Supercapacitor and manufacturing method

Abstract

The disclosure outlines a method for manufacturing a supercapacitor. The process involves laminating a first adhesive on one side of a metal foil, which has an active electrode material on its other side. The metal foil, active electrode material, and first adhesive are then cut to provide a singulated electrode reel with multiple singulated electrodes. This reel is transferred to a laminate foil layer, with the first adhesive positioned between the first side of the metal foil and the laminate foil layer. A connector tab is connected to each singulated electrode on the reel, creating a partial cell reel with multiple partial cell stacks. Finally, a separator with a second adhesive is applied to each partial cell stack on the partial cell reel.

Description

[0001] Supercapacitor and manufacturing method

[0002] Field

[0003] The technology pertains to the field of energy storage devices, specifically focusing on the manufacturing processes and materials used in the production of such devices and in particular ultra-thin supercapacitors.

[0004] Background

[0005] Supercapacitors, also known as ultracapacitors, are energy storage devices that have gained significant attention due to their high-power density, long cycle life, and fast charging and discharging capabilities. However, the manufacturing process of supercapacitors, particularly those with a sandwich structure comprising only one cathode and one anode, presents several challenges.

[0006] One of the main issues is related to the assembly of the supercapacitor components, which typically involves winding multiple layers of cathode, separator, and anode. The separator, which is wound around the stack, serves to insulate the components and maintain their alignment. However, this winding process is less suitable for the assembly of a sandwich structure with only one cathode and one anode.

[0007] One of the problems associated with this method is that the area of the separator in the active area is small compared to the total separator area. This imbalance can cause the capillary effect in the porous separator to pull the electrolyte out from the active area, necessitating an increased amount of electrolyte. This not only increases the cost of production but also leads to faster degradation of the electrolyte, which can impair the electrical performance of the supercapacitor and cause swelling due to gas evolution inside the cell.

[0008] Another issue is that the winding of the separator on the back of the electrodes increases the total thickness of the cell, which can be problematic for applications that require thin form factors. Moreover, the excess of separator and electrolyte can lead to faster degradation of the electrolyte, resulting in impaired electrical performance and swelling.

[0009] Alternative manufacturing methods, such as printing, have been demonstrated. However, these methods also have their drawbacks. For instance, the electrodes are formulated with binder systems that are suitable for printing but not necessarily for electrical properties, resulting in a supercapacitor with poor performance, such as high internal resistance. Furthermore, printing often results in an inhomogeneity in the electrode thickness profile and a high overall mass variation of the electrode, which can affect the performance of the cell and lead to issues such as impaired electrical performance, a shortened lifetime, swelling of the cell, or a need to lower the operation voltage of the cell.

[0010] Additionally, manufacturing methods such as printing are typically done in an environment with a relative humidity between 40 and 70% to reduce problems with static charge build-up and drying of ink. However, battery and supercapacitor manufacturing using organic electrolytes is often done in dry rooms or glove boxes with very low humidity. This discrepancy presents another challenge in the manufacturing process.

[0011] Summary

[0012] According to a first aspect of the disclosure, a method of manufacturing a supercapacitor comprises laminating a first adhesive on a first side of a metal foil wherein the metal foil comprises an active electrode material on a second side of the metal foil. The method further comprises cutting the metal foil, the active electrode material, and the first adhesive to provide a singulated electrode reel having a plurality of singulated electrodes. Additionally, the method comprises transferring the plurality of singulated electrodes from the singulated electrode reel to a laminate foil layer wherein the first adhesive is between the first side of the metal foil and the laminate foil layer. The method also comprises electrically connecting a connector tab to each singulated electrode on the singulated electrode reel to provide a partial cell reel having a plurality of partial cell stacks. Finally, the method comprises applying a separator with a second adhesive to each partial cell stack on the partial cell reel. This method ensures precise alignment and consistent spacing of electrodes, enhancing the overall performance and reliability of the supercapacitor.

[0013] Optionally in some examples, the method of manufacturing a supercapacitor further comprises laminating another partial cell reel of singulated other partial cell stacks on the partial cell reel of singulated partial cell stacks to provide a full cell reel having a plurality of full cell stacks. This step allows for the efficient assembly of full cell stacks, which are for the final energy storage device, ensuring that the cells are properly aligned and securely laminated together.

[0014] Optionally in some examples, the first adhesive is applied using an adhesive tape having a first adhesive release liner. This method simplifies the application process of the adhesive, ensuring that it is evenly distributed and securely attached to the metal foil, which enhances the structural integrity of the supercapacitor.

[0015] Optionally in some examples, the cutting does not cut the first adhesive release liner. This ensures that the adhesive remains properly positioned during the cutting process, protecting the adhesive layer, and can be used as a carrier, all which helps the assembly process.

[0016] Optionally in some examples, the singulated electrode reel is transferred to the laminate foil layer such that only part of each singulated electrode on the singulated electrode reel is glued onto the laminate foil layer. This precise positioning allows for better control over the assembly process, ensuring that the electrodes are correctly aligned and spaced, which is vital for the efficient operation of the supercapacitor.

[0017] Optionally in some examples, the connecting of the connector tab to each singulated electrode on the singulated electrode reel is performed by ultrasonic welding or laser welding. These methods provide strong and reliable connections between the connector tab and the electrode, ensuring that the electrical connections are secure and capable of handling the high currents typically associated with a supercapacitor.

[0018] Optionally in some examples, the method further comprises perforating one or more sides of the separator. This step enhances the flexibility and adaptability of the separator assembly process, which can lead to better performance and longevity of the supercapacitor. This avoids cutting directly on the barrier laminate or the partial cell stack, which can damage it. By having perforations, the waste matrix can be pulled off, leaving only the separators over the singulated electrodes.

[0019] Optionally in some examples, the second adhesive is a hot melt glue. In some examples optionally the hot melt glue is ethylene vinyl alcohol or a polyolefin. This type of adhesive provides a strong and durable bond between the separator and the partial cell stack, ensuring that the components remain securely attached during the assembly and operation of the supercapacitor, which is for maintaining its performance and reliability.

[0020] Optionally in some examples, the hot melt glue is applied as an intermittent stripe to the partial cell reel adjacent to each singulated electrode. This application method ensures that the adhesive is precisely placed, minimising waste and ensuring that the separator is securely attached to the partial cell stack. This precise application enhances the structural integrity and performance of the supercapacitor by ensuring that all components are properly aligned and bonded.

[0021] Optionally in some examples, the method further comprises heat sealing the laminate foil layer of each full cell stack along three sides, leaving an opening on one side of the pouch for subsequent injection of an electrolyte. This sealing method ensures that the full cell stacks are securely enclosed, protecting the internal components from external contaminants and ensuring that the electrolyte can be easily injected later in the process. This step is for maintaining the integrity and performance of the supercapacitor.

[0022] Optionally in some examples, the method further comprises filling open singulated full cells with an electrolyte and sealing the open singulated full cells using heat sealing. This step ensures that the electrolyte is properly contained within the cells, providing the necessary medium for ion transport between the electrodes. The heat-sealing process ensures that the cells are securely closed, preventing any leakage of the electrolyte and maintaining the performance and reliability of the supercapacitor. Optionally in some examples, the method further comprises adding an additive to the electrolyte to scavenge residual water from the electrolyte. This step enhances the stability and effectiveness of the electrolyte by removing any residual water that may have entered during the manufacturing process. This additive helps to maintain the reliability of the supercapacitor by reducing the risk of swelling and gas evolution caused by water contamination.

