Abstract: A long life double layer capacitor and method of making the same including a case and a first terminal with an electrically insulating hermitic seal interposed between the first terminal and the case. A first current collector foil is electrically coupled to an interior portion of the first terminal and a first electrode comprising carbon which is juxtaposed against the first current collector foil. A porous separator is then juxtaposed against the first electrode comprising carbon and separating the first electrode from a second electrode comprising carbon. A second current collector foil is juxtaposed against a side of the second electrode and is electrically coupled to the second terminal.

Abstract: A long life double layer capacitor and method of making the same including a case and a first terminal with an electrically insulating hermitic seal interposed between the first terminal and the case. A first current collector foil is electrically coupled to an interior portion of the first terminal and a first electrode comprising carbon which is juxtaposed against the first current collector foil. A porous separator is then juxtaposed against the first electrode comprising carbon and separating the first electrode from a second electrode comprising carbon. A second current collector foil is juxtaposed against a side of the second electrode and is electrically coupled to the second terminal.

Abstract: A long life double layer capacitor and method of making the same including a case and a first terminal with an electrically insulating hermitic seal interposed between the first terminal and the case. A first current collector foil is electrically coupled to an interior portion of the first terminal and a first electrode comprising carbon which is juxtaposed against the first current collector foil. A porous separator is then juxtaposed against the first electrode comprising carbon and separating the first electrode from a second electrode comprising carbon. A second current collector foil is juxtaposed against a side of the second electrode and is electrically coupled to the second terminal.

Abstract: A method of making an electrode structure, and a double layer capacitor including the electrode structure, the method includes the steps of: applying a first slurry including conducting carbon powder and a binder to a current collector plate; curing the applied first slurry to form a primary coating; applying a second slurry that includes activated carbon powder, a solvent and a binder to the primary coating; and curing the applied second slurry to form a secondary coating, thereby forming a first electrode. In variations, additional primary and secondary coatings may be formed on both sides of the collector plate.

Abstract: A method of making an electrode structure, the electrode structure and a double layer capacitor including the electrode structure, the method comprising the steps of: forming a plurality of electrodes, each having a current collector plate, a primary coating formed on each side of the collector plate, the primary coating including conducting carbon powder and a binder, and a secondary coating formed on each primary coating, the secondary coating including activated carbon powder, a solvent and a binder; positioning a respective separator between each electrodes while stacking the electrodes such that the respective separator is juxtaposed against respective secondary coatings of adjacent electrodes that electrically insulates the adjacent electrodes, whereby forming an electrode stack; and rolling the electrode stack into a cylindrical electrode structure.

Abstract: A long life double layer capacitor and method of making the same including a case and a first terminal with an electrically insulating hermitic seal interposed between the first terminal and the case. A first current collector foil is electrically coupled to an interior portion of the first terminal and a first electrode comprising carbon which is juxtaposed against the first current collector foil. A porous separator is then juxtaposed against the first electrode comprising carbon and separating the first electrode from a second electrode comprising carbon. A second current collector foil is juxtaposed against a side of the second electrode and is electrically coupled to the second terminal.

Abstract: A long life double layer capacitor and method of making the same including a case and a first terminal with an electrically insulating hermitic seal interposed between the first terminal and the case. A first current collector foil is electrically coupled to an interior portion of the first terminal and a first electrode comprising carbon which is juxtaposed against the first current collector foil. A porous separator is then juxtaposed against the first electrode comprising carbon and separating the first electrode from a second electrode comprising carbon. A second current collector foil is juxtaposed against a side of the second electrode and is electrically coupled to the second terminal.

Abstract: A method of making a double layer capacitor, in accordance with one embodiment, includes coupling a top collector disk to a proximal end of a double layer capacitor electrode assembly; electrically coupling a bottom collector disk to a distal end; heating a can; inserting the double layer capacitor electrode assembly into the can; cooling the can, wherein a peripheral edge of the bottom collector disk is coupled to the can as the diameter of the can is decreased; forming a bead around an exterior of the can; heating a lid; placing a concave structure of the lid in juxtaposition with a convex structure on the top collector disk; cooling the lid, wherein the concave structure is coupled to the convex structure as the diameter of the can is decreased; creating a seal between the lid and the can; and placing an electrolyte solution into the electrode assembly.

Abstract: A method of making an electrode structure, the electrode structure and a double layer capacitor including the electrode structure, the method comprising the steps of: forming a plurality of electrodes, each having a current collector plate, a primary coating formed on each side of the collector plate, the primary coating including conducting carbon powder and a binder, and a secondary coating formed on each primary coating, the secondary coating including activated carbon powder, a solvent and a binder; positioning a respective separator between each electrodes while stacking the electrodes such that the respective separator is juxtaposed against respective secondary coatings of adjacent electrodes that electrically insulates the adjacent electrodes, whereby forming an electrode stack; and rolling the electrode stack into a cylindrical electrode structure.

Abstract: A method of making an electrode structure, the electrode structure and a double layer capacitor including the electrode structure, the method comprising the steps of: forming a plurality of electrodes, each having a current collector plate, a primary coating formed on each side of the collector plate, the primary coating including conducting carbon powder and a binder, and a secondary coating formed on each primary coating, the secondary coating including activated carbon powder, a solvent and a binder; positioning a respective separator between each electrodes while stacking the electrodes such that the respective separator is juxtaposed against respective secondary coatings of adjacent electrodes that electrically insulates the adjacent electrodes, whereby forming an electrode stack; and rolling the electrode stack into a cylindrical electrode structure.

