Supercapacitor electrodes and cells having high active mass loading

Abstract

The present invention provides a process for producing an electrode for a supercapacitor cell. The process comprises the steps of: (A) preparing a plurality of electrically conductive porous layers and a plurality of wet electrode layers composed of an electrode active material and an optional conductive additive mixed with a liquid or gel electrolyte, wherein the conductive porous layers containinterconnected conductive pathways and at least 80% by volume of pores; and (B) stacking and consolidating a desired number of the porous layers and a desired number of the wet electrode layers in analternating sequence to form an electrode having a thickness no less than 100 [Mu]m (preferably greater than 200 [Mu]m, more preferably greater than 400 [Mu]m, further more preferably greater than 600[Mu]m, and most preferably greater than 1,000 [Mu]m).

Description

[0001] Cross References to Related Applications [0002] This application claims priority to US Patent Application No. 14 / 757,124, filed November 23, 2015, which is hereby incorporated by reference. technical field [0003] The present invention relates generally to the field of supercapacitors or ultracapacitors, and more particularly to methods of production of electrodes and cells for supercapacitors. Background technique [0004] Electrochemical capacitors (ECs), also known as ultracapacitors or ultracapacitors, are being considered for use in hybrid electric vehicles (EVs), where they can supplement batteries used in electric vehicles to provide the power burst needed for rapid acceleration. However, the biggest technical hurdle is making battery-powered cars commercially viable. The battery will still be used for cruising, but the supercapacitor (with its ability to discharge energy more quickly than a battery) will come into play when the car needs to accelerate for ...

AI Technical Summary

Problems solved by technology

[0010] (2) Although high gravimetric capacitance at the electrode level (based on active material weight alone) is often claimed in the published literature and patent documents, these electrodes unfortunately do not provide supercapacitor cell or component levels with high capacity of the energy storage device (based on total cell weight or component weight)

Furthermore, any electrode thicker than 50 μm prepared in this way is brittle and weak, with a great tendency to delamination and microcracks

These properties make supercapacitor electrode thickness not a design parameter but a fabrication limiting feature

Supercapacitor designers are not free to increase electrode thickness

There have been no effective solutions to these problems

For graphene-based electrodes, multiple issues such as restacking of graphene sheets, need for a large proportion of binder resin, and difficulty in producing thick graphene electrode layers must also be overcome.

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