Exhibit C 

Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 1 of 38 PageID #: 36
USOO7382600B2

(12)United States Patent

Paul et al.

(10)Patent No.: US 753825600 B2

(45)Date of Patent: *Jnn. 3, 2008

(54) CHARGE STORAGE DEVICE

(75) Inventors: George Lange Paul, Chatswood West

(AU); Rory Albert James Pynenbur ,

Hillsboro, OR (US); Peter John

Mahon, Bentleigh East (AU); Anthony

Michael Vassallo, Hornsby Heights

(AU); Philip Andrew Jones, Hornsby

(AU); Sarkis Keshishian, Ermington

(AU); Anthony Gaetano Pandolfo,

Hurstville Grove (AU)

(73) Assignee: CAP-XX Limited, Dee Why, NSW

(AU)

(* ) Notiee: Subjeet to any disclaimer, the term ofthis

patent is extended or adjusted under 35

U.S.C. 154(b) hy 211 days.

This patent is suhjeet to a terminal disclaimer.

(21) Appl. No.: 11/228,294

(22) Filed: Sep. 19, 2005

(65) Prior Publication Data

US 2007/0195486 Al Aug. 23, 2007

R ated U.S. Application Data

(63) Continuation of application No. 11/050,762, filed on

Feb. 7, 2005, now Pat. No. 7,009,833, which is a

continuation of application No. 10/635,775, filed on

Aug. 7, 2003, now Pat. No. 6,920,034, which is a

continuation of application No. 09/763,423, filed as

application No. PCT/AU99/01081 on Dec. 6, 1999,

now Pat. No. 6,631,072.

(60) Provisional application No. 60/110,930, filed on Dec.

5, 1998.

(51) Int. CL

HOIG 9/00 (2006.01)

(52) U.S. Cl 361/502; 361/503; 361/504;

361/508; 361/511; 361/512

(58) Field of Classification Search 361/502-504,

361/508-512, 516-519, 523-534; 29/25.01,

29/25.03

See applieation file for complete search history.

(56) References Cited

U.S. PATENT DOCUMENTS

4,424,262 A 1/1984 von Alpen et al 429/8

4,731,705 A 3/1988 Velasco et al 361/433

5,426,561 A 6/1995 Yen et al 361/502

5,455,999 A 10/1995 Weiss et al 29/623.1

5,532,083 A 7/1996 McCullough

5,646,815 A 7/1997 Owens et al.

5,905,629 A 5/1999 Alford 361/502

5,926,361 A 7/1999 Alford 361/502

5,963,418 A 10/1999 Greenwood 361/508

6,198,623 Bl 3/2001 Amatucci 361/512

6,449,139 Bl* 9/2002 Farahmandi et al 361/502

6,456,484 Bl* 9/2002 Matsuoka et al 361/511

6,510,043 Bl* 1/2003 Shiue et al 361/502

6,697,249 B2 2/2004 Maletin et al 361/502

6,762,926 Bl 7/2004 Shieu et al 361/502

6,920,034 B2* 7/2005 Paul et al 361/502

FOREIGN PATENT DOCUMENTS

EP 054 989 6/1982

EP 397 248 11/1990

EP 449 145 10/1991

EP 930 627 7/1999

EP 938 109 8/1999

WO WO98/15962 4/1998

WO WO99/08298 2/1999

OTHER PUBEICATIONS

Derwent Abstraet Accession No. 95-305668/40, JP 7-201681 A

(Hita li, Ltd.) Aug. 4, 1995.

Derwent Abstraet Aeeession No. 96-244423/25, JP 8-097091 A

(Matsushita Denki Sangyo KK) Apr. 12, 1996.

Miller, John R., Pulse Power performance of Electrochemical

Capacitors: Technical Status of Present Commereial Devices, The

8 International Seminar on Double Layer Capacitors and Similar

Energy Storage Deviees, vol. 8, pp. 1-10, Dec. 1998.

* cited by examiner

Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 2 of 38 PageID #: 37 US007382600B2
US 7,382,600 B2

Page 2

Primary Examiner—Nguyen T. Ha

(74) Attorney, Agent, or Firm— & Kenyon LLP

(57) ABSTRACT

A eharge storage deviee eomprising: a first electrode; a

second electrode being opposed to and spaced apart from the

first electrode; a porous separator disposed between the

eleetrodes; a sealed paekage for containing the eleetrodes,

the separator and an electrolyte in whieh the eleetrodes are

immersed; and a first terminal and a second terminal being

eleetrieally connected to the first electrode and the second

eleetrode respeetively and both extending from the paekage

to allow external electrical connect to the respective electrodes, wherein the gravimetrie FOM ofthe deviee is greater

than about 2.1 Watts/gram. Also described is a method of

manufacturing a charge storage deviee, the method comprising the steps of: providing a first electrode; disposing a

second electrode in opposition to and spaced apart from the

first electrode; disposing a porous separator between the

eleetrodes; eontaining within a sealed paekage the eleetrodes, the separator and an electrolyte, wherein the eleetrodes are immersed in the eleetrolyte; and electrically

connecting a first terminal and a second terminal to the first

electrode and the second eleetrode respeetively sueh that the

terminals extending from the package to allow external

electrical cormection to the respective electrodes, wherein

the gravimetrie FOM ofthe deviee is greater than about 2.1

Watts/gram.

