.

[0113] The housing 1102 is preferably surrounded by an insulating sleeve, the insulator 1104. The insulator 1104 may cover the lower side 1154, the first lateral side 1156, the upper side 1158, and the second lateral side 1160 of the housing 1102, leaving the cathode end 1152 and the cover 1122 of the housing 1102 exposed. The insulator 1104 may be made of any of a variety of materials, including polyimide film, PTFE, FEP, VITON, etc. TM, PVC, polyurethane, etc. are preferably used.

[0114] The anode insulator 1130 is preferably located on the cover 1122 and formed as an insulating shim. The anode insulator 1130 is preferably generally L-shaped with an upright first portion 1131 on the cover 1122 and a generally horizontal lower portion 1133 that extends along the lower side 1154 of the housing 1102 across the insulator 1104, although other shapes may be used. The upright first portion 1131 extends upwardly along the cover 1122 over the portion of the cover 1122 having the GTMS 1124. The generally horizontal lower portion 1133 of the anode insulator 1130 preferably extends along at least a portion of the lower side 1154 of the housing 1102. The anode insulator 1130 also has a hole 1135 that can accommodate the location and dimensions of the positive lead 1116 and the metal tube 1128. The hole 1135 allows the positive lead 1116 and the metal tube 1128 to pass through, facilitating alignment of the positive lead 1116 and the metal tube 1128, and is therefore preferred. The anode insulator 1130 may be made of rubber, plastic, or Teflon. TM and preferably one or more of PTFE, polyimide, PE, and PPP.

[0115] The anode terminal 1132 is preferably disposed entirely over the anode insulator 1130 and is in electrical communication with the positive lead 1116 via the metal tube of the GTMS 1124. The anode terminal 1132 is preferably generally L-shaped with an upstanding first portion 1139 above the anode insulator 1130 and a generally horizontal lower portion 1141 extending along the lower portion 1154 of the housing 1102 above the anode insulator 1130, although other shapes may be used. The upstanding first portion 1139 of the anode terminal 1132 is preferably smaller in size than the first portion 1131 of the anode insulator 1130, such that the first portion 1139 of the anode terminal 1132 is completely insulated from the cover 1122 by the first portion 1131 of the anode insulator 1130. A generally horizontal lower portion 1141 of the anode terminal 1132 preferably extends along at least a portion of the horizontal lower portion 1133 of the anode insulator 1130 and preferably extends toward the cathode end 1152 of the housing 1102. The anode terminal 1132 is preferably constructed of a metal such as nickel, nickel-based alloys, copper, and copper-based alloys. The anode terminal 1132 may be soldered / plated with tin, lead, palladium, gold, and / or alloys thereof. The anode terminal 1132 forms the surface mount terminal of the hermetically sealed capacitor 1100.

[0116] For the anode terminal 1132, a hole 1143 is preferably provided that corresponds in position and size to the positive lead 1116 and the metal tube 1128. The hole 1143 is provided to allow the positive lead 1116 and the metal tube 1128 to pass through. The edges of the hole 1143 are preferably welded to the metal tube 1128 to form an electrical connection.

[0117] The cathode terminal 1106 is preferably welded to the cathode end of the housing 1102 to form an electrical connection. The cathode terminal 1106 is preferably generally L-shaped with an upstanding first portion 1147 overlying the cathode end of the housing 1102 and a generally horizontal lower portion 1149 extending along the underside 1154 of the housing 1102 above the cathode insulator 1130, although other shapes may be used. The upstanding first portion 1147 of the cathode terminal 1106 preferably extends along at least a portion of the cathode end 1152 of the housing 1102. The generally horizontal lower portion 1149 of the cathode terminal 1106 preferably extends along at least a portion of the horizontal lower portion 1133 of the cathode insulator 1130 and is separated from the anode terminal 1132 by a gap. The cathode terminal 1106 is preferably constructed from metals such as nickel, nickel-based alloys, copper, and copper-based alloys. The cathode terminal 1106 may be soldered / plated with tin, lead, palladium, gold, and / or alloys thereof. The cathode terminal 1106 forms the surface mount terminal of the hermetically sealed capacitor 1100.