[0023] Optionally in some examples, the additive is selected from the group consisting of 4- (trimethylsiloxy)-3-penten-2-one (TMSPO), heptamethyldisilazane (HMDS), and 1- (trimethylsilyl)-imidazole (1-TMSI). These specific additives are effective in scavenging residual water from the electrolyte, ensuring that the electrolyte remains stable and effective throughout the life of the supercapacitor.

[0024] Optionally in some examples, the additive is dissolved in the electrolyte in concentrations in a range of 0.5 to 2%. This concentration range ensures that the additive is effective in scavenging residual water without adversely affecting the performance of the electrolyte.

[0025] Optionally in some examples, the additive is a molecular sieve type 4A or a molecular sieve type 3A added as a dry powder to the open singulated full cells before the addition of the electrolyte. This method of adding the additive ensures that it is evenly distributed within the cell, effectively scavenging any residual water.

[0026] According to a second aspect of the disclosure, a supercapacitor comprises a partial cell stack and another partial cell stack sealed together and each having an electrode with a current collector. The current collector has a first side and a second side, the first side being laminated with a first adhesive and the second side having an active electrode material deposited thereon. A laminate foil layer is adhered to the first adhesive. At least one connector tab is electrically connected to the current collector. A separator is applied with a second adhesive to the partial cell stack. An electrolyte is also included. This configuration ensures that the supercapacitor has a robust and reliable structure, with all components securely attached and properly aligned, enhancing its overall performance and longevity. Optionally in some examples, the at least one connector tab is physically connected to the current collector e.g. the connector tab is a separate component connected to the current collector. In other examples, the current collector is optionally integral with the collector tab.

[0027] Optionally in some examples, the electrolyte comprises an additive to scavenge residual water from the electrolyte. This feature ensures that any residual water that may have entered during the manufacturing process is effectively removed, maintaining the stability and effectiveness of the electrolyte. This helps to reduce the risk of swelling and gas evolution, thereby enhancing the reliability and performance of the supercapacitor.

[0028] Optionally in some examples, the additive is selected from the group consisting of 4- (trimethylsiloxy)-3-penten-2-one (TMSPO), heptamethyldisilazane (HMDS), and 1- (trimethylsilyl)-imidazole (1-TMSI). These specific additives are effective in scavenging residual water, ensuring that the electrolyte remains stable and effective throughout the life of the supercapacitor.

[0029] According to a third aspect of the disclosure, a method of manufacturing a supercapacitor comprises cutting a metal foil having an active electrode material and a carrier layer to provide a singulated electrode reel having a plurality of singulated electrodes. The method further comprises transferring the singulated electrode reel to a laminate foil layer wherein each singulated electrode on the singulated electrode reel is fixed with respect to the laminate foil layer. Additionally, the method comprises connecting a connector tab to each singulated electrode on the singulated electrode reel to provide a partial cell reel having a plurality of partial cell stacks. Finally, the method comprises applying a separator to each partial cell stack on the partial cell reel wherein each separator is fixed with respect to the partial cell stack. This method ensures precise alignment and consistent spacing of electrodes, enhancing the overall performance and reliability of the supercapacitor.

[0030] Optionally in some examples, the steps of transferring and applying comprise respectively using a first adhesive and a second adhesive for adhering. This ensures that the components are securely attached during the assembly process, maintaining the structural integrity and performance of the supercapacitor.

[0031] Brief Description of the Drawings

[0032] Examples are described in more detail below with reference to the appended drawings.

[0033] Figure 1a shows a plan view of a plurality of electrodes according to some examples;

[0034] Figure 1b shows a side cross-sectional view of the arrangement of the plurality of electrodes as shown in Figure 1a, according to some examples;

[0035] Figure 2 shows a side cross-sectional view of a plurality of electrodes laminated on a laminate foil layer according to some examples;

[0036] Figure 3 shows a side cross-sectional view of a partial cell stack having an electrode laminated on a laminate foil layer according to some examples;

[0037] Figure 4a shows a plan view of a plurality of separators with a second adhesive, according to some examples;

[0038] Figure 4b shows a side cross-sectional view of a partial cell stack including an electrode laminated on a laminate foil layer according to some examples;

[0039] Figure 5a shows a plan view of another partial cell stack connected to a release liner, according to some examples;

[0040] Figure 5b shows a side cross-sectional view of the other partial cell stack shown in Figure 5a according to some examples; Figure 6 shows a side cross-sectional view of an unsealed full cell stack having a partial cell stack laminated on another partial cell stack, according to some examples;

[0041] Figure 7 shows a cross-sectional side view of a supercapacitor according to some examples;

[0042] Figure 8 shows a schematic flow diagram of the method of manufacturing the supercapacitor, according to some examples; and

[0043] Figure 9 shows a plan view of a supercapacitor according to some examples.

[0044] Detailed Description

[0045] The detailed description set forth below provides information and examples of the disclosed technology with sufficient detail to enable those skilled in the art to practise the disclosure.

[0046] Figure 1a shows a plan view of a plurality of electrodes 102 having a first adhesive 110 with a first adhesive release liner 112 laminated on a metal foil with an active electrode material 114 after a step of laminating 200 a first adhesive 110 on a first side of the metal foil. Figure 1 b shows a side cross-sectional view of the arrangement of the plurality of electrodes 102 as shown in Figure 1a.

[0047] Figure 2 shows a side cross-sectional view of a plurality of electrodes 102 laminated on a laminate foil layer 126 after a step of cutting 202 the metal foil and a step of transferring 204 singulated electrodes 102 to the laminate foil layer 126.

[0048] Figure 3 shows a side cross-sectional view of a partial cell stacks 130 having an electrode 102 laminated on a laminate foil layer 126 and connected to a connector tab 120 after a step of connecting 206 the connector tab 120 to each singulated electrode 102.

[0049] Figure 4a shows a plan view of a plurality of separators 118 with a second adhesive 124. Figure 4b shows a side cross-sectional view of a partial cell stack 130 including an electrode 102 laminated on a laminate foil layer 126 and a separator 118 connected to the partial cell stack 130 via a second adhesive 124. Figure 4b shows the partial cell stack 130 after a step of applying 208 the separator 118 to the partial cell stack 130.

[0050] Figure 5a shows a plan view of another partial cell stack 132 connected to a carrier foil 136 via a disposable stack adhesive 128. Figure 5b shows a side cross-sectional view of the other partial cell stack 132 shown in Figure 5a whereby the other partial cell stack 132 is connected to the carrier foil 136 via a disposable stack adhesive 128.

[0051] Figure 6 shows a side cross-sectional view of an unsealed full cell stack 138 having a partial cell stack 130 laminated on another partial cell stack 132. This is formed after a step of laminating 212 the other partial cell stack 132 on the partial cell stack 130.

[0052] Figure 7 shows a cross-sectional side view of a supercapacitor 100 after the steps of sealing 214 the full cell stack 138, filling 220 each open singulated full cell with an electrolyte 134, and adding 222 an additive to the electrolyte 134 e.g. as discussed in more detail below.

[0053] Figure 8 shows a schematic flow diagram of the method of manufacturing the supercapacitor 100. The steps include laminating 200, cutting 202, transferring 204, connecting 206, applying 208, laminating 210, laminating 212, sealing 214, cutting 216, singulating 218, filling 220, adding 222, sealing 224, and trimming 226.

[0054] Figure 9 shows a plan view of a supercapacitor 100 after the manufacturing process. Here the sealed edge 140 of the laminate foil layer 126 is shown.