Abstract: A method of making a double layer capacitor consists of the steps of: impregnating each of a plurality of carbon preforms with a metal; forming a plurality of current collector foils, each of the plurality of current collector foils having a tab portion and a paddle portion; forming a plurality of electrodes by positioning one of the plurality of carbon preforms against respective paddle portions of each of the plurality of current collector foils, wherein each of the plurality of electrodes comprises one of the plurality of current collector foils and one of the plurality of carbon preforms; stacking each of the plurality of electrodes such that tab portions of adjacent ones of the plurality of current collector foils are offset, thereby forming an electrode stack; interposing respective porous separator portions between each of the plurality of electrodes, wherein the porous separator portions function as electrical insulators between the adjacent ones of the plurality of electrodes preventing electrical sh

Abstract: A method of making an electrode structure, and a double layer capacitor including the electrode structure, the method includes the steps of: applying a first slurry including conducting carbon powder and a binder to a current collector plate; curing the applied first slurry to form a primary coating; applying a second slurry that includes activated carbon powder, a solvent and a binder to the primary coating; and curing the applied second slurry to form a secondary coating, thereby forming a first electrode. In variations, additional primary and secondary coatings may be formed on both sides of the collector plate.

Abstract: A method of making an electrode structure, the electrode structure and a double layer capacitor including the electrode structure, the method comprising the steps of: forming a plurality of electrodes, each having a current collector plate, a primary coating formed on each side of the collector plate, the primary coating including conducting carbon powder and a binder, and a secondary coating formed on each primary coating, the secondary coating including activated carbon powder, a solvent and a binder; positioning a respective separator between each electrodes while stacking the electrodes such that the respective separator is juxtaposed against respective secondary coatings of adjacent electrodes that electrically insulates the adjacent electrodes, whereby forming an electrode stack; and rolling the electrode stack into a cylindrical electrode structure.

Abstract: A method of making a double layer capacitor, in accordance with one embodiment, includes coupling a top collector disk to a proximal end of a double layer capacitor electrode assembly; electrically coupling a bottom collector disk to a distal end; heating a can; inserting the double layer capacitor electrode assembly into the can; cooling the can, wherein a peripheral edge of the bottom collector disk is coupled to the can as the diameter of the can is decreased; forming a bead around an exterior of the can; heating a lid; placing a concave structure of the lid in juxtaposition with a convex structure on the top collector disk; cooling the lid, wherein the concave structure is coupled to the convex structure as the diameter of the can is decreased; creating a seal between the lid and the can; and placing an electrolyte solution into the electrode assembly.

Abstract: A long life double layer capacitor and method of making the same including a case and a first terminal with an electrically insulating hermitic seal interposed between the first terminal and the case. A first current collector foil is electrically coupled to an interior portion of the first terminal and a first electrode comprising carbon which is juxtaposed against the first current collector foil. A porous separator is then juxtaposed against the first electrode comprising carbon and separating the first electrode from a second electrode comprising carbon. A second current collector foil is juxtaposed against a side of the second electrode and is electrically coupled to the second terminal.

Abstract: A single cell, multi-electrode high performance double layer capacitor includes first and second flat stacks of electrodes adapted to be housed in a closeable two-part capacitor case which includes only a single electrolyte seal. Each electrode stack has a plurality of electrodes connected in parallel, with the electrodes of one stack being interleaved with the electrodes of the other stack to form an interleaved stack, and with the electrodes of each stack being electrically connected to respective capacitor terminals. A porous separator is positioned against the electrodes of one stack before interleaving to prevent electrical shorts between the electrodes. The electrodes are made by folding a compressible, low resistance, aluminum-impregnated carbon cloth, made from activated carbon fibers, around a current collector foil, with a tab of the foils of each electrode of each stack being connected in parallel and connected to the respective capacitor terminal.

Abstract: A long life double layer capacitor and method of making the same including a case and a first terminal with an electrically insulating hermitic seal interposed between the first terminal and the case. A first current collector foil is electrically coupled to an interior portion of the first terminal and a first metal impregnated carbon cloth electrode having a metal impregnated side which is juxtaposed against the first current collector foil. A porous separator is then juxtaposed against the first metal impregnated carbon cloth electrode and separating the first metal impregnated carbon cloth electrode from a second metal impregnated carbon cloth electrode having a metal impregnated side which faces away from the porous separator. A second current collector foil is juxtaposed against the metal impregnated side of the second metal impregnated carbon cloth electrode and is electrically coupled to the second terminal.

Abstract: An ultrasonically bonded electrical interconnection for use in a double layer capacitor consists of ten or more current collector foils bonded together and at least one dummy collector foil bonded to the ten or more current collector foils. The at least one dummy collector foil does not function as a current collector foil as a result of the ultrasonic bonding.

Abstract: A method of making an electrode structure, an electrode structure, and a double layer capacitor including the electrode structure, the method includes the steps of: applying a first slurry including conducting carbon powder and a binder to a current collector plate; curing the applied first slurry to form a primary coating; applying a second slurry that includes activated carbon powder, a solvent and a binder to the primary coating; and curing the applied second slurry to form a secondary coating, thereby forming a first electrode. In variations, additional primary and secondary coatings may be formed on both sides of the collector plate.

Abstract: A method of making a double layer capacitor consists of the steps of: impregnating each of a plurality of carbon preforms with a metal; forming a plurality of current collector foils, each of the plurality of current collector foils having a tab portion and a paddle portion; forming a plurality of electrodes by positioning one of the plurality of carbon preforms against respective paddle portions of each of the plurality of current collector foils, wherein each of the plurality of electrodes comprises one of the plurality of current collector foils and one of the plurality of carbon preforms; stacking each of the plurality of electrodes such that tab portions of adjacent ones of the plurality of current collector foils are offset, thereby forming an electrode stack; interposing respective porous separator portions between each of the plurality of electrodes, wherein the porous separator portions function as electrical insulators between the adjacent ones of the plurality of electrodes preventing electrical sh