Channel method for forming a capacitor

Abstract

An improved method for forming a capacitor. The method includes: providing a carrier with a channel therein; providing a metal foil with a valve metal with a first dielectric on a first face of the metal foil; securing the metal foil into the channel with the first dielectric away from a channel floor; inserting an insulative material between the metal foil and each side wall of the channel; forming a cathode layer on the first dielectric between the insulative material; forming a conductive layer on the cathode layer and in electrical contact with the carrier; lap cutting the carrier parallel to the metal foil such that the valve metal is exposed; and dice cutting to form singulated capacitors.

1 - 72 . (canceled) 
     
     
         73 . A capacitor comprising:
 a metal foil anode comprising a bottom and top;   a dielectric on said top of said metal foil anode;   a cathode on said dielectric opposite to said metal foil anode;   a cathode lead in electrical contact with said cathode on a first face where a second face of said cathode lead is coplanar with said bottom of said metal foil anode; and   an insulator on two opposing sides of said cathode lead different than said first face and said second face.   
     
     
         74 . The capacitor of  claim 73  further comprising an insulative coating on at least one face selected from a face opposite to a face comprising terminals and a face adjacent to a face comprising terminals. 
     
     
         75 . The capacitor of  claim 73  wherein said anode is wider than said cathode lead. 
     
     
         76 . The capacitor of  claim 73  further comprising an insulator between said anode and said cathode lead. 
     
     
         77 . A capacitor comprising:
 a metal foil anode comprising a bottom and top;   a dielectric on said top of said metal foil anode;   a cathode layer on top of said dielectric;   said metal foil anode has a cathode lead circumjacent thereto;   a cathode lead in electrical contact with said cathode; and   an insulator between said cathode lead and said metal foil anode.   
     
     
         78 . The capacitor of  claim 77  further comprising an insulative coating on at least one face selected from a face opposite to a face comprising terminals and a face adjacent to a face comprising terminals. 
     
     
         79 . The capacitor of  claim 78  wherein said metal foil comprises metal or a conductive metal oxide. 
     
     
         80 . The capacitor of  claim 79  wherein said metal foil anode comprises at least one conductor selected from Al, W, Ta, Nb, NbO, Ti, Zr and Hf. 
     
     
         81 . The capacitor of  claim 80  wherein said conductor is aluminum. 
     
     
         82 . The capacitor of  claim 80  wherein said dielectric is an oxide of said metal foil anode. 
     
     
         83 . The capacitor of  claim 78  wherein said cathode layer comprises manganese dioxide or a conductive polymeric material. 
     
     
         84 . The capacitor of  claim 83  wherein said conductive polymeric material is an intrinsically conducting polymer. 
     
     
         85 . The capacitor of  claim 78  wherein said cathode layer comprises manganese dioxide or a conductive polymeric material. 
     
     
         86 . The capacitor of  claim 85  wherein said conductive polymeric material is an intrinsically conducting polymer. 
     
     
         87 - 92 . (canceled)