18 Claims, 19 Drawing Sheets

Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 3 of 38 PageID #: 38
U.S. Patent Jun. 3, 2008 Sheet 1 of 19 US 7382,600 B2

8

Figure 1

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U.S. Patent Jun. 3, 2008 Sheet 2 of 19 US 7,382,600 B2

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U.S. Patent Jun. 3, 2008 Sheet 3 of 19 US 7,382,600 B2

Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 6 of 38 PageID #: 41
U.S. Patent Jun. 3, 2008 Sheet 4 of 19 US 7382,600 B2

Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 7 of 38 PageID #: 42
U.S. Patent Jun. 3, 2008 Sheet 5 of 19 US 7,382,600 B2

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U.S. Patent Jun. 3, 2008 Sheet 6 of 19 US 7,382,600 B2

FIG. 11 FIG. 10

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U.S. Patent Jun. 3, 2008 Sheet 7 of 19 US 7,382,600 B2

Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 10 of 38 PageID #: 45
Gra metHc FOM

1.00E-05 1.00E-04 1.00E-03 1.00E-02 1.00E-01 1.00E+00 1.00E+01

Response Time (sec)

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Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 11 of 38 PageID #: 46
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Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 12 of 38 PageID #: 47
Power max. Gravimetric

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Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 13 of 38 PageID #: 48
Power max. Volume c

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Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 14 of 38 PageID #: 49
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Figure 16

US Paf Jun- 3^ 2008 Sheef 12 of 19 US 73382 B2

Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 15 of 38 PageID #: 50
Prfor Art 1

Prior Art 2

Prior Art 3

Capacltanc Retlstanc VoltagB Mass V umft Sl2â

mmxmm x

mm

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FIGURE 17

US Paf Jun- 3^ 2008 She 13of19 US 73382 B2

Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 16 of 38 PageID #: 51
U.S. Patent Jun. 3, 2008 Sheet 14 of 19 US 7,382,600 B2

FIG. 19

103

Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 17 of 38 PageID #: 52
Capaoita Reslatan V tage

V

Mass

g

V time

cc

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mmx

mmx

mm

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mass

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HF-8 0.00037 112.24 2.S 7.1 3.52 110x100

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HF o.ooon 65.78 2.5 7J 3J3 110X100

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FIGURE 2Q

US Paf u s 793829600 B 2 Jun・3^

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8shee- 15 of 19

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U.S. Patent Jun. 3, 2008 Sheet 16 of 19 US 7,382,600 B2

FIGURE 21

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U.S. Patent Jun. 3, 2008 Sheet 17 of 19 US 7,382,600 B2

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U.S. Patent Jun. 3, 2008 Sheet 18 of 19 US 7,382,600 B2

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U.S. Patent Jun. 3, 2008 Sheet 19 of 19 US 7,382,600 B2

FIGURE 25

Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 22 of 38 PageID #: 57
US 7,382,600 B2

CHARGE STORAGE DEVICE

This is a continuation of application Ser. No. 11/050,762

filed 7 Feb. 2005 now U.S. Pat. No. 7,009,833, which is a

continuation of application Ser. No. 10/635,775 filed 7 Aug.

2003, U.S. Pat. No. 6,920,034 B2, which is a continuation of

application Ser. No. 09/763,423 filed 24 Aug. 2001, U.S.

Pat. No. 6,631,072, which is a 371 national phase applieation of PCT/AU99/01081 filed 6 Dee. 1999, whieh elaims

the benefit of Provisional Application No. 60/110,930 filed

5 Dee. 1998, the eontents of which are incorporated herein

by referenee.

BACKGROUND OF THE INVENTION

The present invention relates to a charge storage deviee

and a method of manufacture thereof.

The invention has been developed primarily for use with

the eleetroehemieal charge storage deviees sueh as supercapacitors and will be deseribed hereinafter with reference

to that application. ft will be appreciated that supercapacitors

are designated by terms sueh as ultra capacitors, electric

double layer capacitors and electrochemical capacitors,

amongst others, all of which are included within the term

“supercapacitor" as used within this specification.

It is known to mass produce supercapacitors that have

speeifie operational characteristics that fall within well

defined ranges. Although mass production is advantageous

from a cost point of view, there is an inherent laek of

flexibility. That is, if the desired eharaeteristies of a supercapacitor for a particular application fall outside the eommonly available ranges a compromise solution is required.

An alternative is to produce the desired supercapacitor as a

one off or small rim. The eosts ofthis latter alternative are

often prohibitive and, as such, rarely pursued.

Known supercapacitors generally find application in

power supplies sueh as uninterruptible power supplies for

computers or backup power supplies for volatile memory.

Accordingly, it has been eommon to optimise these supereapaeitors for high energy density, low self-discharge rates,

and low cost.

More reeently it has been thought that supercapacitors are

theoretieally applicable to high power pulsed applieations.

Indeed, some attempts have been made to adapt such supercapacitors as short term current sources or sinks. Examples

of such applications include internal combustion engine

starting, load power leveling or hybrid vehicles and a variety

of pulsed eommunieation systems. However, the sueeess of

these supereapaeitors has been limited by faetors such as a

high equivalent series resistanee, among others. For

example, some prior art double layer capacitors make use of

button cell or spiral wound technology. These, in turn, fall

generally in one of two groups, the first group being eoneerned with high power applications and the second with

low power applications. For the second group, but not the

first, it has been possible to obtain high energy densities.

The first and second groups are broadly defined by the

type of electrolyte used, those being aqueous and nonaqueous respectively. This is predominantly due to the lower

resistance inherently offered by aqueous electrolytes whieh

makes it better suited to high power, and hence high eurrent,

applieations. That is, the low resistance results in lower Fr

losses for aqueous electrolytes. The trade off, however, is

that for these aqueous electrolytes the voltage that can be

applied across a capacitive cell is extremely limited.

The second group of prior art double layer capacitors

suffers the eonverse disadvantages. That is, while they

2

provide a greater voltage window, which improves the

available energy density, they also have had high internal

resistances whieh make them unsuitable the high power

applications.

SUMMARY OF THE INVENTION

It is an object of the present invention, at least in the

preferred embodiments, to overcome or substantially ameliorate one or more ofthe disadvantages of the prior art or

at least to provide a useful alternative.

Aeeording to a first aspect of the invention there is

provided a charge storage deviee ineluding:

a first electrode;

a second electrode being opposed to and spaced apart

from the first electrode;

a porous separator disposed between the eleetrodes;

a sealed paekage for containing the electrodes, the separator and an electrolyte in whieh the eleetrodes are

immersed; and

a first terminal and a second terminal being eleetrieally

connected to the first electrode and the second eleetrode

respeetively and both extending from the paekage to allow

external electrical connection to the respective electrodes,

wherein the gravimetrie FOM ofthe deviee is greater than

about 2.1 Watts/gram.