[0118] Reference is now made to Figure 12, which is a vertical cross-sectional view of the hermetically sealed poly capacitor 1100. The vertical cross-sectional view is taken along line E-E shown in Figure 14A. Figure 12 shows the interior of the hermetically sealed capacitor 1100 in greater detail. Figure 7 shows that the conductive paste 1108 contacts the inner surface of the lower portion 1154 of the housing 1102, the inner surface of the cathode end 1152 of the housing 1102, and the inner surface of the upper portion 1158 of the housing 1102. The conductive paste 1108 preferably contacts the first lateral side 1186 of the first capacitor element 1110, the bottom side 1182 of the first capacitor element 1110, the upper side 1188 of the first capacitor element 1110, and the lower side 1184 of the first capacitor element 1110. The conductive paste 1108 does not extend to the anode end 1180 of the first capacitor element 1110 .

[0119] The anode wire 1134 extends from the anode end 1180 of the first capacitor element 1110, and the anode wire 1134, cross wire 1138 and positive lead 1116 extend through an optional bushing 1114. The positive lead 1116 also extends through a welded metal tube 1128. The metal tube 1128 is disposed within a first glass insulator 1126 of the GTMS 1124, and the cover 1122 is welded to the housing 1102.

[0120] The upright first portion 1131 of the anode insulator is preferably disposed on the cover 1122 and the generally horizontal lower portion 1133 preferably extends along the underside 1154 of the housing 1102 over the entire insulator 1104. The upright first portion 131 extends along the cover 1122 over the portion of the cover 1122 carrying the GTMS 1124. The generally horizontal lower portion 1133 of the anode insulator 1130 preferably extends along at least a portion of the underside 1154 of the housing 1102.

[0121] The anode terminal 1132 is mounted to the anode insulator 1130 and is in electrical communication with the positive lead 1116 via the metal tube 1128. The anode terminal 1132 has an upstanding first portion 1139 mounted to the anode insulator 1130 and a generally horizontal lower portion 1141 extending along the lower side 1154 of the housing 1102 above the anode insulator 1130. The dimensions of the upstanding first portion 1139 of the anode terminal 1132 are preferably smaller than the first portion 1131 of the anode insulator 1130, which in turn completely insulates the first portion 1139 of the anode terminal 1132 from the cover 1122. A generally horizontal lower portion 1141 of the anode terminal 1132 preferably extends along the horizontal lower portion 1133 of the anode insulator 1130 and preferably extends toward the cathode end 1152 of the housing 1102 .

[0122] The cathode terminal 1106 is preferably welded to the cathode end of the housing 1102 to form an electrical connection. An upstanding first portion 1147 of the cathode terminal 1106 is located at the cathode end 1152 of the housing 1102 and a generally horizontal lower portion 1149 extends along the lower side 1154 of the housing 1102 all over the anode insulator 1130. The upstanding first portion 1147 of the cathode terminal 1106 preferably extends along at least a portion of the cathode end 1152 of the housing 1102 and the generally horizontal lower portion 1149 of the cathode terminal 1106 preferably extends along at least a portion of the horizontal lower portion 1133 of the anode insulator 1130 and is separated from the anode terminal 1132 by a gap.

[0123] Reference is now made to Figure 13, which shows a horizontal cross-sectional view of a hermetically sealed poly capacitor 1100. The horizontal cross-sectional view is taken along line FF shown in Figure 14C. As shown in Figure 13, the conductive paste 1108 preferably contacts the inner surface of the first lateral side 1156 of the housing 1102, the inner surface of the cathode end 1152 of the housing 1102, the inner surface of the second lateral side 1160 of the housing, the bottom sides 1182 of the first capacitor element 1110 and the second capacitor element 1112, the first lateral side 1186 of the second capacitor element 1112, and the second lateral side 1190 of the first capacitor element 1110. The conductive paste 1108 preferably does not extend to the anode ends 1180 of the second capacitor element 1112 and the first capacitor element 1110.

[0124] The first and second anode wires 1134, 1136 preferably extend from the anode ends 1180 of the first and second capacitor elements 1110, 1112, and the first and second anode wires 1134, 1136, cross wires 1138 and positive lead 1116 preferably extend through an optional bushing 1114. The positive lead 1116 preferably extends through a welded metal tube 1128. The metal tube 1128 is preferably provided within the first glass insulator 1126 of the GTMS 1124, and the cover 1122 is preferably welded to the housing 1102.

