Method of making a high performance ultracapacitor
First Claim
Patent Images
1. A method of making a double layer capacitor comprising the steps of:
- impregnating an activated carbon fiber preform with an evenly distributed and continuous path of aluminum, thereby forming an aluminum impregnated carbon fiber preform;
bonding a current collector plate on a surface of said aluminum impregnated carbon fiber preform;
aligning a pair of aluminum impregnated carbon fiber preforms having been bonded to a respective current collector plate together, wherein said pair of aluminum impregnated carbon fiber preforms have non-bonded surfaces facing one another;
placing an ionically conductive separator between said facing surfaces of said pair of aluminum impregnated carbon fiber preforms; and
saturating said pair of aluminum impregnated carbon fiber preforms and said ionically conductive separator with an electrolyte solution.
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Abstract
A high performance double layer capacitor having an electric double layer formed in the interface between activated carbon and an electrolyte is disclosed. The high performance double layer capacitor includes a pair of aluminum impregnated carbon composite electrodes having an evenly distributed and continuous path of aluminum impregnated within an activated carbon fiber preform saturated with a high performance electrolytic solution. The high performance double layer capacitor is capable of delivering at least 5 Wh/kg of useful energy at power ratings of at least 600 W/kg.
167 Citations
56 Claims
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1. A method of making a double layer capacitor comprising the steps of:
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impregnating an activated carbon fiber preform with an evenly distributed and continuous path of aluminum, thereby forming an aluminum impregnated carbon fiber preform; bonding a current collector plate on a surface of said aluminum impregnated carbon fiber preform; aligning a pair of aluminum impregnated carbon fiber preforms having been bonded to a respective current collector plate together, wherein said pair of aluminum impregnated carbon fiber preforms have non-bonded surfaces facing one another; placing an ionically conductive separator between said facing surfaces of said pair of aluminum impregnated carbon fiber preforms; and saturating said pair of aluminum impregnated carbon fiber preforms and said ionically conductive separator with an electrolyte solution. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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25. A method of forming a diffusion bond between an aluminum foil current collector plate and an aluminum/carbon composite electrode comprising the steps of:
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reducing any aluminum oxide layers from said aluminum foil current collector plate; and pressing said aluminum/carbon composite electrode against said aluminum foil current collector plate at a bonding temperature well below a melting point of aluminum in an inert atmosphere such that aluminum atoms fill voids at an interface of said aluminum/carbon composite electrode and aluminum foil current collector plate to adhere said aluminum foil to said carbon electrode while preventing formation of aluminum carbide at said interface. - View Dependent Claims (26, 27, 28, 29, 30, 31)
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32. A method of making a double layer capacitor comprising the steps of:
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impregnating a pair of activated carbon fiber preforms with aluminum; pressing a pair of current collector plates each onto a respective surface of respective ones of said pair of activated carbon fiber preforms; aligning the pair of activated carbon fiber preforms together wherein said respective ones of said pair of activated carbon fiber preforms have respective non-bonded surfaces facing one another; placing an ionically conductive separator between said non-bonded surfaces of said respective ones of said pair of activated carbon fiber preforms; and saturating said pair of activated carbon fiber preforms and the ionically conductive separator with an electrolyte solution. - View Dependent Claims (33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55)
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56. A method of making a double layer capacitor comprising the steps of:
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forming the double layer capacitor, wherein the double layer capacitor has an electrode capacitance of greater than 30 farads/cm3 and a cell resistivity of less than 15 ohm-cm comprising; impregnating a pair of activated carbon fiber preforms with aluminum; pressing a pair of current collector plates each onto a respective surface of respective ones of said pair of activated carbon fiber preforms; aligning the pair of activated carbon fiber preforms together wherein said respective ones of said pair of activated carbon fiber preforms have respective non-bonded surfaces facing one another; placing an ionically conductive separator between said non-bonded surfaces of said respective ones of said pair of activated carbon fiber preforms; and saturating said pair of activated carbon fiber preforms and the ionically conductive separator with an electrolyte solution.
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Specification