Preferably, the gravimetrie FOM ofthe deviee is greater

than about 2.5 Watts/gram. More preferably, the gravimetrie

FOM ofthe deviee is greater than about 3 Watts/gram. Even

more preferably, the gravimetrie FOM of the deviee is

greater than about 3.5 Watts/gram. In some embodiments,

the gravimetrie FOM of the deviee is greater than about 5

Watts/gram.

More preferably, the first electrode and the seeond eleetrode form a capacitive cell and the deviee ineludes a

plurality of the cells electrically cormected in parallel and

disposed within the paekage. In other embodiments, however, the eells are eormeeted in series. In still further

embodiments a combination of series and parallel eonneets

are utilised. It wifi be appreeiated that series eonneetions

allow the eells to be applied to higher voltage applieations,

while parallel eonneetions allow the eells to provide a higher

combined eapaeitanee for the deviee. The ease at which

these different eonneetions are accommodated by the invention means that preferred embodiments are applieable to a

wide variety of tasks ranging from high power systems to

low power systems.

In a preferred form, the maximum operating voltage ofthe

or each capacitive cell is less than about 4 Volts. More

preferably, the maximum operating voltage of the or each

capacitive cell is less than about 3.5 Volts. Even more

preferably, the maximum operating voltage of the or each

capacitive cell is less than about 3 Volts

Preferably, the first electrode and the seeond electrode

inelude a first carbon coating and a second carbon coating

respectively wherein the surface area of carbon used in the

eoatings is greater than 20 m^/gram.

According to a second aspect of the invention there is

provided a method of manufacturing a charge storage

device, the method including the steps of:

providing a first electrode;

disposing a second electrode in opposition to and spaced

apart from the first electrode;

disposing a porous separator between the eleetrodes;

eontaining within a sealed paekage the eleetrodes, the

separator and an electrolyte, wherein the eleetrodes are

immersed in the eleetrolyte; and

5

10

15

20

25

30

35

40

45

50

55

60

65

Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 23 of 38 PageID #: 58
US 7,382,600 B2

3

electrically connecting a first terminal and a second

terminal to the first electrode and the second electrode

respectively such that the terminals extending from the

package to allow external electrical connection to the

respective electrodes, wherein the gravimetrie FOM of the

deviee is greater than ahont 2.1 Watts.

Preferably, the gravimetrie FOM ofthe deviee is greater

than ahont 2.5 Watts/gram. More preferably, the gravimetrie

FOM ofthe deviee is greater than ahont 3 Watts/gram. Even

more preferably, the gravimetrie FOM of the deviee is

greater than ahont 3.5 Watts/gram. In some embodiments,

the gravimetrie FOM of the deviee is greater than ahont 5

Watts/gram.

More preferably, the first electrode and the seeond eleetrode form a capacitive cell and the deviee includes a

plurality of the cells electrically connected in parallel and

disposed within the package. In other embodiments, however, the cells are connected in series. In still further

embodiments a combination of series and parallel eonneets

are utilised.

In a preferred form, the maximum operating voltage ofthe

or each capacitive cell is less than about 4 Volts. More

preferably, the maximum operating voltage of the or each

capacitive cell is less than about 3.5 Volts. Even more

preferably, the maximum operating voltage of the or each

capacitive cell is less than about 3 Volts

Preferably, the first electrode and the seeond electrode

inelude a first carbon coating and a second carbon coating

respectively wherein the surface area of carbon used in the

eoatings is greater than 20 m^/gram.

According to a third aspect of the invention there is

provided a charge storage deviee ineluding:

a first electrode;

a second electrode being opposed to and spaced apart

from the first electrode;

a porous separator disposed between the eleetrodes;

a sealed paekage for containing the electrodes, the separator and an electrolyte in whieh the eleetrodes are

immersed; and

a first terminal and a second terminal being eleetrieally

connected to the first electrode and the seeond electrode

respeetively and both extending from the paekage to allow

external electrical connection to the respective electrodes,

wherein the volumetrie FOM of the deviee is greater than

about 3.2 Watts/cm^.

Preferably, the volumetrie FOM of the deviee is greater

than about 4 Watts/cm^. More preferably, the volumetrie

FOM ofthe deviee is greater than about 5 Watts/cm^. Even

more preferably, the volumetrie FOM ofthe deviee is greater

than about 7 Watts/cm^. In some embodiments, the volumetrie FOM ofthe deviee is greater than about 8 Watts/cm^.

More preferably, the first electrode and the seeond electrode form a capacitive cell and the device includes a

plurality of the eells eleetrieally connected in parallel and

disposed within the package. In other embodiments, however, the cells are connected in series. In still further

embodiments a combination of series and parallel eonneets

are utilised. It will be appreeiated that series eonneetions

allow the eells to be applied to higher voltage applieations,

while parallel eonneetions allow the eells to provide a higher

combined eapaeitanee for the deviee. The ease at which

these different eonneetions are accommodated by the invention means that preferred embodiments are applieable to a

wide variety of tasks ranging from high power systems to

low power systems.

In a preferred form, the maximum operating voltage ofthe

or each capacitive cell is less than about 4 Volts. More

4

preferably, the maximum operating voltage of the or each

capacitive cell is less than about 3.5 Volts. Even more

preferably, the maximum operating voltage of the or each

capacitive cell is less than about 3 Volts

Preferably, the first electrode and the seeond electrode

inelude a first carbon coating and a second carbon coating

respectively where the surface area of carbon used in the

eoatings is greater than 20 m^/gram.

According to a fourth aspect of the invention there is

provided a method of manufacturing a charge storage

device, the method including the steps of:

providing a first electrode;

disposing a second electrode in opposition to and spaced

apart from the first electrode;

disposing a porous separator between the eleetrodes;

eontaining within a sealed paekage the eleetrodes, the

separator and an electrolyte, wherein the eleetrodes are

immersed in the eleetrolyte; and

electrically connecting a first terminal and a second

terminal to the first electrode and the seeond electrode

respeetively sueh that the terminals extending from the

paekage to allow external electrical connection to the

respective electrodes, wherein the volumetrie FOM of the

deviee is greater than about 3.2 Watts/cm^.