[0055] Figures 1 to 7 and 9 show the different steps of manufacture of the supercapacitor 100 and how the layers of the supercapacitor 100 are built up after each stage. Figure 8 shows the flow diagram for the method of manufacture of the supercapacitor 100. Accordingly, some of the steps of the method of manufacture which are shown in Figures 1 to 7 correspond to the various stages as shown in Figure 8. However, not all of the steps as described with reference to Figure 8 are shown in Figures 1 to 7 Reference will now be made to the fully manufactured supercapacitor 100, which is best shown in Figures 7 and 9.

[0056] The supercapacitor 100 is an energy storage device that is designed to store and release electric charge rapidly. It comprises a number of components that work together to facilitate the movement of electric charge within the supercapacitor 100. These components include a partial cell stack 130, an electrode 102, a current collector 104, an active electrode material 114, a first adhesive 110, a laminate foil layer 126, a connector tab 120, a separator 118, a second adhesive 124, and an electrolyte 134. Each of these components plays a specific role in the operation of the supercapacitor 100, and their design and configuration are carefully optimised to ensure the efficient and effective performance of the supercapacitor 100.

[0057] The supercapacitor 100 as shown in Figure 7 is manufactured from a plurality of different layers. As discussed below, the supercapacitor 100 is manufactured from different subcomponents. The supercapacitor 100 includes a partial cell stack 130 laminated on another partial cell stack 132. The partial cell stack 130 and the other partial cell stack 132 are best shown in Figure 6. The partial cell stack 130 is a plurality of different layers laminated together to form a subcomponent of the full cell stack 138. In some examples, the full cell stack 138 comprises two partial cell stacks 130 e.g. the partial cell stack 130 and the other partial cell stack 132. In other examples, the full cell stack 138 can comprise different numbers of partial cell stacks 130, 132 (not shown).

[0058] In some examples, the partial cell stack 130 and the other partial cell stack 132 are the same and comprise the same layers. This means that both the partial cell stack 130 and the other partial cell stack 132 can be manufactured in the same manufacturing process e.g. as discussed below. In other examples, the partial cell stack 130 and the other partial cell stack 132 can be different and e.g. the partial cell stack 130 or the other partial cell stack 132 can comprise one or more additional layers. For example, the other partial cell stack 132 can comprise a separator 118. The structure of the partial cell stack 130 will now be discussed in more detail. The structure of the partial cell stack 130 is also applicable to the other partial cell stack 132. The partial cell stack 130 is best shown in Figure 3.

[0059] The partial cell stack 130 is a component of the supercapacitor 100 that comprises a singulated electrode 102 connected to a connector tab 120. The partial cell stack 130 serves as a basic building block of the supercapacitor 100, and multiple partial cell stacks 130 are assembled together to form the full cell stack 138 of the supercapacitor 100.

[0060] The electrode 102 is a component of the partial cell stack 130. It is a conductive element that facilitates the movement of electric charge within the supercapacitor 100. The electrode 102 comprises a current collector 104 and an active electrode material 114. The current collector 104 is a conductive substrate e.g. a metal foil that supports the active electrode material 114, and the active electrode material 114 is a material that is capable of storing and releasing electric charge.

[0061] The active electrode material 114 is deposited on the second side 106 of the current collector 104. The first adhesive 110 is laminated on the first side 108 of the current collector 104, and the first adhesive release liner 112 is shown covering the first adhesive 110.

[0062] The current collector 104 is a component of the electrode 102 in the partial cell stack 130 of the supercapacitor 100. In one embodiment, the current collector 104 is a conductive substrate that supports the active electrode material 114. The current collector 104 is designed to facilitate the movement of electric charge within the supercapacitor 100, serving as a pathway for the flow of electrons during the charging and discharging cycles of the supercapacitor 100. The current collector 104 is typically made from a conductive material such as aluminium, copper, nickel, titanium, or silver. Preferably, the current collector 104 is made from aluminium foil.

[0063] The choice of material for the current collector 104 can vary depending on the specific requirements of the supercapacitor 100, including factors such as the desired energy density, power density, and operational lifespan of the supercapacitor 100. The current collector 104 is designed to have a high surface area to maximise the contact area with the active electrode material 114, thereby enhancing the efficiency of charge transfer within the supercapacitor 100.

[0064] The first adhesive 110 is a component of the partial cell stack 130 in the supercapacitor 100. In one example, the first adhesive 110 is used to adhere the singulated electrode 102 to the laminate foil layer 126 as shown in Figures 2, 3 etc. The first adhesive 110 is typically applied to the first side 108 of the metal foil, which is the side of the electrode 102 that does not receive the active electrode material 114. The first adhesive 110 is designed to form a bond between the metal foil and the laminate foil layer 126, ensuring that the singulated electrode 102 remains securely in place during subsequent steps in the manufacturing process.

[0065] The first adhesive 110 may be a water-soluble adhesive, which allows for easy removal of the adhesive if required. The first adhesive 110 is selected to be compatible with the materials of the metal foil and the laminate foil layer 126, and to withstand the conditions encountered during the operation of the supercapacitor 100, such as high temperatures and electrical currents. In some examples the first adhesive 110 is selected to be compatible with the materials of the electrolyte 134 as well.

[0066] The first adhesive 110 may include an adhesive tape. The first adhesive 110 may include a first adhesive release liner 112.

[0067] The laminate foil layer 126 is a component of the partial cell stack 130 in the supercapacitor 100. In one embodiment, the laminate foil layer 126 serves as a protective layer for the singulated electrode. The laminate foil layer 126 provides a surface onto which the singulated electrode can be adhered using the first adhesive 110.

[0068] The laminate foil layer 126 is typically made from a plurality of layers and a material that is resistant to the conditions encountered during the operation of the supercapacitor 100, such as high temperatures and electrical currents. The laminate foil layer 126 may comprise multiple layers of different materials, including a metal layer, a polymer layer, a barrier layer, and a heat-sealing layer. The laminate foil layer 126 is designed to provide the external packaging layer of the supercapacitor 100, protecting the internal components of the supercapacitor 100 from environmental factors such as moisture and mechanical stress. Furthermore, a laminate foil layer 126 of the partial cell stack 130 is arranged to be heat sealed against another laminate foil layer 126 of the other partial cell stack 132. This is because the polymer layer of the laminate foil layer 126 can melt and adhere to another surface when exposed to heat.

[0069] The connector tab 120 is a component of the partial cell stack 130 in the supercapacitor 100. In one embodiment, the connector tab 120 is connected to each singulated electrode 102 on the singulated electrode reel. The connector tab 120 serves as a conductive link between the singulated electrode 102 and the external circuitry of the supercapacitor 100. It is through these connector tabs 120 that electric charge is transferred into and out of the supercapacitor 100 during charging and discharging cycles. The connector tab 120 is typically made from a conductive material such as aluminium, and is designed to form a secure and conductive connection with the singulated electrode 102. The connection between the singulated electrode 102 and the connector tab 120 can be made using a conductive adhesive or by welding.

[0070] As shown in Figure 3, the connector tab 120 has a first side and a second side on which a polymer tape 122. In some configurations, the polymer tape 122 may be mounted on the first side and on the second side of the connector tab 120. The connector tab 120 may be formed from aluminium.

[0071] The separator 118 is a component of the supercapacitor 100. In one embodiment, the separator 118 is applied with a second adhesive 124 to each partial cell stack 130 on the partial cell reel. The separator 118 may be applied with a second adhesive 124 to the second side of the metal foil of each partial cell stack on the partial cell reel. The separator 118 serves as an insulating barrier to maintain separation between the electrode 102 in the partial cell stack 130 and the electrode 102 in the other partial cell stack 132. The separator 118 is typically larger than the size of the active area of the electrode 102 and is designed to prevent electrical short circuits between the electrode 102 while allowing ions to pass through during the operation of the supercapacitor 100. The separator 118 can be made from various materials such as paper, cellulose, or aramid paper, depending on the specific requirements of the supercapacitor 100.

