Low resistance ultracapacitor electrode and manufacturing method thereof

Patent metadata

Field	Value
Publication number	US-9941059-B2
Application number	US-201615365313-A
Country	US
Kind code	B2
Filing date	Nov 30, 2016
Priority date	Aug 30, 2013
Publication date	Apr 10, 2018
Grant date	Apr 10, 2018

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.

First claim

We claim:

1. A method of forming a carbon-based electrode, comprising:
thermally growing a first conductive layer formed of carbon on at least one major surface of a substrate;
forming a slurry including activated carbon particles, carbon black particles and binder;
coating the slurry onto the first conductive layer to form a thin film;
and drying the thin film to form a carbon mat, wherein the binder comprises a fluoro-polymer having from 40 to 70 wt. % fluorine and a molecular weight of at least 500,000.

2. The method according to claim 1 , wherein the coating comprises slot coating.

3. The method according to claim 1 , wherein the thin film is formed over both major surfaces of the substrate.

4. The method according to claim 1 , wherein the substrate comprises a current collector having opposing first and second major surfaces, a second conductive layer comprising thermally-grown carbon formed over the second major surface, and the slurry is coated onto each respective thermally-grown carbon layer.

5. The method according to claim 4 , wherein the first and second conductive layers each have an organic content of less than 0.5 wt. %.

6. The method according to claim 1 , further comprising laminating, the carbon mat onto the substrate.

7. The method according to claim 1 , further comprising applying an alkali metal napthalenide-based solution to the substrate prior to the coating, wherein the alkali metal is selected from the group consisting of lithium, sodium, and potassium.

8. The method according to claim 7 , wherein the solution comprises 1 to 10% wt. % sodium napthalenide.

Assignees

• Corning Inc

Inventors

• Gadkaree Kishor Purushottam
• Kadam Rahul Suryakant
• Kumar Atul

Classifications

• H01G11/28 Primary

  arranged or disposed on a current collector; Layers or phases between electrodes and current collectors, e.g. adhesives · CPC title

• H01G11/70

  characterised by their structure · CPC title

• Y02E60/13

  Energy storage using capacitors · CPC title

• H01G11/38 Primary

  Carbon pastes or blends; Binders or additives therein · CPC title

• H01G11/34

  characterised by carbonisation or activation of carbon · CPC title