Preferably, the volumetrie FOM of the deviee is greater

than about 4 Watts/cm^. More preferably, the volumetrie

FOM ofthe deviee is greater than about 5 Watts/cm^. Even

more preferably, the volumetrie FOM ofthe deviee is greater

than about 7 Watts/cm^. In some embodiments, the volumetrie FOM ofthe deviee is greater than about 8 Watts/cm^.

According to a fifth aspect of the invention there is

provided a charge storage deviee ineluding:

a first electrode having a first conductive substrate;

a first carbon layer supported on the first substrate and

being formed from a carbon having a surface area greater

than 400 m^/gram;

a second electrode having a second conductive substrate;

a second carbon layer supported on the seeond substrate

and being formed from a carbon having a surface area

greater than 400 m^/gram;

a porous separator disposed between the eleetrodes;

a sealed paekage for containing the electrodes, the separator and an organic electrolyte in whieh the eleetrodes are

immersed, wherein the first and second layers are opposed

and spaced apart; and

a first terminal and a second terminal being eleetrieally

connected to the first electrode and the seeond electrode

respeetively and both extending from the paekage to allow

external electrical connection to the respective electrodes,

wherein the volumetrie FOM of the deviee is greater than

about 1.1 Watts/cm^.

According to a sixth aspect of the invention there is

provided a method of manufacturing a charge storage

device, the method including the steps of:

providing a first electrode having a first conductive substrate;

supporting a first carbon layer on the first substrate, the

first layer being formed from a carbon having a surface area

greater than 400 m^/gram;

providing a second electrode having a second conductive

substrate;

supporting a second carbon layer on the seeond substrate,

the seeond layer being formed from a carbon having a

surface area greater than 400 m^/gram;

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disposing a porous separator between the eleetrodes;

eontaining the eleetrodes, the separator and an organic

electrolyte in whieh the eleetrodes are immersed in a sealed

paekage, wherein the first and second layers are opposed and

spaced apart; and

electrically connecting a first terminal and a second

terminal to the first electrode and the second eleetrode

respeetively sueh that the terminals both extend from the

paekage to allow external electrical connection to the

respective eleetrodes, and wherein the volumetrie FOM of

the deviee is greater than abont 1.1 Watts/cm^.

According to a seventh aspeet of the invention there is

provided a charge storage deviee ineluding:

a first electrode;

a second electrode being opposed to and spaced apart

from the first electrode;

a porous separator disposed between the eleetrodes;

a sealed paekage for containing the electrodes, the separator and an electrolyte in whieh the eleetrodes are

immersed; and

a first terminal and a second terminal being eleetrieally

connected to the first electrode and the second eleetrode

respeetively and both extending from the paekage to allow

external electrical connection to the respective electrodes,

wherein the response time T of the deviee is less than

abont 0.09 seconds.

Preferably, T is less than abont lO"^ seconds. More

preferably, T is less than abont 10~^ seconds. Even more

preferably, T is less than abont 10 seconds. In some

embodiments, T is less than abont 5xl〇~^ seconds.

According to an eighth aspeet of the invention there is

provided a method of manufacturing a charge storage

device, the method including the steps of:

providing a first electrode;

providing a second electrode being opposed to and spaced

apart from the first electrode;

disposing a porous separator between the eleetrodes;

eontaining the eleetrodes, the separator and an electrolyte

in whieh the eleetrodes are immersed a sealed paekage; and

electrically connecting a first terminal and a second

terminal to the first electrode and the second eleetrode

respeetively sueh that the terminals extending from the

package to allow external electrical connection to the

respective electrodes, wherein the response time T ofthe

deviee is less than abont 0.09 seconds.

Preferably, T is less than abont 10 seconds. More

preferably, T is less than abont 10~^ seconds. Even more

preferably, T is less than abont 10 seconds. In some

embodiments, T is less than abont 533 10~“ seconds.

According to a ninth aspect of the invention there is

provided a charge storage deviee ineluding:

a first electrode;

a second electrode being opposed to and spaced apart

from the first electrode;

a porous separator disposed between the eleetrodes;

a sealed paekage for containing the electrodes, the separator and an electrolyte in whieh the eleetrodes are

immersed; and

a first terminal and a second terminal being eleetrieally

connected to the first electrode and the second eleetrode

respeetively and both extending from the paekage to allow

electrical connection to the respeetive eleetrodes, wherein

the gravimetrie power maximum of the deviee is greater

than abont 12.5 Watts/gram.

Preferably, the gravimetrie power maximum ofthe deviee

is greater than abont 15 Watts/gram. More preferably, the

gravimetrie power maximum of the deviee is greater than

6

abont 17 Watts/gram. Even more preferably, the gravimetrie

power maximum of the deviee is greater than about 20

Watts/gram. lu some embodiments the gravimetrie power

maximum ofthe deviee is greater than about 26 Watts/gram.

According to a tenth aspeet of the invention there is

provided a method of manufacturing a charge storage

device, the method including the steps of:

providing a first electrode;

disposing a second electrode in opposition to and spaced

apart from the first electrode;

disposing a porous separator between the eleetrodes;

eontaining within a scaled package the electrodes, the

separator and an electrolyte, wherein the eleetrodes are

immersed in the eleetrolyte; and

electrically connecting a first terminal and a second

terminal to the first electrode and the second eleetrode

respeetively sueh that the terminals extending from the

package to allow external electrical cormection to the

respective electrodes, wherein the gravimetrie power maximum of the deviee is greater than about 12.5 Watts/gram.

Preferably, the gravimetrie power maximum ofthe deviee

is greater than about 15 Watts/gram. More preferably, the

gravimetrie power maximum of the deviee is greater than

about 17 Watts/gram. Even more preferably, the gravimetrie

power maximum of the deviee is greater than about 20

Watts/gram. In some embodiments the gravimetrie power

maximum ofthe deviee is greater than about 26 Watts/gram.