[0072] The separator 118 can be any suitable insulating material with a low thickness.

[0073] The electrolyte 134 is a component of the supercapacitor 100. In one embodiment, the electrolyte 134 provides the medium for ion transport between the electrodes 102 in the supercapacitor 100. The electrolyte 134 is typically a liquid or gel that contains ions, which are electrically charged particles. The electrolyte 134 facilitates the movement of ions between the electrodes 102 during the charging and discharging cycles of the supercapacitor 100, thereby enabling the storage and release of electric charge. The specific composition of the electrolyte 134 can vary depending on the requirements of the supercapacitor 100, and may include acetonitrile-based electrolytes or propylene carbonate-based electrolytes 134.

[0074] In some specific examples, examples of the electrolyte 134 that can be used in the supercapacitor 100 include acetonitrile-based electrolytes 134 and propylene carbonate-based electrolytes 134. Acetonitrile-based electrolytes 134 can include a solution of tetraethylammonium tetrafluoroborate (TEATFB), 5-azaspiro[4.4]nonan-5- ium tetrafluoroborate (ASNtfb), or tetrabutylammonium tetrafluoroborate (TBATFB) in acetonitrile. Propylene carbonate-based electrolytes 134 can include a solution of tetraethylammonium tetrafluoroborate (TEATFB), 5-azaspiro[4.4]nonan-5-ium tetrafluoroborate (ASNtfb), or tetrabutylammonium tetrafluoroborate (TBATFB) in propylene carbonate. The concentration of the salt in these electrolyte 134 can be in the range of 0.5 to 3 M for acetonitrile-based electrolytes 134 and 0.5 to 2 M for propylene carbonate-based electrolytes 134.

[0075] The additive is a component of the supercapacitor 100. In one embodiment, an additive is added to the electrolyte 134 to enhance the performance of the supercapacitor 100. The additive can serve various functions, such as scavenging residual water from the electrolyte 134, maintaining the stability and effectiveness of the electrolyte 134, and reducing the risk of swelling and gas evolution caused by water contamination. The specific type and amount of additive used can vary depending on the requirements of the supercapacitor 100. Various types of additive can be used in the electrolyte 134 of the supercapacitor 100. For example, 4-(trimethylsiloxy)-3-penten-2-one (TMSPO), heptamethyldisilazane (HMDS), and 1-(trimethylsilyl)-imidazole (1-TMSI), tris(trimethy|silyl)phosphate TMSPa, tris(trimethylsilyl) phosphite TMSPi can be used as an additive. These additives are capable of scavenging residual water from the electrolyte 134, thereby maintaining the stability and effectiveness of the electrolyte 134. The additive can be dissolved in the electrolyte 134 in concentrations in a range of 0.5 to 2%. In some implementations, a molecular sieve type 4A or 3A is added as a dry powder to the open singulated full cells before the addition of the electrolyte 134. This helps to remove any residual water from the cell materials, including the adhesives, thereby enhancing the reliability and performance of the supercapacitor 100.

[0076] In some instances, an alternative additive may be included. The additive can be one or more of trimethylsilyl trifluoromethanesulfonate, hexamethyldisiloxane, bis(trimethylsilyl)acetamide, silylated polyethylenimine, octamethylcyclotetrasiloxane, tetramethylsilane, ethoxytrimethylsilane, triethylsilyl chloride, tetramethylsilicate, or ditert-amyl peroxide.

[0077] Whilst the method of manufacture described herein relates to the supercapacitor 100, in other examples, the method of manufacture can apply to other energy storage devices e.g. any thin energy storage device that comprises a plurality of laminated layers. For example, the method of manufacture of the energy storage device can apply to one or more of a lithium-ion capacitor, a sodium ion-capacitor, a sodium-ion battery, a lithium-ion battery, a lithium metal battery, or a zinc battery.

[0078] The method of manufacturing a supercapacitor 100 includes a series of method steps and will now be discussed in more detail with reference to Figures 1 to 8.

[0079] The method of manufacturing a supercapacitor 100 may involve a systematic sequence of steps, starting with initial preparation and culminating in the final filling 220 and sealing 224 of the supercapacitor 100 as shown in Figure 8.

[0080] Variations or alternatives may be employed at different stages to accommodate specific material choices, desired device properties, or manufacturing constraints. These alternatives provide flexibility in the manufacturing process, allowing for optimization based on specific requirements. For instance, the type of adhesive or the method of connecting components can be modified based on the materials used and the desired performance of the supercapacitor 100.

[0081] Before the assembly process begins, the individual components of the supercapacitor 100 undergo initial preparation. The metal foil, which will serve as the current collector 104, is unwound from a roll, and the active electrode material 114 is prepared for deposition. The preparation of the active electrode material 114 may involve mixing and processing various chemical compounds to achieve the desired electrochemical properties. The metal foil, after being unwound, may undergo cleaning and surface treatment processes to enhance its adhesion properties and ensure compatibility with the active electrode material 114. The initial preparation stage sets the foundation for the subsequent manufacturing steps, ensuring that the components are ready for assembly.

[0082] The active electrode material 114 preparation begins with creating a slurry or paste of the active electrode material 114. This slurry consists of fine particles of the active material, a binder, and a solvent. The active material can be any material with good electrochemical properties, such as activated carbon, carbon nanotubes, graphene, or metal oxides. The binder helps to hold the active material particles together and adhere them to the current collector 104. The solvent is used to create a homogenous mixture and facilitate the coating process.

[0083] Once the slurry is prepared, it is applied to the current collector 104 using various coating techniques, such as doctor blading, slot-die coating, or screen printing. The choice of coating technique depends on factors such as the desired thickness and uniformity of the coating, the viscosity of the slurry, and the production scale. After coating, the material is dried to remove the solvent, leaving behind a thin and uniform layer of the active electrode material 114 on the current collector 104. This coated material is then ready for further and lamination with the first adhesive 110. As can be seen from Figure 1a, at least a portion of the current collector 104 is not covered with the active electrode material 114. This leaves space on the current collector 104 for the current collector 104 to be electrically connected to another component e.g. the collector tabs 120.

[0084] The metal foil is unwound, and the unwinding process is typically automated and involves feeding the metal foil roll through a series of rollers and tension control mechanisms. These mechanisms ensure a smooth and controlled unwinding process, preventing wrinkles, tears, or variations in tension that could affect the quality of the final product. The speed of unwinding is carefully controlled to match the subsequent coating or processing steps.

[0085] The unwound metal foil is then fed into the next stage of the manufacturing process, where it will be laminated with the first adhesive 110. The quality of the unwinding process directly impacts the uniformity and quality of the subsequent coating, highlighting its importance in the overall manufacturing process.

[0086] The laminating 200 process as shown in Figure 8 is a step in the manufacturing of the supercapacitor 100, involving the application of a first adhesive 110 to the metal foil. The first adhesive 110 bonds the metal foil to the laminate foil layer 126, which forms the external packaging of the supercapacitor 100.

[0087] The first adhesive 110 is applied using a controlled process to ensure uniform transfer using a roll to roll manufacturing process. The first adhesive release liner 112 protects the adhesive before application and is removed as mentioned below. The choice of adhesive may depend on factors such as the type of metal foil, the laminate foil layer 126 material, and the required adhesion strength. Preferably the first adhesive 110 is an adhesive tape with a first adhesive release liner 112. This allows the first adhesive 110 to be applied during a using a roll to roll manufacturing process.

