Abstract: A method of forming an electrolyte solution involves combining ammonium tetrafluoroborate and a quaternary ammonium halide in a liquid solvent to form a quaternary ammonium tetrafluoroborate and an ammonium halide. The ammonium halide precipitate is removed from the solvent to form an electrolyte solution. The reactants can be added step-wise to the solvent, and the method can include using a stoichiometric excess of the ammonium tetrafluoroborate to form a substantially halide ion-free electrolyte solution.

Abstract: A method for producing an amorphous activated carbon material includes heating a carbon precursor to a temperature effective to form a partially-dense amorphous carbon, and activating the partially-dense amorphous carbon to produce an amorphous activated carbon. To facilitate efficient activation of the amorphous carbon, the carbonization is controlled to produce an amorphous carbon material that, prior to activation, has a density of from 85% to 99% of a maximum density for the amorphous carbon.

Abstract: Carbon particles are exposed to an activating gas to form activated carbon. The morphology of the carbon particles is controlled prior to activation. Efficient activation can be achieved by minimizing the elongation and maximizing the circularity of the carbon particles.

Abstract: A lithium ion battery having a cathode and an anode, the cathode includes a material having an olivine or spinel structure, the anode includes a coating of a composite lithium powder coated with a complex lithium salt, such as LiPF6, LiBF4, LiClO4, LiAsF6, LiF3SO3, and mixtures thereof. A separator is disposed between the anode and the cathode, and a non-aqueous electrolyte solution in contact with the cathode, the anode, and the separator. The anode can include a carbon material. A layer of a composite lithium powder coated with a complex lithium salt can be disposed between the anode and the separator.

Abstract: An energy storage device such as an electric double layer capacitor has positive and negative electrodes, each including a blend of respective first and second activated carbon materials having distinct pore size distributions. The blend (mixture) of first and second activated carbon materials may be equal in each electrode.

Abstract: A method for making activated carbon includes heating a mixture of a carbon precursor or a carbonized precursor and a chemical activating agent in a furnace. The furnace includes an internal surface either formed from or lined with a corrosion resistant material such as high purity silicon carbide or silicon nitride.

Abstract: Nanoporous activated carbon material having a high specific capacitance in EDLCs and controlled oxygen content, and methods for making such activated carbon material. Reduction of oxygen content is achieved by (a) curing a carbon precursor/additive mixture in an inert or reducing environment, and/or (b) refining (heating) activated carbon material after synthesis in an inert or reducing environment. The inert or reducing environment used for curing or refining is preferably substantially free of oxygen.

Abstract: A carbon-based electrode includes activated carbon, carbon black, and a binder. The binder is fluoropolymer having a molecular weight of at least 500,000 and a fluorine content of 40 to 70 wt. %. A method of forming the carbon-based electrode includes providing a binder-less conductive carbon-coated current collector, pre-treating the carbon coating with a sodium napthalenide-based solution, and depositing onto the treated carbon coating a slurry containing activated carbon, carbon black and binder.

Abstract: A positive electrode for an energy storage device includes a first activated carbon material comprising pores having a size of ?1 nm, which provide a combined pore volume of >0.3 cm3/g, pores having a size of >1 nm to ?2 nm, which provide a combined pore volume of ?0.05 cm3/g, and <0.15 cm3/g combined pore volume of any pores having a size of >2 nm. A negative electrode for the energy storage device includes a second activated carbon material comprising pores having a size of ?1 nm, which provide a combined pore volume of ?0.3 cm3/g, pores having a size of >1 nm to ?2 nm, which provide a combined pore volume of ?0.05 cm3/g, and <0.15 cm3/g combined pore volume of any pores having a size of >2 nm. The total oxygen content in at least the first activated carbon material is at most 1.5 wt. %.

Abstract: Carbon-based electrodes such as for incorporation into ultracapacitors or other high power density energy storage devices, include activated carbon, carbon black, binder and at least one molecular sieve material. The molecular sieve component can adsorb and trap water, which can facilitate the use of the device at higher voltage, such as greater than 3V. The molecular sieve material may be incorporated into the carbon-based electrodes or formed as a layer over a carbon-based electrode surface.