According to an eleventh aspeet ofthe invention there is

provided a charge storage deviee ineluding:

a first electrode;

a second electrode being opposed to and spaced apart

from the first electrode;

a porous separator disposed between the eleetrodes;

a sealed paekage for containing the electrodes, the separator and an electrolyte in whieh the eleetrodes immersed;

and

a first terminal and a second terminal being eleetrieally

connected to the first electrode and the second eleetrode

respeetively and both extending from the paekage to allow

external electrical connection to the respective electrodes,

wherein the volumetrie power maximum of the deviee is

greater than about 35 Watts/cm°.

According to a twelfth aspeet of the invention there is

provided a method of manufacturing a charge storage

device, the method including the steps of:

providing a first electrode;

disposing a second electrode in opposition to and spaced

apart from the first electrode;

disposing a porous separator between the eleetrodes;

eontaining within a sealed paekage the eleetrodes, the

separator and an electrolyte, wherein the eleetrodes are

immersed in the eleetrolyte; and

electrically connecting a first terminal and a second

terminal to the first electrode and the second eleetrode

respeetively sueh that the terminals extending from the

package to allow external electrical cormection to the

respective electrodes, wherein the volumetrie power maximum of the deviee is greater than about 35 Watts/cm^.

According to a thirteenth aspeet of the invention there is

provided a charge storage deviee ineluding:

first electrode;

a second electrode being opposed to and spaced apart

from the first electrode;

a porous separator disposed between the eleetrodes;

a sealed paekage for containing the electrodes, the separator and an electrolyte in whieh the eleetrodes are

immersed; and

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a first terminal and a second terminal being eleetrieally

connected to the first electrode and the seeond eleetrode

respeetively and both extending from the paekage to allow

external electrical connection to the respective electrodes,

wherein the time eonstant of the deviee is less than ahont

0.03 seconds.

Preferably, the time eonstant of the deviee is less than

ahont l q seconds. More preferably, the time eonstant of

the deviee is less than ahont 10~^ seconds. In some embodiments the time eonstant ofthe deviee is less than ahont 10 4

seconds.

According to a fourteenth aspeet ofthe invention there is

provided a method of manufacturing a charge storage

device, the method including the steps of:

providing a first electrode;

providing a second electrode being opposed to and spaced

apart from the first electrode;

disposing a porous separator between the eleetrodes;

eontaining the eleetrodes, the separator and an electrolyte

in whieh the eleetrodes are immersed a sealed paekage; and

electrically connecting a first terminal and a second

terminal to the first electrode and the seeond electrode

respeetively sueh that the terminals extending from the

paekage to allow external electrical connection to the

respective electrodes, wherein the time eonstant of the

deviee is less than ahont 0.03 seconds.

Preferably, the time eonstant of the deviee is less than

ahont l q seconds. More preferably, the time eonstant of

the deviee is less than ahont 10~^ seconds. Even more

preferably, the time eonstant ofthe deviee is less than ahont

1 T seconds. In some embodiments the time eonstant ofthe

deviee is less than ahont 10 ’ seconds.

According to a fifteenth aspeet of the invention there is

provided a charge storage deviee ineluding:

a plurality offirst sheet eleetrodes having respective first

tabs extending therefrom;

a plurality of second sheet eleetrodes alternated with the

first electrodes and having respective second tabs extending

therefrom;

a porous separator means disposed between adjaeent

electrodes; and

a sealed paekage for containing the electrodes, the separator means and an electrolyte, whereby the first tabs are

eleetrieally connected to a first terminal and the seeond tabs

are eleetrieally connected to a second terminal, both the first

and second terminals extending from the paekage to allow

external electrical connection to the respective electrodes.

Aeeording to a sixteenth aspeet of the invention there is

provided a method of manufacturing a charge storage

device, the method including the steps of:

providing a plurality of first sheet eleetrodes having

respective first tabs extending therefrom;

alternating a plurality of second sheet eleetrodes with the

first electrodes, the seeond sheet eleetrodes having respective seeond tabs extending therefrom;

disposing a porous separator means between adjaeent

eleetrodes;

eontaining within a sealed paekage the eleetrodes, the

separator means and an electrolyte;

electrically cormecting the first tabs to a first terminal and

the seeond tabs to a second terminal, wherein both the first

and second terminals extending from the paekage to allow

external electrical connection to the respective electrodes.

Aeeording to a seventeenth aspeet ofthe invention there

is provided a charge storage deviee ineluding:

8

a first sheet eleetrode;

a second sheet eleetrode disposed adjaeent to the first

electrode, whereby the eleetrodes are folded baek upon their

respective lengths;

a porous separator disposed between adjaeent eleetrodes;

and

a sealed paekage for containing the electrodes, the separator and an electrolyte, whereby the first electrode is

eleetrieally connected to a first terminal and the seeond

electrode is eleetrieally connected to a second terminal, both

the first and second terminals extending from the paekage to

allow external electrical cormection to the respective electrodes.

Aeeording to an eighteenth aspeet ofthe invention there

is provided a method of manufacturing a charge storage

device, the method including the steps of:

providing a first sheet eleetrode;

disposing a second sheet eleetrode adjaeent to the first

electrode;

folding the electrodes are baek upon their respective

lengths;

disposing a porous separator between adjaeent eleetrodes;

sealing within a package the eleetrodes, the separator and

an electrolyte; and

electrically connecting the first electrode to a first terminal

and the seeond electrode to a second terminal, wherein both

the first and second terminals extend from the paekage to

allow external electrical cormection to the respective electrodes.

Aeeording to a nineteenth aspeet ofthe invention there is

provided a multiple eharge storage deviee ineluding:

a first electrode being eleetrieally cormectod to a first

terminal;

a second electrode disposed adjaeent the first electrode

and being eleetrieally cormectod to a second terminal;

a third electrode disposed adjaeent to the first electrode

and being eleetrieally cormectod to the second terminal;

one or more porous separators disposed between adjaeent

eleetrodes; and

a package for containing the eleetrodes, the one or more

separators and an electrolyte, whereby the terminals extend

from the paekage to allow external electrical cormection to

the respective electrodes.