[0088] The first adhesive 110 in the step of laminating 200 as shown in Figure 8 is typically applied to the current collector 104 using a controlled application process. This process can involve various techniques such as roll-to-roll transfer. In this case, the first adhesive 110 is unwound from a first adhesive unwinding and winding system (not shown) and then laminated on the metal foil e.g. the current collector 104. The first adhesive 110 is applied to the first side of the current collector 104 that does not have the active electrode material 114, ensuring that the active material remains exposed for electrochemical reactions.

[0089] At this point, the first adhesive 110 has been laminated to the metal foil e.g. the current collector 104 as shown in Figures 1a and 1b.

[0090] As shown in Figures 1a and 1 b, the first adhesive release liner 112 is attached to the first adhesive 110. The first adhesive release liner 112 protects the first adhesive 110 before its application to the current collector 104. In addition, first adhesive release liner 112 acts as a temporary carrier so that the active electrode material 114 can be singulated into separate electrodes 102. In some examples, an acrylic-based adhesive on a tape may be used as the first adhesive 110. The first adhesive 110 is chosen for its adhesion to both aluminium of the current collector 104 and the laminate foil layer 126. Any other suitable adhesive can be used for the first adhesive 110.

[0091] In some examples the first adhesive 110 is arranged to barely stick to the current collector 104. This means that the first adhesive 110 is arranged to adhere to the current collector 104 and the laminate foil layer 126 during the assembly process (e.g. both to keep the layers in place before the step of heat sealing 214. In some examples, when the pouch of the open singulated full cell is filled and sealed after the step of sealing 224, in some examples the first adhesive 110 can lose adhesion. In other examples, the first adhesive 110 remains connected between the current collector 104 and the laminate foil layer 126 after the step of sealing 224.

[0092] The first adhesive release liner 112 is made of a material with a low surface energy, such as silicone-coated paper or film. This low surface energy allows the first adhesive 110 to be peeled away easily from the liner when required, without leaving any residue or damaging the first adhesive 110 layer. The first adhesive release liner 112 also provides a smooth and consistent surface for the first adhesive 110, ensuring a uniform thickness and preventing any wrinkles or air bubbles from forming in the adhesive layer. During the laminating 200 step of the first adhesive 110, the first adhesive 110 is initially applied onto the first adhesive release liner 112, forming a thin and uniform layer. The first adhesive release liner 112, with the first adhesive 110 layer, is then wound onto a roll for easy handling and storage. When the first adhesive 110 is applied to the current collector 104, the first adhesive release liner 112 is unwound and fed through a laminating machine (not shown) that performs the step of laminating 200. The machine presses the first adhesive 110 against the current collector 104, transferring the first adhesive 110 onto the target surface of the metal foil e.g. the current collector 104.

[0093] Once the first adhesive 110 is applied to the metal foil and attached thereto, the next stage involves cutting 202 and transferring 204 the material as shown in Figure 8.

[0094] This process transforms the continuous film of material into individual e.g. singulated electrodes 102, ready for further assembly. The cutting 202 process utilises a technique called kiss cutting, where the material is cut precisely without penetrating the underlying layer e.g. the first adhesive release liner 112. This ensures that the active electrode material 114 can be handled on a reel in the assembly process and properly aligned on the metal foil. Accordingly, a plurality of singulated electrodes 102 is formed on the metal foil laminated to the first adhesive 110 and first adhesive release liner 112.

[0095] The cutting 202 step as shown in Figure 8 in some examples is a kiss cutting technique. The kiss cutting technique is a precise cutting 202 method employed in supercapacitor 100 manufacturing to create individual electrodes 102 from a continuous sheet of material. This technique is characterised by its ability to cut through the upper layers of a material without penetrating the first adhesive release liner 112, ensuring that the active electrode material 114 can be handled on a reel in the assembly process and properly aligned on the current collector 104.

[0096] Kiss cutting is typically performed using a die-cutting machine (not shown) equipped with a sharp, precision-engineered die. The die is a custom-shaped blade that matches the desired outline of the electrodes 102. The material to be cut, which consists of the current collector 104, the active electrode material 114, and the first adhesive 110, is fed through the die-cutting machine. The die then applies pressure to the material, cutting 202 through the current collector 104 and the first adhesive 110 layer but stopping short of penetrating the first adhesive release liner 112 . At this point, a plurality of singulated electrodes 102 is formed on a singulated electrode reel. The cuts performed in the cutting 202 step can be seen in Figure 1a whereby the singulated electrodes 102 have been defined.

[0097] After the singulated electrode reel comprising the plurality of singulated electrodes 102 has been formed, the singulated electrode reel is transferred on to the laminate foil layer 126. In some examples the step of transferring 204 as shown in Figure 8 can be achieved with an island transfer process. Figure 2 shows the singulated electrode reel comprising the plurality of singulated electrodes 102 having been transferred to the laminate foil layer 126.

[0098] As shown in Figure 2, only a part of the singulated electrode reel comprising the plurality of singulated electrodes 102 is adhered to the laminate foil layer 126 with the first adhesive 110. Although not shown, the first adhesive release liner 112 has been removed and rewound during the step of transferring 204.

[0099] The island transfer process begins with the singulated electrode reel comprising the plurality of singulated electrodes 102 being fed through a transfer station (not shown). The island transfer process is known and will not be discussed in any further detail.

[0100] The transfer of the singulated electrode reel to the laminate foil layer 126 involves transferring 204 the individual electrodes 102 from the release liner to the laminate foil layer 126, which will eventually form the outer packaging of the supercapacitor 100. The process requires precision to ensure that the electrodes 102 are accurately positioned and spaced on the laminate foil layer 126.

[0101] After the transferring 204 step, the connector tabs 120 are connected to the singulated electrode reel as shown in the step of connecting 206.

[0102] With the individual electrodes 102 are precisely positioned on the laminate foil layer 126, the next step is to connect the connector tab 120. These tabs serve as the electrical contacts for the supercapacitor 100, allowing it to connect to external circuits. The connector tab 120 is typically made of a highly conductive material, such as aluminium, to ensure efficient current flow.

[0103] The connection process involves electrically connecting 206 the connector tab 120 to the electrodes 102. In some examples the connecting 206 comprises attaching the connector tab 120 to the designated areas on the electrodes 102, which are free from the active electrode material 114 and the first adhesive 110. This ensures a secure and reliable electrical connection. Two primary methods are commonly employed for connecting 206 the connector tab 120: ultrasonic welding and laser welding. Ultrasonic welding utilises high-frequency vibrations to create heat and friction, resulting in a solid-state weld between the connector tab 120 and the electrode 102. Laser welding, on the other hand, uses a focused laser beam to melt and fuse the materials together. The choice between these methods depends on factors such as the specific materials used, the desired weld strength, and the manufacturing scale. Optionally, the at least one connector tab 120 is physically connected to the current collector 104 e.g. the connector tab 120 is a separate component connected to the current collector 104. In other examples, the current collector 104 is optionally integral with the collector tab. In this alternative option, the step of connecting 206 is optional and not necessary.

[0104] At this point a partial cell stack 130 has been created as shown in Figure 3.

[0105] The next step is the step of applying 208 the separator 118 to the partial cell stack 130 as shown in Figure 8. As mentioned above, the separator 118 is a component in the supercapacitor 100, preventing electrical shorts between the electrodes 102 while allowing for ion transport.

