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Method of forming an electrode structure useful in energy storage devices

  • US 7,419,745 B2
  • Filed: 02/09/2005
  • Issued: 09/02/2008
  • Est. Priority Date: 03/31/2004
  • Status: Expired due to Fees
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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