[0125] An upstanding first portion 1131 of the anode insulator is preferably disposed on the cover 1122 and extends along the cover 1122 over the portion of the cover 1122 carrying the GTMS 1124 .

[0126] The anode terminal 1132 is preferably mounted to the anode insulator 1130 and is preferably in electrical communication with the positive lead 1116 via a metal tube 1128. The upstanding first portion 1139 of the anode terminal 1132 is preferably mounted to the anode insulator 1130 and is preferably sized smaller than the first portion 1131 of the anode insulator 1130 such that the first portion 1131 of the anode insulator 1130 completely insulates the first portion 1139 of the anode terminal 1132 from the cover 1122.

[0127] The cathode terminal 1106 is preferably welded to the cathode end of the housing 1102 to form an electrical connection. The upstanding first portion 1147 of the cathode terminal 1106 is preferably provided at the cathode end 1152 of the housing 1102. The upstanding first portion 1147 of the cathode terminal 1106 preferably extends along at least a portion of the cathode end 1152 of the housing 1102, and the insulator 1104 is preferably provided at a first lateral side 1156 of the housing 1102 and a second lateral side 1160 of the housing 1102.

[0128] 13 shows the gap between the first capacitor element 1110 and the second capacitor element 1112, which is intended to be filled with conductive paste 1108. The inset shows the opposing silver plated anode portions 1120 of the first capacitor element 1110 and the second capacitor element 1112.

[0129] The description will now continue with reference to Figures 14A-14G, which are different views of the hermetically sealed polymer capacitor. Figure 14A is a front view of the hermetically sealed polymer capacitor 1100 showing the anode end. Figure 14B is a rear view of the hermetically sealed polymer capacitor 1100 showing the cathode end. Figure 14C is a side view of the hermetically sealed polymer capacitor 100. Figure 14D is a top view of the hermetically sealed polymer capacitor 100 showing the upper portion 1158 of the housing 1102. Figure 14E is a bottom view of the hermetically sealed polymer capacitor 1100 showing the lower portion 1154 of said housing 1102. Figure 14F is a front perspective view of the hermetically sealed polymer capacitor 1100 showing the anode end. Figure 14G is a rear perspective view of the hermetically sealed polymer capacitor 1100 showing the cathode end.

[0130] 15 illustrates a method of assembly of a hermetically sealed polymer capacitor 1100. In step 1502, a quantity of conductive paste 1108 is preferably dispensed inside the housing 1102.

[0131] In step 1504, the first anode wire 1134 and the second anode wire 1136 are preferably welded to a cross wire 1138. The positive lead 1116 is then preferably welded to the cross wire 1138.

[0132] In step 1506, the first capacitor element 1110 and the second capacitor element 1112 are inserted into the housing 1102, preferably press-fit into the conductive paste 1108. The positive lead 1116 may extend toward the anode end 1150 of the housing 1102.

[0133] At optional step 1508, the first capacitor element 1110 and the second capacitor element 1112 are preferably provided with bushings 1114. The positive lead 1116, the cross wire 1138, the first anode wire 1134 and the second anode wire 1136 are preferably threaded into holes in the bushing 1114.

[0134] A cover 1122 is preferably attached to the housing. The first positive lead 1116 is threaded into a first metal tube 1128 of the GTMS 1124.

[0135] At step 1510, the conductive paste 108 is preferably allowed to cure. At step 1512, the cover 1122 is preferably seam welded to the housing 1102.

[0136] In step 1514, the positive lead 1116 is preferably clipped to the same length as the metal tube 1128.

[0137] The capacitor assembly is preferably dried and the package dehumidified, step 1516. After drying, the capacitor assembly is preferably sealed, step 1518, by welding the positive lead 1116 to the metal tube 1128 of the GTMS 1124.

[0138] At step 1520, insulator 1104 is preferably applied to the sides of housing 1102. At step 1522, anode insulator 1130 is preferably applied to cover 1122 with a hole aligned with metal tube 1128. At step 1524, anode terminal 1132 is preferably applied to anode insulator 1130 and the edge of the hole is preferably welded to metal tube 1128. At step 1526, cathode terminal 1106 is preferably welded to the bottom portion of housing 1102.

