Abstract: A dry process based capacitor and method for a self-supporting dry adhesive electrode film for use therein is disclosed.

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 mesoporous 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: An energy storage device electrode product is provided. The product comprises: at least one current collector and at least one electrode film disposed adjacent to the at least one current collector. The at least one current collector comprises a plurality of voids extending through a thickness of the current collector, wherein the plurality of voids allow electrolyte to flow through the thickness of the current collector. The plurality of voids extending through the current collector is formed without reducing a surface area of a conductive material of the current collector disposed adjacent to the electrode by more than about fifty percent. A method of producing an electrode product and a double layer capacitor product are also disclosed.

Abstract: An inexpensive and reliable dry process based capacitor and method for making a self-supporting dry electrode film for use therein is disclosed. Also disclosed is an exemplary process for manufacturing an electrode for use in an energy storage device product, the process comprising: supplying dry carbon particles; supplying dry binder; dry mixing the dry carbon particles and dry binder; and dry fibrillizing the dry binder to create a matrix within which to support the dry carbon particles as dry material.

Abstract: A dry process based capacitor and method for using one or more recyclable electrode film structure is disclosed.

Abstract: Electrodes of a double-layer capacitor are designed so that sub-capacitors formed at each electrode are stressed substantially equally at the rated voltage of the double-layer capacitor. In an exemplary embodiment, each electrode includes a current collector and an active electrode layer, such as a layer of activated carbon. The electrodes are held apart by a porous separator, and the assembly is immersed in an electrolyte. The thicknesses of the active electrode layers differ, resulting in asymmetrical construction of the capacitor. Different thicknesses cause the sub-capacitors to have different capacitances. When voltage is applied to the double-layer capacitor, the voltage is divided unequally between the unequal sub-capacitors. Properly selected thicknesses allow the voltages at the sub-capacitors to stress equally each sub-capacitor. The rated voltage of the double-layer capacitor can then be increased without overstressing the sub-capacitors.

Abstract: Particles of active electrode material are made by blending and fibrillizing (i.e., fibrillating) a mixture of activated carbon, conductive carbon, and fibrillizable binder. In selected embodiments, chloride level in the activated carbon is relatively low, a small amount of conductive carbon with low impurity levels and high conductivity is used, and the binder is inert. For example, chloride content of the activated carbon is below 50 ppm, and total impurities in the conductive carbon are below 120 ppm. The mixture may include about 10% of PTFE and 0.5% or less of conductive carbon. Blending and fibrillization may be performed without solvents. The fibrillized particles are dried, blended again to reduce clumping, and used to make active electrode material film. The film is attached to a current collector to obtain an electrode for use in various electrical devices, including double layer capacitors. The electrode increases breakdown voltage of the capacitor electrolyte.

Abstract: Active electrode material, such as fibrillized blend of activated carbon, polymer, and conductive carbon, is pretreated by immersion in a sealing coating. After the active electrode material is dried, the coating seals micropores of the activated carbon or another porous material, thus preventing exposure of water molecules or other impurities trapped in the micropores to outside agents. At the same time, the sealing coating does not seal most mesapores of the porous material, allowing exposure of the mesapores' surface area to the outside agents. The pretreated active electrode material is used for making electrodes or electrode assemblies of electrical energy storage devices. For example, the electrodes may be immersed in an electrolyte to construct electrochemical double layer capacitors. Pretreatment with the sealing coating reduces the number of water molecules interacting with the electrolyte, enhancing the breakdown voltage of the capacitors.

Abstract: A dry process based capacitor and method for making a self-supporting dry adhesive electrode film for use therein is disclosed.

Abstract: Particles of active electrode material are made by blending and fibrillizing (i.e., fibrillating) a mixture of activated carbon, conductive carbon, and fibrillizable binder. In selected embodiments, chloride level in the activated carbon is relatively low, a small amount of conductive carbon with low impurity levels and high conductivity is used, and the binder is inert. For example, chloride content of the activated carbon is below 50 ppm, and total impurities in the conductive carbon are below 120 ppm. The mixture may include about 10% of PTFE and 0.5% or less of conductive carbon. Blending and fibrillization may be performed without solvents. The fibrillized particles are dried, blended again to reduce clumping, and used to make active electrode material film. The film is attached to a current collector to obtain an electrode for use in various electrical devices, including double layer capacitors. The electrode increases breakdown voltage of the capacitor electrolyte.

Abstract: A dry process based energy storage product and method for making is disclosed.

