Method of forming an electrode structure useful in energy storage devices
First Claim
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1. A method of forming an electrode structure, comprising:
- (a) providing a carbon having a surface area determined using the Brunauer, Emmett, Teller (BET) method of 500 to 2,500 m2/g and a pore size distribution with at least one peak at a pore size of between 0.1 to 5.0 nm measured using the Horvath-Kawazoe method and at least one second peak at a pore size between 2.0 and 50.0 nm measured using the Barrett-Joyner-Halenda method;
(b) providing an aluminum foil current collector;
(c) depositing a porous electrode on a current collector by spraying onto the current collector a mixture comprising;
(i) the carbon; and
(ii) a binder;
wherein the mixture is a powder and wherein the mixture comprises 50 to 85 wt % carbon; and
,(d) heating the product of (c) to a temperature above a glass transition temperature of the binder for 2 to 120 minutes to cure the binder.
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Abstract
The present invention relates to a method for forming an electrode structure useful in energy storage devices, which method involves the spray deposition of a mixture of carbon and a binder on a current collector. In addition, the present invention relates to energy storage devices including an electrode structure produced using a spray deposition method to deposit a mixture of carbon and a binder on a current collector.
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Citations
10 Claims
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1. A method of forming an electrode structure, comprising:
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(a) providing a carbon having a surface area determined using the Brunauer, Emmett, Teller (BET) method of 500 to 2,500 m2/g and a pore size distribution with at least one peak at a pore size of between 0.1 to 5.0 nm measured using the Horvath-Kawazoe method and at least one second peak at a pore size between 2.0 and 50.0 nm measured using the Barrett-Joyner-Halenda method; (b) providing an aluminum foil current collector; (c) depositing a porous electrode on a current collector by spraying onto the current collector a mixture comprising; (i) the carbon; and (ii) a binder; wherein the mixture is a powder and wherein the mixture comprises 50 to 85 wt % carbon; and
,(d) heating the product of (c) to a temperature above a glass transition temperature of the binder for 2 to 120 minutes to cure the binder. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of forming an electrode structure, comprising:
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(a) providing a carbon having a surface area determined using the Brunauer, Emmett, Teller (BET) method of 500 to 2,500 m2/g and a pore size distribution with at least one peak at a pore size of between 0.1 to 5.0 nm measured using the Horvath-Kawazoe method and at least one second peak at a pore size between 2.0 and 50.0 nm measured using the Barrett-Joyner-Halenda method; (b) providing an aluminum foil current collector; (c) depositing a porous electrode on the aluminum foil current collector by spraying onto the current collector a mixture comprising; (i) 50 to 85 wt % of the carbon; (ii) 0.5 to 50 wt % of a binder; and
,(iii) <
2 wt % of an electrically conductive additive;wherein the mixture is a powder; and
,(d) heating the product of (c) to a temperature above a glass transition temperature of the binder for 2 to 120 minutes to cure the binder.
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10. A method of forming an electrode structure, comprising:
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(a) providing a carbon having a surface area determined using the Brunauer, Emmett, Teller (BET) method of 500 to 2,500 m2/g and a pore size distribution with at least one peak at a pore size of between 0.1 to 5.0 nm measured using the Horvath-Kawazoe method and at least one second peak at a pore size between 2.0 and 50.0 nm measured using the Barrett-Joyner-Halenda method; (b) providing an aluminum foil current collector; (c) depositing a porous electrode on the aluminum foil current collector by spraying onto the current collector a mixture consisting essentially of; (i) the carbon; and (ii) a binder; wherein the mixture is a powder and wherein the mixture comprises 50 to 85 wt % carbon; and
,(d) heating the product of (c) to a temperature above a glass transition temperature of the binder for 2 to 120 minutes to cure the binder.
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Specification