[0106] The step of applying 208 the separator 118 with respect to the partial cell stack 130 is achieved with the use of a second adhesive 124. The second adhesive 124 provides sufficient adhesion to withstand the internal forces within the supercapacitor 100 during its operational life, preventing any movement or displacement of the separator 118 that could lead to short circuits or performance degradation. The application method and the amount of adhesive used are ensure a secure bond without impeding the flow of electrolyte 134 between the electrodes 102. In some examples, the second adhesive 124 is a hot melt glue. The intermittent application of hot melt glue is a specific technique used in applying 208 the second adhesive 124 for securing the separator 118 in supercapacitor 100 manufacturing. This method involves applying 208 the hot melt glue in a pattern of dots, lines, or stripes, rather than a continuous layer, along the edges or specific areas of the separator 118. The intermittent pattern of the second adhesive 124 can be seen in Figure 4a. This approach offers several advantages. Firstly, it reduces the amount of adhesive used, minimising material cost and the risk of excess adhesive interfering with the performance of the supercapacitor 100. Secondly, the intermittent application allows for the second adhesive 124 to be applied adjacent to each singulated electrode 102 on the singulated electrode reel.

[0107] In some examples the second adhesive 124 used in this example is a hot-melt adhesive based on a thermoplastic polymer. The second adhesive 124 is chosen for its fast-curing time and strong adhesion to the separator 118 material, which is a cellulose based material. The hot-melt adhesive is applied in an intermittent stripe pattern along the edges of the separator 118 using a heated dispensing nozzle. This controlled application method ensures secure adhesion while minimising the amount of second adhesive 124 used and allowing for efficient electrolyte 134 flow paths. In other examples, any other suitable adhesive can be used e.g. adhesive tape etc. In some examples optionally the second adhesive 124 is hot melt glue and is ethylene vinyl alcohol or a polyolefin.

[0108] In some examples, in order to apply the separator 118 in the applying 208 step, the separator 118 can be perforated e.g. as shown in Figure 4a. Perforating the separator 118 allows a predefined shape of the separator 118 and allows for the individual separator 118 to be released more easily. This can be helpful because the separator 118 is very thin and prone to tearing. The perforation process is typically automated and tightly controlled to ensure consistency and prevent any defects that could compromise the integrity of the separator 118 or the supercapacitor 100 performance. Figure 4b shows the partial cell stack 130 with the separator 118 applied to the laminate foil layer 126. In some examples the separator 118 is only applied to each partial cell stack 130.

[0109] With the separator 118 in place, the next stage involves laminating 212 another partial cell stack 132 on a partial cell stack 130 to form the full cell stack 138. As mentioned above, the other partial cell stack 132 is formed via the same process as the partial cell stack 130.

[0110] The laminating 212 process involves aligning the partial cell reel of singulated partial cell stack 130 with the other partial cell reel of singulated other partial cell stack 132, and then bonding the two reels together to form a full cell reel having a plurality of full cell stacks 138, each of which includes a pair of singulated electrodes 102 that sandwich the separator 118.

[0111] In order to ensure that the partial cell stacks 130 remains fixed with the other partial cell stacks 132, a disposable stack adhesive 128 applied. The step of laminating 210 the disposable stack adhesive 128 is shown in Figure 8. The step of laminating 210 the disposable stack adhesive 128 also comprises laminating a carrier foil 136 to the disposable stack adhesive 128 and the other partial cell stacks 132. The other partial cell stacks 132 laminated to the carrier foil 136 is shown in Figures 5a and 5b. The disposable stack adhesive 128 provides temporary adhesion to a carrier foil 136, facilitating the lamination of the partial cell stacks 130 to the other partial cell stacks 132.

[0112] The disposable stack adhesive 128 can be any suitable adhesive e.g. an adhesive tape, hot melt glue or any other means for fixing the partial cell stacks 130 with respect to the other partial cell stacks 132.

[0113] During the laminating 212 of the other partial cell stack 132 on the partial cell stack 130, it is also possible to adjust the position between the partial cell stack 130 and the other partial cell stack 132. This adjustment can be made to ensure that the singulated electrodes 102 in the partial cell stack 130 and the other partial cell stack 132 are properly aligned and spaced apart. The correct alignment and spacing of the singulated electrodes 102 are prerequisites for the efficient operation of the supercapacitor 100.

[0114] In this way a partial cell reel having a plurality of other partial cell stacks 132 is laminated to another partial cell reel having a plurality of partial cell stacks 130.

[0115] As discussed, above, the step of laminating 212 comprises laminating the other partial cell stack 132 on the partial cell stack 130. In this way, the step laminating 212 can either be laminating 212 the other partial cell stack 132 on the partial cell stack 130 or laminating 212 the partial cell stack 130 on the other partial cell stack 132. Accordingly, the term laminating 212 is used to describe the layering of the partial cell stack 130 and the other partial cell stack 132 together, irrespective of which of the partial cell stack 130 and the other partial cell stack 132 is transferred.

[0116] An alternative to laminating 212 a partial cell reel having a plurality of partial cell stacks 130 to another partial cell reel having a plurality of other partial cell stacks 132 is folding. Instead of using two separate partial cell reels, a single wider partial cell reel having two stripes of partial cell stacks 130, 132 can be optionally used. In this case, the signal wider partial cell reel having two stripes of partial cell stacks 130, 132 is folded such that the two stripes of partial cell stacks 130, 132 are laminated on top of each other and form a reel having a plurality of full cell stacks 138.

[0117] At this point, the full cell reel is formed having a plurality of full cell stacks 138. The full cell stack 138 is shown in Figure 6. However, the full cell stack 138 as shown in Figure 6 is open and has not been sealed.

[0118] Once the lamination or folding is complete, a portion of each full cell stack 138 is sealed, typically using heat sealing techniques.

[0119] In the method of manufacturing a supercapacitor 100, the sealing 214 as shown in Figure 8 process involves heat sealing techniques. Heat sealing is a process that involves applying heat and pressure to a material or materials in order to seal them together. In the context of the supercapacitor 100, heat sealing is used to seal the laminate foil layer 126 of each full cell stack 138 along three sides. This creates a pouch that houses the internal components of the supercapacitor 100, protecting them from environmental factors and providing structural support. By heat sealing the full cell stack 138 along three sides, the full cell stack 138 can be filled with electrolyte 134 as discussed below.

[0120] In some examples, the heat sealing 214 process can be performed using various techniques, including impulse heating or ultrasonic welding, depending on the specific requirements of the supercapacitor 100. Indeed, any suitable source of heat can be used for sealing the full cell stack 138.

[0121] As shown in Figure 8, the next step is another cutting 216 process which involves cutting the disposable stack adhesive 128 from the full cell reel. Since the full cell stack 138 is partially sealed, the disposable stack adhesive 128 is no longer needed and trimmed from the full cell stack 138.

[0122] The full cell reel having a plurality of full cell stacks 138 is then singulated as shown in a step of singulating 218 in Figure 8. The singulation process involves cutting the full cell reel of partially sealed full cell stacks 138 to provide individual open singulated full cells. The singulation is a process that involves separating a larger group of components into individual units. In the context of the supercapacitor 100, singulation involves cutting the full cell reel into individual open singulated full cells. Each open singulated full cell is an individual energy storage unit that is ready to receive electrolyte 134.

[0123] In the method of manufacturing a supercapacitor 100, optionally following the singulating 218 step, the next step may involve drying the open singulated full cells. The drying process involves exposing the open singulated full cells to heat for a specified period of time in order to remove any residual moisture. In one implementation, the open singulated full cells are dried at 120 degrees Celsius for a period of 8 to 12 hours. The drying process is a prerequisite for the efficient operation of the supercapacitor 100, as it helps remove water contaminating the electrolyte 134.

