초록 ▼

A double layer capacitor includes first and second electrode structures separated by a porous separator. The first and second electrode structures each include a current collector foil, a primary coating formed on the current collector foil, and a secondary coating formed on the primary coating. The

A double layer capacitor includes first and second electrode structures separated by a porous separator. The first and second electrode structures each include a current collector foil, a primary coating formed on the current collector foil, and a secondary coating formed on the primary coating. The primary coatings include conducting carbon powder, and the secondary coatings include activated carbon powder. A method of making the electrode structures includes the steps of: preparing a first slurry that includes conducting carbon powder and a binder; applying the first slurry to a current collector plate; drying the applied first slurry to form a primary coating; preparing a second slurry that includes activated carbon powder, a solvent and a binder; and applying the second slurry to the primary coating.

대표청구항 ▼

1. A method of making an electrode structure for use in a double layer capacitor, comprising the steps of: preparing a first slurry that includes conducting carbon powder and a binder; applying the first slurry to a current collector plate; drying the applied first slurry to form a primary coat

1. A method of making an electrode structure for use in a double layer capacitor, comprising the steps of: preparing a first slurry that includes conducting carbon powder and a binder; applying the first slurry to a current collector plate; drying the applied first slurry to form a primary coating; preparing a second slurry that includes activated carbon powder, a solvent and a binder; and applying the second slurry to the primary coating. 2. A method in accordance with claim 1, wherein an amount of the conducting carbon powder in the first slurry falls in the range of 25 to 95 percent-by-weight. 3. A method in accordance with claim 1, wherein the first slurry is free of activated carbon. 4. A method in accordance with claim 1, wherein an amount of the activated carbon powder in the second slurry falls in the range of 50 to 98 percent-by-weight. 5. A method in accordance with claim 1, wherein the second slurry further comprises conducting carbon powder. 6. A method in accordance with claim 1, wherein the step of preparing the second slurry comprises the steps of: mixing the binder and the solvent; stirring the mixed binder and solvent; adding the activated carbon powder to the mixed binder and solvent; and mixing the activated carbon powder into the mixed binder and solvent. 7. A method in accordance with claim 6, wherein the step of mixing the activated carbon powder into the mixed binder and solvent comprises the step of: initially mixing slowly to allow the carbon powders to get wet; mixing with an automatic mixer for approximately 10 minutes; and shaking vigorously for approximately 30 seconds. 8. A method in accordance with claim 1, wherein the step of applying the first slurry to a current collector plate comprises the step of: applying the first slurry to the current collector plate with a metering rod. 9. A method in accordance with claim 1, wherein the step of drying the applied first slurry to form a primary coating comprises the step of: curing the applied first slurry in an oven. 10. A method in accordance with claim 1, wherein an amount of the conducting carbon powder in the first slurry falls in the range of 50 to 95 percent-by-weight. 11. A method of making an electrode structure for use in a double layer capacitor, comprising the steps of: preparing a first slurry that includes a liquid, conducting carbon powder and a polymeric binder; coating the first slurry on to a surface of a current collector plate; drying the applied first slurry to remove the liquid to form a primary coating layer: preparing a second slurry that includes activated carbon powder, a binder of polymeric material and a solvent for the polymeric material; coating the second slurry on to the primary coating layer; and removing the solvent to form a secondary coating layer to create an overall electrode structure containing a polymer and carbon.