[0139] The above description of the embodiments of the present invention is for illustrative purposes. The description is not exhaustive and does not limit the present invention to the precise form disclosed, and many variations and modifications are possible in light of the above disclosure. The embodiments are intended to explain the principles of the present technology and its technical development, so that those skilled in the art can best implement the present technology and various embodiments including various modifications according to the specific intended use. The accompanying drawings and the specification show preferred embodiments of the present invention, but the specific terms used are merely generic and descriptive terms and are not limiting. The form of each member and the substitution of equivalent members may be changed as circumstances require without departing from the spirit and scope of the present invention as described in the claims. [Explanation of symbols]

[0140] 100 Hermetically sealed polymer capacitors 102 Case 103 Internal area 104 Insulators 108 Conductive Paste 110 First condenser element 112 Second Condenser Element 114 Bush 116 1st positive lead 118 2nd positive lead 122 Cover 124 Glass / Metal Seal (GTMS) 126 First Glass Insulator 128 1st metal pipe 130 Anode insulator 131 Part 1 132 Anode terminal 133 Lower 134 Second Glass Insulator 135 Hole 1 136 Second metal pipe 137 2nd hole 139 Part 1 141 Lower 143 Hole 1 145 2nd hole 147 Upright 1st part 150 Open anode end 152 Cathode end 154 Lower part 156 First side 158 Upper part 160 Second side part 180 Anode side 182 Bottom side 184 Lower part 186 First side 188 Upper part 190 Second side 502 process 504 Process 506 Process 508 Process 510 Process 512 Process 514 Process 516 Process 518 Process 520 process 522 Process 524 Process 600 Hermetically sealed polymer capacitor 602 Case 603 Internal area 604 Insulators 606 Cathode terminal 608 Conductive Paste 610 First Condenser Element 612 Second Condenser Element 614 Bush 616 1st positive lead 618 2nd positive lead 620 Cathode end 622 Cover 624 GTMS 626 First Glass Insulator 628 1st metal pipe 630 Anode Insulator 631 Part 1 632 Anode terminal 633 Horizontal lower part 634 No. 1 anode wire 635 Second Glass Insulator 636 No. 2 anode wire 637 Second metal pipe 638 Hole 1 639 Upright 1st part 641 Lower 643 Hole 1 645 Hole 2 647 Upright 1st part 649 Lower 650 Open anode end 652 Cathode end 654 Lower part 656 First side 658 Upper part 660 Second side 670 Hole 2 680 Anode side 682 Bottom side 684 Lower part 686 First side 688 Upper part 690 Second side 1002 Process 1004 Process 1006 Process 1008 Process 1010 Process 1012 Process 1014 Process 1016 Process 1018 Process 1020 process 1022 Process 1024 Process 1026 Process 1100 Hermetically sealed polymer capacitor 1102 Case 1103 Internal area 1104 Insulators 1106 Cathode terminal 1108 Conductive paste 1110 First condenser element 1112 Second capacitor element 1114 Bush 1116 Positive lead 1122 Cover 1124 GTMS 1126 Glass insulator 1128 Metal tube 1130 Anode insulator 1131 Part 1 1132 Anode terminal 1133 Lower 1134 No. 1 anode wire 1135 hole 1136 2nd anode wire 1138 Cross wire, second anode wire 1139 Part 1 1141 Lower 1143 hole 1147 Part 1 1149 Lower 1150 Open anode end 1152 Cathode end 1154 Lower part 1156 First side part 1158 Upper part 1160 Second side part 1180 Anode side 1182 Bottom side 1184 Lower part 1186 First side 1188 Upper part 1190 Second side 1502 Process 1504 Process 1506 Process 1508 Process 1510 Process 1512 Process 1514 Process 1516 Process 1518 Process 1520 Process 1522 Process 1524 Process 1526 Process