Aeeording to a twentieth aspeet ofthe invention there is

provided a method of manufacturing a multiple charge

storage device, the method including the steps of:

providing a first electrode;

eleetrieally connecting the first electrode to a first terminal;

disposing a second electrode adjaeent the first electrode;

eleetrieally cormecting the second electrode to a second

terminal;

disposing a third electrode adjaeent to the first electrode;

eleetrieally cormecting the third electrode to the second

terminal;

disposing one ormore porous separators between adjaeent

eleetrodes; and

containing within a package the electrodes, the one or

more separators and an electrolyte, whereby the terminals

extend from the paekage to allow external electrical connection to the respective electrodes.

Aeeording to a twenty first aspect of the invention there

is provided a multiple eharge storage deviee ineluding:

a package defining a sealed eavity containing an electrolyte

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two spaced apart capacitor terminals each extending

between a first end located within the cavity and a second

end external to the paekage;

a first capacitor cell located within the cavity and being in

contact with the electrolyte, wherein the first cell has both a

first predetermined time eonstant and two cell terminals

which are eleetrieally connected to respective capacitor

terminals; and

a second capacitor cell located within the cavity and being

both in contact with the electrolyte and maintained in a

spaced apart configuration with respect to the first cell, the

second eell having both a second predetermined time eonstant and two cell terminals which are eleetrieally connected

to respective capacitor terminals.

According to a twenty second aspect of the invention

there is provided a method of manufacturing a multiple

charge storage deviee ineluding the steps of:

containing an electrolyte in a sealed eavity defined by a

package;

providing two spaced apart capacitor terminals each

extending between a first end located within the cavity and

a second end external to the paekage;

locating a first capacitor cell within the cavity and in

contact with the electrolyte, wherein the first cell has both a

first predetermined time eonstant and two cell terminals

which are eleetrieally connected to respective capacitor

terminals; and

locating a second capacitor cell within the cavity and in

contact with the electrolyte while being maintained in a

spaced apart configuration with respect to the first cell, the

second eell having both a second predetermined time eonstant and two cell terminals which are eleetrieally connected

to respective capacitor terminals.

According to a twenty third aspect of the invention there

is provided a multiple eharge storage deviee ineluding:

a first sheet eleetrode being eleetrieally connected to a

first terminal and having a first coating on at least one side

thereof, the eoating being of predetermined varying thickness;

a second electrode disposed adjaeent to the first electrode

and being eleetrieally connected to a second terminal;

one or more porous separators disposed between adjaeent

eleetrodes; and

a package for containing the eleetrodes, the one or more

separator and an electrolyte, whereby the terminals extend

from the paekage to allow external electrical connection to

the respective electrodes.

Aeeording to a twenty fourth aspect ofthe invention there

is provided a method of manufacturing a multiple charge

storage device, the method including the steps of:

providing a first sheet eleetrode;

eleetrieally connecting the first electrode to a first terminal;

applying a first coating on at least one side of the first

electrode, the eoating being ofpredetermined varying thickness;

disposing a second electrode adjaeent to the first electrode;

eleetrieally connecting the second electrode to a second

terminal;

disposing one ormore porous separators between adjaeent

eleetrodes; and

containing within a package the electrodes, the one or

more separator and an electrolyte, whereby the terminals

extend from the paekage to allow external electrical connection to the respective electrodes.

10

Aeeording to a twenty fifth aspeet of the invention there

is provided a multiple eharge storage deviee ineluding:

a first sheet eleetrode being eleetrieally connected to a

first terminal and inclnding a first coating on one side thereof

and a second coating on the other side thereof, the first

coating being of a first predetermined thiekness and the

seeond eoating being of a second predetermined thiekness;

a second sheet eleetrode being eleetrieally connected to a

second terminal and disposed adjaeent to the one side ofthe

first electrode, wherein the seeond electrode ineludes a third

coating on one side thereof of a third predetermined thiekness, the third coating being opposed to the first coating;

a third electrode being eleetrieally connected to the seeond terminal and disposed adjaeent to the other side ofthe

first electrode, wherein the third electrode includes a fourth

coating on one side thereof a fourth predetermined thiekness, the fourth coating being opposed to the seeond coating;

one or more porous separators disposed between adjaeent

eleetrodes; and

a package for containing the eleetrodes, the one or more

separators and an electrolyte, whereby the terminals extend

from the paekage to allow external electrical connection to

the respective electrodes.

Aeeording to a twenty sixth aspeet ofthe invention there

is provided a method of manufacturing a multiple charge

storage device, the method including the steps of:

providing a first sheet eleetrode;

eleetrieally connecting the first electrode to a first terminal;

applying a first coating to one side of the first electrode

and a second coating to the other side, the first coating being

of a first predetermined thiekness and the seeond coating

being of a second predetermined thiekness;

applying a third coating on one side of a second electrode,

the third coating being of a third predetermined thiekness;

disposing the seeond sheet eleetrode adjaeent to the first

electrode sueh that the third coating is opposed to the first

coating;

electrically connecting the second electrode to a second

terminal;

applying a fourth coating of a fourth predetermined

thiekness to a third electrode;

disposing the third electrode adjaeent to the first electrode

sueh that the fourth coating is opposed to the seeond coating;

electrically connecting the third electrode to the seeond

terminal;

disposing one ormore porous separators between adjaeent

eleetrodes; and

containing within a package the electrodes, the one or

more separators and an electrolyte, whereby the terminals

extend from the paekage to allow external electrical connection to the respective electrodes.

Aeeording to a twenty seventh aspeet of the invention

there is provided eleetrodes for use in a supercapacitor, the

electrodes including:

a substrate; and

carbon particles mixed with a suspension of protonated

earboxy-methyl-eellulose eoated on the substrate.

