Methods are disclosed for manufacturing an electrode for use in a device such as a secondary battery. Electrodes may include a first layer having first active particles adhered together by a binder, a second layer having second active particles adhered together by a binder, and an interphase layer interposed between the first and second layers. In some examples, the interphase layer may include an interpenetration of the first and second particles, such that substantially discrete fingers of the first layer interlock with substantially discrete fingers of the second layer.

A solid electrolytic capacitor that includes a plurality of linear conductors arranged in parallel and made of a valve action metal in which a dielectric layer is formed on a surface of the valve action metal; a conductive polymer layer covering the plurality of linear conductors and shared by linear conductors; a conductor layer covering conductive polymer layer; an anode terminal in contact with end faces of the plurality of linear conductors; and a cathode terminal electrically connected to conductor layer.

An electrolytic capacitor that includes a capacitor element including an anode portion made of a metal layer, a dielectric layer on an outer surface of the metal layer, and a cathode portion on an outer surface of the dielectric layer; an insulating resin body covering the capacitor element; and a gas barrier film on an outer surface of the insulating resin body, the gas barrier film having a water vapor transmittance of 1 g/m.sup.2 per day or less.

Fabricating an electrode for capacitor includes performing a first set of one or more preliminary oxide formation operations on a sheet of material. The method also includes performing a capacitance test on the sheet of material so as to determine the capacitance of the sheet of material after the one or more preliminary oxide formation operations. The method proceeds on a first path in response to a first result of the capacitance test and on a second path in response to a second result of the capacitance test. The first path includes performing a second set of the one or more preliminary oxide formation operations on the sheet of material so as to reduce the capacitance of the sheet of material below the determined capacitance. The second path excludes performing any preliminary oxide formation operations on the sheet of material.

Fabricating an electrode for capacitor includes performing a first set of one or more preliminary oxide formation operations on a sheet of material. The method also includes performing a capacitance test on the sheet of material so as to determine the capacitance of the sheet of material after the one or more preliminary oxide formation operations. The method proceeds on a first path in response to a first result of the capacitance test and on a second path in response to a second result of the capacitance test. The first path includes performing a second set of the one or more preliminary oxide formation operations on the sheet of material so as to reduce the capacitance of the sheet of material below the determined capacitance. The second path excludes performing any preliminary oxide formation operations on the sheet of material.

An improved method of forming a capacitor, and capacitor formed thereby, is described. The method comprises forming an anode with an anode lead extending therefrom, forming a dielectric on the anode, forming a solid cathode layer on the dielectric and forming a hermetic encasement on the capacitor wherein the hermetic encasement comprises a conformal non-conductive layer.

An improved method of forming a capacitor, and capacitor formed thereby, is described. The method comprises forming an anode with an anode lead extending therefrom, forming a dielectric on the anode, forming a solid cathode layer on the dielectric and forming a hermetic encasement on the capacitor wherein the hermetic encasement comprises a conformal non-conductive layer.

Methods are disclosed for manufacturing an electrode for use in a device such as a secondary battery. Electrodes may include a first layer having first active particles adhered together by a binder, a second layer having second active particles adhered together by a binder, and an interphase layer interposed between the first and second layers. In some examples, the interphase layer may include an interpenetration of the first and second particles, such that substantially discrete fingers of the first layer interlock with substantially discrete fingers of the second layer.

Methods are disclosed for manufacturing an electrode for use in a device such as a secondary battery. Electrodes may include a first layer having first active particles adhered together by a binder, a second layer having second active particles adhered together by a binder, and an interphase layer interposed between the first and second layers. In some examples, the interphase layer may include an interpenetration of the first and second particles, such that substantially discrete fingers of the first layer interlock with substantially discrete fingers of the second layer.

An electrolytic capacitor includes a capacitor element and a solution containing a solute. The capacitor element includes: an anode foil provided with a dielectric layer on the anode foil; a cathode foil disposed to face the anode foil; and a conductive polymer layer disposed between the anode foil and the cathode foil. The cathode foil is provided with a first layer disposed on the cathode foil, the first layer including at least one selected from the group consisting of carbon, nickel, a nickel compound, titanium, and a titanium compound. The conductive polymer layer includes a conductive polymer in contact with at least a part of a surface of the first layer. The cathode foil has a roughened surface, and the roughened surface of the cathode foil has a surface expansion rate ranging from 1.5 cm.sup.2/cm.sup.2 to 500 cm.sup.2/cm.sup.2, inclusive.