Claims

1. 1. A method for making a hermetically sealed polymer capacitor, comprising: forming a housing having an interior region, a cathode end and an anode end; dispensing a quantity of conductive paste in an uncured state into said interior region, said conductive paste being configured to harden to a hardened state; inserting a first capacitor element and a second capacitor element into the interior region and contacting each of the first and second capacitor elements with the conductive paste while leaving a gap between the first capacitor element and the second capacitor element, coupling an anode side of the first capacitor element to a first positive lead extending toward the anode end of the housing and coupling an anode side of the second capacitor element to a second positive lead extending toward the anode end of the housing, the conductive paste covering at least a portion of a surface of the first and second capacitor elements; at least a portion of the conductive paste is disposed between a surface of the first capacitor element facing the cathode end of the housing and an inner surface of the cathode end of the housing, and in contact with at least a portion of these surfaces and the inner surface; At least a portion of the conductive paste is disposed between a surface of the first capacitor element facing the inner surface of the second lateral side portion of the housing and the inner surface of the second lateral side portion of the housing, and in contact with at least a portion of these surfaces and the inner surface; Furthermore, at least a portion of the conductive paste is disposed between a front surface of the second capacitor element facing the cathode end of the housing and an inner surface of the cathode end of the housing, and in contact with at least a portion of the front surface and the inner surface; and further comprising: at least a portion of the conductive paste is disposed between a front surface of the second capacitor element facing an inner surface of the first lateral side of the housing and the inner surface of the first lateral side of the housing, and in contact with at least a portion of the front surface and the inner surface, wherein the first lateral side and the second lateral side are opposing sides of the housing; At least a portion of the conductive paste is at least partially located within the gap and hardened, and at least a portion of the conductive paste is in contact with both the first capacitor element and the second capacitor element in a hardened state; and a bushing having at least one opening positioned between the anode side of each of the first and second capacitor elements and the anode end of the housing, the bushing having at least one opening for each of the first and second positive leads extending into at least one of the at least one opening, the bushing being positioned in contact with and adjacent to the first and second capacitor elements but not in contact with the conductive paste, and the conductive paste being allowed to harden.

2. The method of claim 1 further comprising drying said condenser.

3. 3. The method of claim 2 further comprising welding a cover adjacent said anode end of said housing to form a capacitor body.

4. 4. The method of claim 3, further comprising providing a surface-mount anode terminal in electrical communication with said first positive lead and said second positive lead at a location insulated from said capacitor body.

5. The method according to claim 4, further comprising providing a surface-mounted cathode terminal at a position in electrical communication with the housing.

6. 6. The method of claim 5, further comprising providing an anode insulator located adjacent an exterior surface of the capacitor body, the anode insulator having a lower portion extending along an underside of the capacitor body, at least a portion of the surface mounted anode terminal extending along at least a portion of the lower portion of the anode insulator, and at least a portion of the surface mounted cathode terminal extending along at least a portion of the lower portion of the anode insulator.

7. 6. The method of claim 5, wherein the cover has a first hole and a second hole, a first glass to metal seal (GTMS) located in the first hole, a second glass to metal seal (GTMS) located in the second hole, the first glass to metal seal (GTMS) receiving the first positive lead, and the second glass to metal seal (GTMS) receiving the second positive lead.

8. 8. The method of claim 7, wherein the first glass-to-metal seal (GTMS) has a first metal tube insulated from the cover by glass, the second glass-to-metal seal (GTMS) has a second metal tube insulated from the cover by glass, the first positive lead is welded to the first metal tube, and the second positive lead is welded to the second metal tube.

9. 6. The method of claim 5, wherein the relative humidity of the capacitor body is less than approximately 25% at approximately 20°C to approximately 30°C.

10. 6. The method of claim 5, wherein the first positive lead comprises a first anode wire, the second positive lead comprises a second anode wire, and further comprises a cross wire welded and electrically connecting the first anode wire to the second anode wire.

11. The method of claim 5 , wherein the capacitor body is encased in an insulator that covers at least a portion of the capacitor body.

12. 6. The method of claim 5, wherein each of said surface mounted anode terminal and said surface mounted cathode terminal is generally L-shaped.

13. 6. The method of claim 5, wherein inserting the first capacitor element and the second capacitor element includes forcing the first capacitor element and the second capacitor element into the conductive paste before the conductive paste cures and hardens.

Images