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 particle packaging system and method for making is disclosed.

Abstract: A method for making an electrode including a particle based film is disclosed in which the film is coated and/or impregnated with veins of conductive material. A support backing is placed adjacent to one side of the film to provide support and prevent damaging the film while the conductive material is applied onto the opposite side of the film. The film is bonded directly to a current collector of an energy storage device.

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: 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: Electrodes are constructed with pressure-bonding techniques that simplify alignment of various electrode components during lamination. In an exemplary embodiment, a current collector is made from aluminum foil that has been roughed or pitted on both surfaces. The surfaces of the current collector can be further treated to enhance adhesion properties of these surfaces. Layers of film that include active electrode material, such as activated carbon particles, are fabricated using non-lubricated techniques. Each film is coated on one side with an adhesive binder solution, such as a thermoplastic solution. The adhesive binder is dried, and the films are laminated to the current collector using a calender with heated rollers. The resulting electrode product is processed to shape electrodes, which can then be used in electrical energy storage devices, including double layer capacitors.

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

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.

Abstract: A compressible and deformable layer is densified and laminated to a layer of a material that is relatively resistant to stretching. The densification and bonding take place in a single step. As used in fabrication of electrodes, for example, electrodes for double layer capacitors, a deformable and compressible active electrode film is manufactured from activated carbon, conductive carbon, and a polymer. The electrode film may be bonded directly to a collector. Alternatively, a collector may be coated with a wet adhesive layer. The adhesive layer is subsequently dried onto the foil. The dried adhesive and foil combination may be manufactured as a product for later sale or use, and may be stored as such on a storage roll or other storage device. The active electrode film is overlayed on the metal foil, and processed in a laminating device, such as a calender. Lamination both densifies the active electrode film and bonds the film to the metal foil.

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

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

Abstract: Dry process based energy storage device structures and methods for using a dry adhesive therein are 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 in 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 coated electrode is provided for use in energy storage devices. The coated electrode comprises a dry particles that are fibrillized.

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

Abstract: Particles of active electrode material, such as a fibrillized mixture of carbon, and binder are deposited onto a surface of a current collector sheet. The current collector sheet and the particles are processed in a high-pressure nip, such as a calender. As a result of the high-pressure processing, a film of active electrode material is formed on and bonded to the surface of the current collector sheet. The process is then repeated to form a second film on the second surface of the current collector sheet. In an embodiment, the particles are applied to both surfaces of the current collector sheet at the same time, followed by a pass through a calender. The current collector sheet with the bonded films is shaped into electrodes suitable for use in various electrical devices, including double layer capacitors.

Abstract: A dry process-based electro-chemical device and method for making a self-supporting dry electrode film for use therein is disclosed. Cost effective manufacture of electrochemical devices such as batteries, capacitors, and fuel cells is enabled.

Abstract: A dry process-based particle packaging method and system is disclosed where a matrix of dry fibrillized binder is formed so as to support one or more type of particle. Reliable and inexpensive products, including films, sheets, electrodes, batteries, capacitors, fuel cells, and/or medical devices can be thus manufactured.

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: A method for making an electrode including a particle based film is disclosed in which the film is coated and/or impregnated with veins of conductive material. A support backing is placed adjacent to one side of the film to provide support and prevent damaging the film while the conductive material is applied onto the opposite side of the film. The film is bonded directly to a current collector of an energy storage device.