METHOD OF MANUFACTURING A CURRENT COLLECTOR FOR A DOUBLE ELECTRIC LAYER CAPACITOR
First Claim
1. A method of manufacturing a capacitor current collector that is resistant to acidic electrolytes, comprising:
- providing a conductive basis formed from an electrically conductive metal;
coating at least certain surfaces of said conductive basis with a protective coating material comprising a conductive composite that includes a conductive carbon powder and a polymer binder;
subjecting said protective coating material to a solvent evaporation step; and
subjecting said protective coating material to a thermal treatment step.
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Accused Products
Abstract
A method of manufacturing a current collector for use in a capacitor (e.g., a DEL capacitor) having an aqueous or non-aqueous electrolyte, such as an aqueous sulfuric acid electrolyte. The conductive basis of the current collector is preferably, but not necessarily, comprised of lead or a lead alloy. The portion of the conductive basis that will be in contact with the electrolyte is provided with a protective layer that is created by deposition of one or more layers of one or more protective coating materials thereto. Each protective coating material is comprised of at least a conductive carbon powder and a polymer binder that is resistant to the electrolyte. Preferably, but not essentially, the protective coating material(s) are applied to the conductive basis in the form of a paste, which is subsequently subjected to a solvent evaporation step and a thermal treatment step.
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Citations
38 Claims
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1. A method of manufacturing a capacitor current collector that is resistant to acidic electrolytes, comprising:
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providing a conductive basis formed from an electrically conductive metal; coating at least certain surfaces of said conductive basis with a protective coating material comprising a conductive composite that includes a conductive carbon powder and a polymer binder; subjecting said protective coating material to a solvent evaporation step; and subjecting said protective coating material to a thermal treatment step. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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21. A method of manufacturing a capacitor current collector that is resistant to acidic electrolytes, comprising:
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providing a conductive basis formed from lead or a lead alloy; forming a protective layer on said conductive basis by coating at least certain surfaces of said conductive basis with one or more layers of one or more protective coating materials, each of which comprises a conductive composite that includes a conductive carbon powder and a polymer binder; and subjecting each layer of said protective coating material to a solvent evaporation step and a thermal treatment step, said solvent evaporation step and said thermal treatment step occurring prior to the deposition of any additional layers of protective coating material; wherein said resulting protective layer is substantially non-porous and capable of preventing an aqueous acid electrolyte from contacting and oxidizing said conductive basis. - View Dependent Claims (22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34)
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35. A method of manufacturing a current collector for a double electric layer capacitor, said current collector resistant to acidic electrolytes, and comprising:
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providing a conductive basis formed from lead or a lead alloy; preparing at least one protective coating material comprising a conductive composite that includes a conductive carbon powder and a polymer binder that is resistant to at least a sulfuric acid electrolyte, said at least one protective coating material exhibiting p-type conductivity; forming a protective layer on said conductive basis by coating at least certain surfaces of said conductive basis with at least one layer of said at least one protective coating material in the form of a paste; and subjecting each layer of said protective coating material to a solvent evaporation step and a thermal treatment step, said solvent evaporation step and said thermal treatment step occurring prior to the deposition of any additional layers of protective coating material; wherein said resulting protective layer is substantially non-porous and capable of preventing an aqueous sulfuric acid electrolyte from contacting and oxidizing said conductive basis. - View Dependent Claims (36, 37, 38)
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Specification