[0124] The next step involves filling 220 as shown in Figure 8. Accordingly, the open singulated full cells are filled with the electrolyte 134 discussed above. The filling 220 process is carefully controlled to ensure that the correct amount of electrolyte 134 is injected into each open singulated full cell, ensuring the efficient operation of the supercapacitor 100.

[0125] In the method of manufacturing a supercapacitor 100, either following or preceding the filling 220, another step involves optionally adding 222 an additive to the electrolyte 134. The additive, as discussed above, scavenges water. The additive can be added to the electrolyte 134 before or after the step of filling 220. For example, the additive can be added to the open singulated full cells before the filling 220. Alternatively, the additive can be added to the electrolyte 134 and mixed with the electrolyte 134 before filling 220. Furthermore, the additive can be added to the electrolyte 134 once in the open singulated full cells.

[0126] The additive serves to enhance the performance and longevity of the supercapacitor 100 as discussed above. In one embodiment, the additive is used to scavenge residual water from the electrolyte 134, maintaining its stability and effectiveness. This may be particularly useful if the first adhesive 110 or the second adhesive 124 contain or trap moisture which is released into the electrolyte 134 after manufacture.

[0127] In the method of manufacturing a supercapacitor 100, following the addition of the additive to the electrolyte 134 or the filling 220 of the electrolyte 134, the next step involves a step of sealing 224 the open singulated full cells. The step of sealing 224 is similar to the previous step of sealing 214. The step of sealing 224 of the open singulated full cells involves closing the remaining open side of the open singulated full cells. This creates a sealed pouch that houses the internal components of the supercapacitor 100, protecting them from environmental factors and preventing leakage of the electrolyte 134. The sealing 224 process can be performed using various techniques as discussed above e.g. including heat sealing, impulse heating, or ultrasonic welding, etc. In some examples, optionally the step of sealing 214, 224 may be done under vacuum.

[0128] In the method of manufacturing a supercapacitor 100, the final step involves trimming 226 the edge of the singulated full cell stack 138. This step is a part of the assembly process that contributes to the formation of the supercapacitor 100. The trimming 226 process involves removing excess material from the edges of the singulated full cell stack 138. This is done to ensure that the singulated full cell stack 138 is of the correct size and shape for the supercapacitor 100. The trimming 226 process is performed using a precision cutting tool that is capable of cutting the full cell stack 138 without damaging the components or causing them to separate from each other.

[0129] The supercapacitor 100 is shown in Figure 7 which has been sealed. The laminate foil layer 126 from the partial cell stack 130 and the laminate foil layer 126 from the other partial cell stack 132 are bonded together. Furthermore, the polymer tape 122 has melted as well and deforms around the connector tabs 120. The supercapacitor 100 is also shown in Figure 9 wherein the laminate foil layer 126 from the partial cell stack 130 and the laminate foil layer 126 from the other partial cell stack 132 are bonded together along a sealed edge 140.

[0130] Examples

[0131] Item 1 . A method of manufacturing a supercapacitor 100 comprising: laminating 200 a first adhesive 110 on a first side of a metal foil wherein the metal foil comprises an active electrode material 114 on a second side of the metal foil; cutting 202 the metal foil, the active electrode material 114 and the first adhesive 110 to provide a singulated electrode reel having a plurality of singulated electrodes; transferring 204 the plurality of singulated electrodes from the singulated electrode reel to a laminate foil layer 126 wherein the first adhesive 110 is between the first side of the metal foil and the laminate foil layer 126; electrically connecting 206 a connector tab 120 to each singulated electrode on the singulated electrode reel to provide a partial cell reel having plurality of partial cell stacks 130; applying 208 a separator 118 with a second adhesive 124 to each partial cell stack 130 on the partial cell reel.

[0132] Item 2. The method of manufacturing a supercapacitor 100 according to example 1 wherein the method comprises laminating 212 on another partial cell reel 1 of singulated other partial cell stack 132 on the partial cell reel of singulated partial cell stacks 130 to provide full cell reel having a plurality of full cell stacks 138s.

[0133] Item 3. The method of manufacturing a supercapacitor 100 according to examples 1 or 2, wherein the first adhesive 110 is applied using an adhesive tape having a first adhesive release liner 112.

[0134] Item 4. The method of manufacturing a supercapacitor 100 according to example 3, wherein the cutting 202 does not cut the first adhesive release liner 112.

[0135] Item 5. The method of manufacturing a supercapacitor 100 according to any of examples 1 to 4, wherein the singulated electrode reel is transferred to the laminate foil layer 126 such that only part of each singulated electrode on the singulated electrode reel is glued onto the laminate foil layer 126.

[0136] Item 6. The method of manufacturing a supercapacitor 100 according to any of examples 1 to 5, wherein the connecting 206 of the connector tab 120 to each singulated electrode on the singulated electrode reel is performed by ultrasonic welding or laser welding.

[0137] Item 7. The method of manufacturing a supercapacitor 100 according to any of examples 1 to 6, further comprising perforating one or more sides of the separator 118.

[0138] Item 8. The method of manufacturing a supercapacitor 100 according to any of examples 1 to 7, wherein the second adhesive 124 is a hot melt glue.

[0139] Item 9. The method of manufacturing a supercapacitor 100 according to example 8, wherein the hot melt glue is applied as an intermittent stripe to the partial cell reel adjacent to each singulated electrode.

[0140] Item 10. The method of manufacturing a supercapacitor 100 according to any of examples 1 to 9, further comprising heat sealing 214 the laminate foil layer 126 of each full cell stack 138 along three sides, leaving an opening on one side of the pouch for subsequent injection of an electrolyte 134.

[0141] Item 11 . The method of manufacturing a supercapacitor 100 according to any of examples 1 to 10, further comprising filling 220 open singulated full cells with an electrolyte 134 and sealing 224 the open singulated full cells using heat sealing.

[0142] Item 12. The method of manufacturing a supercapacitor 100 according to example 11 , further comprising adding 222 an additive to the electrolyte 134 to scavenge residual water from the electrolyte 134.

[0143] Item 13. The method of manufacturing a supercapacitor 100 according to example 12, wherein the additive is selected from the group consisting of 4-

[0144] (trimethylsiloxy)-3-penten-2-one (TMSPO), heptamethyldisilazane (HMDS), and 1- (trimethylsilyl)-imidazole (1 -TMSI).

[0145] Item 14. The method of manufacturing a supercapacitor 100 according to any of examples 12 to 13, wherein the additive is dissolved in the electrolyte 134 in concentrations in a range of 0.5 to 2%.

[0146] Item 15. The method of manufacturing a supercapacitor 100 according to any of examples 12 to 14, wherein the additive is a molecular sieve type 4A or a molecular sieve type 3A added as a dry powder to the open singulated full cells before addition of the electrolyte 134.

[0147] Item 16. A supercapacitor 100 comprising: a partial cell stack 130 and another partial cell stack 132 sealed together and each having an electrode 102 with a current collector 104, wherein the current collector 104 has a first side and a second side, the first side being laminated with a first adhesive 110 and the second side having an active electrode material 114 deposited thereon; a laminate foil layer 126 adhered to the first adhesive 110; at least one connector tab 120 electrically connected to the current collector

[0148] 104; a separator 118 applied with a second adhesive 124 to the partial cell stack 130; and an electrolyte 134.

[0149] Item 17. The supercapacitor 100 according to example 16 wherein the electrolyte 134 comprises an additive to the electrolyte 134 to scavenge residual water from the electrolyte 134.