Aeeording to a twenty eighth aspeet ofthe invention there

is provided a supercapacitor including:

at least one pair of electrodes having a mixture of carbon

particles and a suspension of protonated earboxy-methyleellulose eoated on facing surfaces ofthe at least one pair of

electrodes;

a separator positioned between said facing surfaees of

said at least one pair of electrodes; and

an electrolyte wetting the separator.

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According to a twenty ninth aspect ofthe invention there

is provided a charge storage device including:

a first electrode having a first layer formed from a

11011-foamed earbon;

a second electrode having a second layer formed from a

11011-foamed earbon, the seeond layer being opposed to and

spaced apart from the first layer;

a porous separator disposed between the eleetrodes;

a sealed paekage for containing the electrodes, the separator and an electrolyte in whieh the eleetrodes are

immersed; and

a first terminal and a second terminal being eleetrieally

connected to the first electrode and the seeond electrode

respeetively and both extending from the paekage to allow

external electrical connection to the respective electrodes,

wherein the surfaee area ofthe earbon used to form the first

and second layers is greater than 20 m^/gram.

According to a thirtieth aspect of the invention there is

provided a method of manufacturing a charge storage

device, the method including the steps of:

coating a first electrode with a first layer formed from a

non-foamed carbon;

coating a second electrode with a second layer formed

from a non-foamed earbon;

opposing the first and second layers in a spaced apart

configuration;

disposing a porous separator between the eleetrodes;

eolleetively eontaining the eleetrodes, the separator and

an electrolyte in whieh the eleetrodes are immersed in a

sealed paekage; and

electrically connecting a first terminal and a second

terminal to the first electrode and the seeond electrode

respeetively sueh that the eleetrodes both extend from the

paekage to allow electrical connection to the respeetive

eleetrodes, wherein the surfaee area of the earbon nsed to

form the first and second layers is greater than 20 m^/gram.

According to a thirty first aspect of the invention there is

provided a charge storage device including:

a first electrode having a first substrate and a first carbon

layer supported by the substrate, the layer being formed

from a carbon having a surface area of at least about 400

m^/gram;

a second electrode having a second substrate and a second

carbon layer supported by the seeond substrate, the seeond

layer being formed from a carbon having a surface area of

at least about 400 m^/gram, the seeond layer being opposed

to and spaced apart from the first layer;

a porous separator disposed between the eleetrodes;

a sealed paekage for containing the electrodes, the separator and an electrolyte in whieh the eleetrodes are

immersed; and

a first terminal and a second terminal being eleetrieally

connected to the first electrode and the seeond electrode

respeetively and both extending from the paekage to allow

external electrical connection to the respective electrodes,

wherein the gravimetrie power maximum of the deviee is

greater than about 4.8 Watts/gram.

Preferably, the surfaee area ofthe earbon is at least 1200

m^/gram. More preferably, at least one ofthe layers contains

more than one type of carbon.

According to a thirty second aspect ofthe invention there

is provided a method of manufacturing a charge storage

device, the method including the steps of:

providing a first electrode having a first substrate and a

first carbon layer supported by the substrate, the first carbon

layer being formed from a carbon having a surface area of

at least about 400 m^/gram;

12

providing a second electrode having a second substrate

and a second carbon layer supported by the seeond substrate,

the seeond layer being formed from a carbon having a

surface area of at least about 400 m^/gram, the seeond layer

being opposed to and spaced apart from the first layer;

disposing a porous separator by the eleetrodes;

eontaining the eleetrodes, the separator and an electrolyte

in whieh the eleetrodes are immersed in a sealed paekage;

and

electrically connecting a first terminal and a second

terminal to the first electrode and the seeond electrode

respeetively sueh that both the terminals extending from the

paekage to allow external electrical connection to the

respective electrodes, wherein the gravimetrie power maximum of the deviee is greater than about 4.8 Watts/gram.

Preferably, the surfaee area ofthe earbon is at least 1200 

m^/gram. More preferably, at least one ofthe layers contains

more than one type of carbon.

According to a thirty third aspect ofthe invention there is

provided an energy storage deviee ineluding:

a housing;

a first and a second opposed eleetrodes having respective

first and a second charge storage eapaeities, the eleetrodes

being disposed within the housing and the first charge

storage eapaeity being greater than the seeond charge storage eapaeity;

a separator intermediate the eleetrodes; and

an electrolyte disposed within the housing for transferring

charge with the eleetrodes.

Preferably, the first electrode includes an aluminium sheet

having a first carbon coating on one side thereof and the

seeond electrode ineludes an aluminium sheet having a

second carbon coating on one side thereof wherein the first

and the seeond coatings are opposed. More preferably, the

sheets are substantially dimensionally equivalent and the

eharge storage eapaeities vary due to differences between the

first coating and the second coating. Even more preferably,

the first coating is thicker than the second coating. In other

embodiments, however, the speeifie eapaeitanee ofthe first

coating is greater than that ofthe seeond coating. That is, the

first coating includes a carbon which provides a predetermined eapaeitanee per gram, which is greaterthan that ofthe

earbon included within the second coating. In further

embodiments the diflerenee in eharge storage eapaeities is

due to diflerences in the loading ofthe eoatings, expressed

in milligrams of coating per cm% while in other embodiments it is due to diflerences in active surface area of the

earbon per unit area of electrode.

Preferably, the eharge storage eapaeities are different due

to a difference in surface area of the first and second

electrodes.

In a preferred form the ratio of the first charge storage

eapaeity and the seeond charge storage eapaeity is in the

range of about 9:7 to 2:1. More preferably, the ratio is in the

range of about 5:3 to 2:1.

In a preferred from the difierenee in the first and second

charge storage eapaeities is due to the seeond electrode

ineluding a filler material. In some embodiments this filler

material is a lower surface area carbon, while in other

embodiments use is made of metal fibres or carbon nanotubes. More preferably, the filler material is conductive.

Even more preferably, the first and the second electrodes ore

of about the same nominal thickness notwithstanding the

inelusion of the filler material.

