Enhanced capacitor tabs

Patent metadata

Field	Value
Publication number	US-11705286-B2
Application number	US-202017133717-A
Country	US
Kind code	B2
Filing date	Dec 24, 2020
Priority date	Dec 30, 2019
Publication date	Jul 18, 2023
Grant date	Jul 18, 2023

Abstract

A capacitor manufacturing method is disclosed herein that includes a process for the isolation of electrode tabs attached to the capacitors' electrodes from other elements in the capacitor. An isolation patch or layer may be deposited over the tabs by a machine or a device after the tab is attached and before the electrodes are wound into a cylindrical internal element of a capacitor. The device may coat the tabs and surrounding regions with an isolating material. Electrode tabs may be provided with an isolating material pre-deposited at least in part over the tabs.

First claim

The invention claimed is:

1. A capacitor comprising:
an anode foil;
a cathode foil;
a separator between the anode foil and the cathode foil;
an electrode tab attached to one of the anode foil or the cathode foil, wherein the electrode tab comprises a plurality of surfaces, and wherein the plurality of surfaces comprises a first surface attached to the one of the anode foil or the cathode foil, and a second surface that is:
bell-shaped,
trapezoidal shaped, or
separated from the first surface by an s-shaped edge; and

an isolating patch between the electrode tab and the separator, wherein the isolating patch mechanically and chemically isolates at least a portion of the electrode tab from the separator.

2. The capacitor of claim 1 , wherein the isolating patch further electrically isolates the electrode tab from the separator.

3. The capacitor of claim 1 , wherein the isolating patch is in direct contact with, at least in part, an adjacent region, around the electrode tab, of the one of the anode foil or the cathode foil.

4. The capacitor of claim 3 , wherein an edge of the adjacent region is less than 10 millimeters from an edge of the electrode tab.

5. The capacitor of claim 3 , wherein an edge of the adjacent region is less than 5 millimeters from an edge of the electrode tab.

6. The capacitor of claim 3 , wherein the isolating patch comprises:
a layer of an adhesive material and a layer of an isolating polymer; or
a layer of an electrically isolating polymer and a layer of a chemically isolating material.

7. The capacitor of claim 1 , further comprising a second isolating patch;
wherein the electrode tab further comprises:
a third surface positioned between the first surface and the second surface, and
a fourth surface positioned between the first surface and the second surface and opposite to the third surface;

wherein the second surface is opposite to the first surface and is covered at least in part by the separator,
wherein the third surface, and a first adjacent region around the third surface of the one of the anode foil or the cathode foil, is covered at least in part by the isolating patch; and
wherein the fourth surface, and a second adjacent region around the fourth surface of the one of the anode foil or the cathode foil, is covered at least in part by the second isolating patch.

8. The capacitor of claim 1 , wherein the isolating patch comprises an adhesive material that adheres the isolating patch to the one of the anode foil or the cathode foil.

9. The capacitor of claim 1 , wherein:
the second surface is bell-shaped and separated from the first surface by a plurality of edges; or
the second surface is bell-shaped and separated from the first surface by the s-shaped edge.

10. The capacitor of claim 1 , wherein the isolating patch adheres to, at least in part, an adjacent region, around the electrode tab, of the one of the anode foil or the cathode foil.

11. A method, comprising:
positioning at least one electrode tab on one side of a conducting foil, wherein the at least one electrode tab comprises a plurality of surfaces, wherein the plurality of surfaces comprises a first surface and a second surface that is:
bell-shaped,
trapezoidal shaped, or
separated from the first surface by an s-shaped edge;

attaching the first surface of the at least one electrode tab to the one side of the conducting
covering the at least one electrode tab and at least an adjacent region, around the at least one electrode tab, of the one side of the conducting foil with an isolating material that mechanically and chemically isolates the at least one electrode tab from a separator; and
winding the conducting foil with the separator to form a roll.

12. The method of claim 11 , wherein the electrode tab comprises a rounded or beveled corner between the second surface and the s-shaped edge.

13. The method of manufacturing of claim 11 , further comprising forming the at least one electrode tab by rolling, three-dimensional printing, or extruding a conducting metal.

14. An assembly comprising:
an electrode tab comprising:
a first surface configured to be attached to of an anode foil or a cathode foil; and
an second surface, wherein the second surface is:
bell-shaped,
trapezoidal shaped, or
separated from the first surface by an s-shaped edge; and

an isolating patch that covers at least a portion of the electrode tab and that mechanically and chemically isolates the portion of the electrode tab from a separator between the one of the anode foil or the cathode foil and another anode foil or cathode foil.

15. The assembly of claim 14 , wherein the isolating patch comprises a recess configured to allow access to the second surface by a tool for cold welding the first surface to the one of the anode foil or the cathode foil.

16. The assembly of claim 14 , wherein:
the second surface is bell-shaped and separated from the first surface by a plurality of edges; or
the second surface is bell-shaped and separated from the first surface by the s-shaped edge.

17. The electrode tab of claim 14 , wherein the isolating patch is adhered to an adjacent region, around the electrode tab, of the one of the anode foil or the cathode foil.

18. The electrode tab of claim 14 , wherein the isolating patch comprises:
a layer of an adhesive material and a layer of an isolating polymer; or

a layer of an electrically isolating polymer and a layer of a chemically isolating material.

Assignees

• Solaredge Technologies Ltd

Inventors

• Lang Joel
• Romm Ronit
• Gomberg Bryon Roos

Classifications

• H01G9/008 Primary

  Terminals · CPC title

• H01G9/0029

  Processes of manufacture · CPC title

• H01G9/02

  Diaphragms; Separators · CPC title

• H01G9/048

  characterised by their structure (H01G11/22 takes precedence) · CPC title

• H01G9/151

  with wound foil electrodes · CPC title