Abstract: A method of forming an electrolyte solution involves combining ammonium tetrafluoroborate and spiro-bi-pyrrolidinium bromide in a liquid solvent to form spiro-bi-pyrrolidinium tetrafluoroborate and an ammonium halide. The ammonium halide precipitate is removed from the solvent to form an electrolyte solution. The reactants can be added step-wise to the solvent, and the method can include using a stoichiometric excess of the ammonium tetrafluoroborate to form a substantially halide ion-free electrolyte solution.

Abstract: A method for producing activated carbon includes heating a phenolic novolac resin carbon precursor at a carbonization temperature effective to form a carbon material, and reacting the carbon material with CO2 at an activation temperature effective to form the activated carbon. The resulting activated carbon can be incorporated into a carbon-based electrode of an EDLC. Such EDLC can exhibit a potential window and thus an attendant operating voltage of greater than 3V.

Abstract: A method for producing activated carbon includes heating a coconut shell carbon precursor at a carbonization temperature effective to form a carbon material, and reacting the carbon material with CO2 at an activation temperature effective to form the activated carbon. The resulting activated carbon can be incorporated into a carbon-based electrode of an EDLC. Such EDLC can exhibit a potential window and thus an attendant operating voltage of greater than 3V.

Abstract: A method for forming activated carbon comprises forming a feedstock mixture from a carbon feedstock and a chemical activating agent, and heating the feedstock mixture with microwaves in a plurality of successive heating steps to react the carbon feedstock with the chemical activating agent and form activated carbon. Step-wise heating can be used to efficiently control the microwave activation process.

Abstract: Stabilized lithium particles include a lithium-containing core and a coating of a complex lithium salt that surrounds and encapsulates the core. The coating, which is a barrier to oxygen and water, enables the particles to be handled in the open air and incorporated directly into electrochemical devices. The coating material is compatible, for example, with electrolytic materials that are used in electrochemical cells. The average coated particle size is less than 500 microns.

Abstract: Water-based conductive ink compositions may include acid-washed graphite particles, carbon black particles, at least one polymeric dispersant, at least one acrylic binder, at least one polyvinylpyrrolidone binder, at least one defoamer, and an aqueous carrier. At least 90 wt. % of the acid-washed graphite particles and the carbon black particles, based on the combined weight of the acid-washed graphite particles and the carbon black particles, may have particle sizes less than 10 ?m. The water-based conductive ink composition may have a total elemental contaminant level of less than 100 ppm, based on the total weight of the water-based conductive ink composition. Methods for preparing the water-based conductive ink compositions may include preparing a letdown phase from a first premix containing carbon black and a second premix containing acid-washed graphite. The methods may include washing graphite particles in an strong acid such as hydrochloric acid, nitric acid, sulfuric acid, or mixtures thereof.

Abstract: A lithium-ion capacitor includes a cathode, an anode, and a porous separator positioned between the cathode and the anode. The cathode is formed using activated carbon, and the anode is formed from a composite material that includes lithium titanium oxide and a carbon material such as hard carbon or graphite.

Abstract: An electro-chemical double layer capacitor comprises positive and negative electrodes, where the carbon material that is incorporated into the positive electrode is halogenated carbon material, while the carbon material that is incorporated into the negative electrode is un-halogenated carbon material. Further, the carbon material incorporated into each respective electrode can have a distinct pore size distribution. A pore volume ratio of the carbon material incorporated into the positive electrode is greater than a pore volume ratio of the carbon material incorporated into the negative electrode. The pore volume ratio R is defined as R=V1/V, where V1 is a total volume of pores having a pore size of less than 1 nm, and V is a total volume of pores having a pore size greater than 1 nm.

Abstract: A method of making a multi-layer current collector comprises forming a first layer from a first formulation over each major surface of a current collector substrate, and forming a second layer from a second formulation over each of the first layers, wherein one of the first formulation and second formulation is a graphite formulation and the other of the first formulation and second formulation is a carbon black formulation.

Abstract: A method for activating carbon via alkali activation processes includes the introduction of water vapor during the activation phase to control the formation of highly reactive by-products. The method includes heating the mixture of a carbon-containing first material and a alkali-containing second material, introducing water vapor at a first threshold temperature and stopping water vapor introduction at a second threshold temperature. The activated carbon material is suitable for carbon-based electrodes and for use in high energy density devices.