[0150] Item 18. The method of manufacturing a supercapacitor 100 according to example 17 wherein the additive is selected from the group consisting of 4- (trimethylsiloxy)-3-penten-2-one (TMSPO), heptamethyldisilazane (HMDS), and 1- (trimethylsilyl)-imidazole (1 -TMSI).

[0151] Item 19. A method of manufacturing a supercapacitor 100 comprising: cutting 202 a metal foil having an active electrode material 114 and a carrier layer to provide a singulated electrode reel having a plurality of singulated electrodes; transferring 204 the plurality of singulated electrodes from the singulated electrode reel to a laminate foil layer 126 wherein each singulated electrode on the singulated electrode reel is adhered to the laminate foil layer 126; connecting 206 a connector tab 120 to each singulated electrode on the singulated electrode reel to provide a partial cell reel having plurality of partial cell stacks 130; and applying 208 a separator 118 to each partial cell stack 130 on the partial cell reel wherein each separator 118 is fixed with respect to the partial cell stack 130.

[0152] Item 20. The method of manufacturing a supercapacitor 100 according to example 19 wherein the steps of transferring 204 and applying 208 comprise respectively using a first adhesive 110 and a second adhesive 124 for adhering.

[0153] The terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms "comprises," "comprising," "includes," and / or "including" when used herein specify the presence of stated features, integers, actions, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, actions, steps, operations, elements, components, and / or groups thereof.

[0154] It will be understood that, although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element without departing from the scope of the present disclosure.

[0155] Relative terms such as "below" or "above" or "upper" or "lower" or "horizontal" or "vertical" may be used herein to describe a relationship of one element to another element as illustrated in the Figures. It will be understood that these terms and those discussed above are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. It will be understood that when an element is referred to as being "connected" or "coupled" to another element, it can be directly connected or coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements present.

[0156] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0157] It is to be understood that the present disclosure is not limited to the aspects described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the present disclosure and appended claims. In the drawings and specification, there have been 5 disclosed aspects for purposes of illustration only and not for purposes of limitation, the scope of the disclosure being set forth in the following claims.

Claims

Claims1 . A method of manufacturing a supercapacitor (100) comprising: laminating (200) a first adhesive (110) on a first side of a metal foil wherein the metal foil comprises an active electrode material (114) on a second side of the metal foil; cutting (202) the metal foil, the active electrode material (114) and the first adhesive (110) to provide a singulated electrode reel having a plurality of singulated electrodes; transferring (204) the plurality of singulated electrodes from the singulated electrode reel to a laminate foil layer (126) wherein the first adhesive (110) is between the first side of the metal foil and the laminate foil layer (126); electrically connecting (206) a connector tab (120) to each singulated electrode on the singulated electrode reel to provide a partial cell reel having plurality of partial cell stacks (130); applying (208) a separator (118) with a second adhesive (124) to the second side of the metal foil of each partial cell stacks on the partial cell reel such that the separator (118) covers the active electrode material (114).

2. The method of manufacturing a supercapacitor (100) according to claim 1 wherein the method comprises laminating (212) another partial cell reel of singulated other partial cell stacks (132) on the partial cell reel of singulated partial cell stacks (130) such that the second side of the metal foil face each other to provide a full cell reel having a plurality of full cell stacks (138).

3. The method of manufacturing a supercapacitor (100) according to claims 1 or 2, wherein the first adhesive (110) is applied using an adhesive tape having a first adhesive release liner (112).

4. The method of manufacturing a supercapacitor (100) according to claim 3, wherein the cutting (202) does not cut the first adhesive release liner (112).

5. The method of manufacturing a supercapacitor (100) according to any of claims 1 to 4, wherein the singulated electrode reel is transferred to the laminate foil layer(126) such that only part of each singulated electrode on the singulated electrode reel is glued onto the laminate foil layer (126).

6. The method of manufacturing a supercapacitor (100) according to any of claims 1 to 5, wherein the connecting (206) of the connector tab (120) to each singulated electrode on the singulated electrode reel is performed by ultrasonic welding or laser welding.

7. The method of manufacturing a supercapacitor (100) according to any of claims 1 to 6, further comprising perforating one or more sides of the separator (118).

8. The method of manufacturing a supercapacitor (100) according to any of claims 1 to 7, wherein the second adhesive (124) is a hot melt glue.

9. The method of manufacturing a supercapacitor (100) according to claim 8, wherein the hot melt glue is applied as an intermittent stripe to the partial cell reel adjacent to each singulated electrode.

10. The method of manufacturing a supercapacitor (100) according to any of claims 1 to 9, further comprising heat sealing (214) the laminate foil layer (126) of each full cell stack (138) along three sides, leaving an opening on one side of the pouch for subsequent injection of an electrolyte (134).11 . The method of manufacturing a supercapacitor (100) according to any of claims 1 to 10, further comprising filling (220) open singulated full cells with an electrolyte (134) and sealing (214) the open singulated full cells using heat sealing (214).

12. The method of manufacturing a supercapacitor (100) according to claim 11 , further comprising adding (222) an additive to the electrolyte (134) to scavenge residual water from the electrolyte (134).

13. The method of manufacturing a supercapacitor (100) according to claim 12, wherein the additive is selected from the group consisting of 4-(trimethylsiloxy)-3-penten-2-one (TMSPO), heptamethyldisilazane (HMDS), and 1 -(trimethylsilyl)- imidazole (1-TMSI).

14. The method of manufacturing a supercapacitor (100) according to any of claims 12 to 13, wherein the additive is dissolved in the electrolyte (134) in concentrations in a range of 0.5 to 2%.

15. The method of manufacturing a supercapacitor (100) according to any of claims 12 to 14, wherein the additive is a molecular sieve type 4A or molecular sieve type 3A added as a dry powder to the open singulated full cells before addition of the electrolyte (134).

16. A supercapacitor (100) comprising: a partial cell stack (130) and another partial cell stack (132)sealed together and each partial cell stack (130, 132) having an electrode (102) with a current collector (104), wherein the current collector (104) has a first side and a second side, the first side being laminated with a first adhesive (110) and the second side having an active electrode material (114) deposited thereon wherein the second sides of the current collector (104) of the partial cell stack (130) and the other partial cell stack (132) face each other; a laminate foil layer (126) adhered to the first adhesive (110); at least one connector tab (120) electrically connected to the current collector (104); a separator (118) applied with a second adhesive (124) to one or more of the partial cell stack (130) and the other partial cell stack (132); and an electrolyte (134).

17. The supercapacitor (100) according to claim 16 wherein the electrolyte (134) comprises an additive to the electrolyte (134) to scavenge residual water from the electrolyte (134).

18. The supercapacitor (100) according to claim 17 wherein the additive is selected from the group consisting of 4-(trimethylsiloxy)-3-penten-2-one (TMSPO), heptamethyldisilazane (HMDS), and 1-(trimethylsilyl)-imidazole (1-TMSI).

19. A method of manufacturing a supercapacitor (100) comprising: cutting (202) a metal foil having an active electrode material (114) and a carrier layer to provide a singulated electrode reel having a plurality of singulated electrodes; transferring (204) the plurality of singulated electrodes from the singulated electrode reel to a laminate foil layer (126) wherein each singulated electrode on the singulated electrode reel is fixed with respect to the laminate foil layer (126) using a first adhesive (110); electrically connecting (206) a connector tab (120) to each singulated electrode on the singulated electrode reel to provide a partial cell reel having plurality of partial cell stacks (130, 132); and applying (208) a separator (118) to each partial cell stack (130) on the partial cell reel wherein each separator (118) is fixed with respect to the partial cell stack (130) using a second adhesive (124).

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