Abstract: A method for producing an electrode for an energy storage device includes: forming a current collector from a conductive material; forming a primer layer on the current collector; injecting dry powder electrode materials into the primer layer, wherein the dry powder electrode materials injected into the primer layer form an electrode film in electrical contact with the current collector.

Abstract: A method for fabricating an electrode includes: determining a thickness of an active layer; selecting lithium (Li) foil having a specified thickness; determining widths of one or more Li strips based on an active layer to Li layer weight ratio or volume ratio; laminating the active layer onto a conductive substrate; forming one or more grooves in the active layer exposing a bare surface of the conductive substrate; and pressing the one or more Li strips into the one or more grooves, wherein widths of the one or more grooves are slightly larger than the widths of the Li strips.

Abstract: A method for producing an electrode for an energy storage device includes: forming a current collector from a conductive material; forming a primer layer on the current collector; injecting dry powder electrode materials into the primer layer, wherein the dry powder electrode materials injected into the primer layer form an electrode film in electrical contact with the current collector.

Abstract: A method for producing an electrode for an energy storage device includes: forming a current collector from a conductive material; forming a primer layer on the current collector; injecting dry powder electrode materials into the primer layer, wherein the dry powder electrode materials injected into the primer layer form an electrode film in electrical contact with the current collector.

Abstract: The present invention is directed to an electrode for energy storage devices and a method for making the electrode for energy storage devices is disclosed, where a flexible binder in the electrode formulation is activated by certain additives and is uniformly deposited on to the active and conductive particles by high speed mixing. The particles deposited with activated binder particles are then pressed together to form free standing electrode film. High performance and cost effective products, such as free standing electrode films, laminated electrodes, ultracapacitors, lithium ion capacitors, batteries, fuel cells and hybrid cells which are the combination of the above devices, and the energy storage system or the system blocks, such as modules, can be manufactured using this process.

Abstract: A method for fabricating an electrode includes: determining a thickness of an active layer; selecting lithium (Li) foil having a specified thickness; determining widths of one or more Li strips based on an active layer to Li layer weight ratio or volume ratio; laminating the active layer onto a conductive substrate; forming one or more grooves in the active layer exposing a bare surface of the conductive substrate; and pressing the one or more Li strips into the one or more grooves, wherein widths of the one or more grooves are slightly larger than the widths of the Li strips.

Abstract: Dry process based energy storage device structures and methods for using a dry adhesive therein are disclosed.

Abstract: A method for fabricating an electrode, includes: determining a thickness of an active layer; selecting a lithium (Li) foil having a specified thickness; determining a Li layer pattern for the Li foil based on a portion of a surface of the active layer to be covered by the Li foil; and pressing the Li layer pattern into the surface of the active layer.

Abstract: Dry process based energy storage device structures and methods for using a dry adhesive therein are disclosed.

Abstract: The present invention is directed to a low cost, high performance electrode for energy storage devices and energy storage systems and a method for making same is disclosed, where a flexible binder is mixed with partial active and conductive materials in the electrode formulation and activated by mixing with a minimum amount of solvent it is then mixed with the remaining active and conductive materials and the binder is uniformly deposited on to the active and conductive particles by high speed mixing. The active and conductive particles deposited with activated binder particles are then pressed together to form free standing electrode film. High performance and low cost products, such as free standing electrode films, laminated electrodes, ultracapacitors, lithium-ion capacitors, batteries, fuel cells and hybrid cells which are the combination of the above devices, and the energy storage system or the system blocks, such as modules, can be manufactured using this process.

Abstract: Dry process based energy storage device structures and methods for using a dry adhesive therein are disclosed.

Abstract: The present invention is directed to a low cost, high performance electrode for energy storage devices and energy storage systems and a method for making same is disclosed, where a flexible binder is mixed with partial active and conductive materials in the electrode formulation and activated by mixing with a minimum amount of solvent it is then mixed with the remaining active and conductive materials and the binder is uniformly deposited on to the active and conductive particles by high speed mixing. The active and conductive particles deposited with activated binder particles are then pressed together to form free standing electrode film. High performance and low cost products, such as free standing electrode films, laminated electrodes, ultracapacitors, lithium-ion capacitors, batteries, fuel cells and hybrid cells which are the combination of the above devices, and the energy storage system or the system blocks, such as modules, can be manufactured using this process.

Abstract: Dry process based energy storage device structures and methods for using a dry adhesive therein are disclosed.

Abstract: A method of making an active electrode material is provided. Activated carbon having between about 70 and 98 percent microporous activated carbon particles of a total amount of activated carbon by weight and between about 2 and 30 percent mesoporous activated carbon particles of the total amount of activated carbon by weight is provided. Binder is provided. The activated carbon and the binder is mixed to form an active electrode material mixture. In some implementations, a method of making an electrode film includes forming a film of active electrode material comprising activated carbon having between about 70 and 98 percent microporous activated carbon particles of a total amount of activated carbon by weight and between about 2 and 30 percent mesoporous activated carbon particles of the total amount of activated carbon by weight. The method further includes bonding the film to a current collector to form an electrode film.

Abstract: The present invention is directed to an electrode for energy storage devices and a method for making the electrode for energy storage devices is disclosed, where a flexible binder in the electrode formulation is activated by certain additives and is uniformly deposited on to the active and conductive particles by high speed mixing. The particles deposited with activated binder particles are then pressed together to form free standing electrode film. High performance and cost effective products, such as free standing electrode films, laminated electrodes, ultracapacitors, lithium ion capacitors, batteries, fuel cells and hybrid cells which are the combination of the above devices, and the energy storage system or the system blocks, such as modules, can be manufactured using this process.

Abstract: A dry process based battery that includes an electrode with one or more recycled structure is disclosed.

Abstract: A method of making an active electrode material is provided. Activated carbon having between about 70 and 98 percent microporous activated carbon particles of a total amount of activated carbon by weight and between about 2 and 30 percent mesoporous activated carbon particles of the total amount of activated carbon by weight is provided. Binder is provided. The activated carbon and the binder is mixed to form an active electrode material mixture. In some implementations, a method of making an electrode film includes forming a film of active electrode material comprising activated carbon having between about 70 and 98 percent microporous activated carbon particles of a total amount of activated carbon by weight and between about 2 and 30 percent mesoporous activated carbon particles of the total amount of activated carbon by weight. The method further includes bonding the film to a current collector to form an electrode film.

Abstract: Particles of active electrode material are made by blending or mixing a mixture of activated carbon, optional conductive carbon, and binder. In selected implementations, the activated carbon particles have between about 70 and 98 percent microporous activated carbon particles and between about 2 and 30 percent mesaporous activated carbon particles by weight. Optionally, a small amount of conductive particles, such as conductive carbon particles may be used. In one implementation, the binder is inert. The electrode material may be attached to a current collector to obtain an electrode for use in various energy storage devices, including a double layer capacitor.

Abstract: In one embodiment, an energy storage device having a first electrode supported by a first collector sheet; a second electrode supported by a second collector sheet; and a dielectric separator therebetween, all spirally wound together. A container houses this spiral winding, with the first collector sheet having an end in contact with the base and the second collector sheet having an end oriented towards an opening opposite to the base. A collector plate is interposed between the second collector sheet and the opening and is restrained in posibion by a crimp in the container. A lid is positioned in the opening and has one side in electrical contact with the collector plate an an opposite side oriented outwardly of the container. The lid is restrained in position by rolling the one or more container walls over the lid.

Abstract: A coated electrode is provided for use in energy storage devices. The coated electrode comprises a dry fibrillized polymer that is fibrillized with no processing additives.