Abstract: Particles of active electrode material are made by blending and fibrillizing (i.e., fibrillating) a mixture of activated carbon, conductive carbon, and fibrillizable binder. In selected embodiments, chloride level in the activated carbon is relatively low, a small amount of conductive carbon with low impurity levels and high conductivity is used, and the binder is inert. For example, chloride content of the activated carbon is below 50 ppm, and total impurities in the conductive carbon are below 120 ppm. The mixture may include about 10% of PTFE and 0.5% or less of conductive carbon. Blending and fibrillization may be performed without solvents. The fibrillized particles are dried, blended again to reduce clumping, and used to make active electrode material film. The film is attached to a current collector to obtain an electrode for use in various electrical devices, including double layer capacitors. The electrode increases breakdown voltage of the capacitor electrolyte.

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, binder content in the electrode material is relatively low, typically the binder content of the mixture being between about 3 percent and about 10 percent by weight. The electrode material may be attached to a current collector to obtain an electrode for use in various electrical devices, including a double layer capacitor. The composition of the mixture increases the energy density and the integrity of the electrode.

Abstract: An ultracapacitor design minimizes the internal pressure of the cell package by using gas getters, either alone or in combination with a resealable vent in the package. Reducing pressure extends the life of the ultracapacitor. The primary gas types generated within a particular ultracapacitor are measured under multiple possible application conditions. Such conditions may include variables of temperature, application voltage, electrolyte type, length of use, and cycles of use. The primary gas components may be determined and suitable gas getters for different conditions may be formulated. The gas getters may be packed within the ultracapacitor packages, formulated as a negative electrode, doped into the negative current collector, or layered with the negative current collector.

Abstract: An active electrode material is made by blending or mixing a mixture of activated carbon, optional conductive carbon, and binder; wherein the activated carbon has a high soakability to provide a reduced capacitance fade. The electrode material may be attached to a current collector to obtain an electrode for use in various electrical devices, including a double layer capacitor.

Abstract: Electrodes of a double-layer capacitor are designed so that sub-capacitors formed at each electrode are stressed substantially equally at the rated voltage of the double-layer capacitor. In an exemplary embodiment, each electrode includes a current collector and an active electrode layer, such as a layer of activated carbon. The electrodes are held apart by a porous separator, and the assembly is immersed in an electrolyte. The thicknesses of the active electrode layers differ, resulting in asymmetrical construction of the capacitor. Different thicknesses cause the sub-capacitors to have different capacitances. When voltage is applied to the double-layer capacitor, the voltage is divided unequally between the unequal sub-capacitors. Properly selected thicknesses allow the voltages at the sub-capacitors to stress equally each sub-capacitor. The rated voltage of the double-layer capacitor can then be increased without overstressing the sub-capacitors.

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

Abstract: Active electrode material, such as fibrillized blend of activated carbon, polymer, and conductive carbon, is pretreated by immersion in a sealing coating. After the active electrode material is dried, the coating seals micropores of the activated carbon or another porous material, thus preventing exposure of water molecules or other impurities trapped in the micropores to outside agents. At the same time, the sealing coating does not seal most mesapores of the porous material, allowing exposure of the mesapores' surface area to the outside agents. The pretreated active electrode material is used for making electrodes or electrode assemblies of electrical energy storage devices. For example, the electrodes may be immersed in an electrolyte to construct electrochemical double layer capacitors. Pretreatment with the sealing coating reduces the number of water molecules interacting with the electrolyte, enhancing the breakdown voltage of the capacitors.

Abstract: Composite electrodes are constructed with pressure-bonding techniques instead of an adhesive. A current collector is made from aluminum foil roughed on both surfaces. The surfaces of the collector can be treated to enhance adhesion to the surfaces. Layers of film that includes active electrode material, such as activated carbon, are fabricated and pressure-bonded to the current collector using a calender with heated rollers. The resulting composite sheet is then processed to shape electrodes, which can be used in electrical energy storage devices, including double layer capacitors.

Abstract: Particles of active electrode material are made by blending and fibrillizing (i.e., fibrillating) a mixture of activated carbon, conductive carbon, and fibrillizable binder. In selected embodiments, chloride level in the activated carbon is relatively low, a small amount of conductive carbon with low impurity levels and high conductivity is used, and the binder is inert. For example, chloride content of the activated carbon is below 50 ppm, and total impurities in the conductive carbon are below 120 ppm. The mixture may include about 10% of PTFE and 0.5% or less of conductive carbon. Blending and fibrillization may be performed without solvents. The fibrillized particles are dried, blended again to reduce clumping, and used to make active electrode material film. The film is attached to a current collector to obtain an electrode for use in various electrical devices, including double layer capacitors. The electrode increases breakdown voltage of the capacitor electrolyte.