According to a thirty fourth aspect ofthe invention there

is provided a method ofproducing an energy storage deviee

having a housing, the method including the steps of:

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disposing within the honsing a first and a second opposed

electrodes having respective first and a second charge storage eapaeities wherein the first charge storage eapaeity

being greater the seeond charge storage capacity;

disposing a separator intermediate the eleetrodes; and

providing an electrolyte within the housing for transferring charge with the eleetrodes.

Preferably, the first electrode includes an aluminium sheet

having a first carhon coating on one side thereof and the

seeond electrode ineludes an aluminium sheet having a

second carbon coating on one side thereof wherein the

method includes the further step ofopposing the first and the

seeond coatings. More preferably, the sheets are substantially dimensionally equivalent and the method include the

further step of providing differences between the first coating and the second coating to provide the variation in the

eharge storage eapaeities. Even more preferably, the first

coating is thicker than the second coating. In other embodiments, however, the speeifie eapaeitanee ofthe first coating

is greater than that of the seeond coating.

According to a thirty fifth aspect ofthe invention there is

provided a charge storage device including:

a housing;

a first sheet eleetrode disposed within the housing;

a second sheet eleetrode disposed within the housing

adjacent to and opposed with the first sheet eleetrode;

a separator for enveloping substantially all of the first

electrode and for maintaining the electrodes in a spaced

apart configuration;

an electrolyte disposed intermediate the eleetrodes; and

two terminals extending from the respeetive eleetrodes

and terminating outside the housing for allowing external

electrical connection to the electrodes.

Preferably, the separator includes two opposed separator

sheets whieh are eonneeted along at least one eommon edge

and the first electrode is disposed between the separator

sheets. More preferably, the separator sheets are integrally

formed. Even more preferably, the separator sheets are

integrally formed along the eommon edge.

Preferably also, each separator sheet includes a first edge

and a second edge spaeed apart from the first, both ofwhich

extend away from the eommon edge. More preferably, each

separator sheet also includes a third edge which extends

between the first edge and the second edge, wherein the first

edges are opposed and joined together and the seeond edges

are opposed and joined together. Even more preferably, the

third edges are opposed.

In a preferred form, the first electrode ineludes a first

sub-sheet and a second sub-sheet whieh is opposed to the

first. More preferably, the first and the seeond sub-sheets are

opposed. Even more preferably, each ofthe first and second

sub-sheets are joined along a common edge. Preferably also,

the eommon edge between the first and second sub-sheets is

disposed adjaeent to the eommon edge between two opposed

separator sheets.

Aeeording to a thirty sixth aspect ofthe invention there is

provided a method of constructing a charge storage device

having a housing, the method including the steps of:

disposing at least two opposed sheet eleetrodes within the

housing;

enveloping substantially all of a first one ofthe eleetrodes

with a separator for maintaining the eleetrodes in a spaced

apart configuration;

disposing an electrolyte intermediate the eleetrodes; and

providing two terminals extending from the respeetive

eleetrodes and terminating outside the housing for allowing

external electrical connection to the electrodes.

14

Preferably, the separator includes two opposed separator

sheets eonneeted along at least one eommon edge and the

method includes the further step of disposing the first

electrode between the separator sheets. More preferably, the

separator sheets are integrally formed. Even more preferably, the separator sheets are integrally formed along the

eommon edge.

Preferably also, each separator sheet includes a first edge

and a second edge spaeed apart from the first, both ofwhich

extend away from the eommon edge. More preferably, each

separator sheet also includes a third edge which extends

between the first edge and the second edge, wherein the

method includes the further step ofjoining together the first

edges and joining together the seeond edges. Even more

preferably, the third edges are opposed.

Aeeording to a thirty seventh aspeet ofthe invention there

is provided a charge storage deviee ineluding:

two opposed eleetrodes having respective eoatings of

carbon particles, the particles having a predetermined nominal diameter and the eoatings having of a thickness greater

than but in the order of the nominal diameter;

a porous separator disposed between the eleetrodes;

a sealed paekage for containing the electrodes, the separator and an electrolyte in whieh the eleetrodes are

immersed; and

a first terminal and a second terminal being eleetrieally

connected to the first electrode and the seeond electrode

respeetively and both extending from the paekage to allow

external electrical connection to the respective electrodes.

Preferably, the predetermined nominal diameter is less

than about 8 microns and the eoating thickness is less than

100 microns. More preferably, the predetermined nominal

diameter is less than about 6 microns and the eoating

thickness is less than about 36 microns. Even more preferably, the predetermined nominal diameter is less than about

2 micron and the eoating thickness is less than about 6

microns.

According to a thirty eighth aspeet ofthe invention there

is provided a method of manufacturing a charge storage

device, the method including the steps of:

opposing two electrodes having respective eoatings of

carbon particles, the particles having a predetermined nominal diameter and the eoatings having of a thickness greater

than but in the order of the nominal diameter;

disposing a porous separator between the eleetrodes;

eontaining in a sealed paekage the eleetrodes, the separator and an electrolyte in whieh the eleetrodes are

immersed; and

electrically connecting a first terminal and a second

terminal to the first electrode and the seeond electrode

respeetively for extending from the paekage to allow external electrical connection to the respective electrodes.

Unless the eontext elearly requires otherwise, throughout

the deseription and the elaims, the words 'comprise', 'comprising', and the like are to be eonstmed in an inclusive

sense as opposed to an exclusive or exhaustive sense; that is

to say, in the sense of '*including, but not limited to".

Additionally, the words 'includes', 'including' and the like

are used interchangeably with the words 'comprise', 'eomprising', and the like.

BRIEF DESCRIPTION OE THE DRAWINGS

FIG. 1 is a perspective view of a charge storage device

according to the invention in the form of a supercapacitor.

FIG. 2 is a schematic view of an electrode eonfiguration

according to a first embodiment of the invention;

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FIG. 3 is a schematic side view of a sheet electrode;

FIG. 4 is a schematic plan view of a charge storage device

according to another aspect of the invention ntilising an

interleaved plurality of the sheet eleetrodes of FIG. 3;

FIG. 5 is a schematic front view of an alternative super- 5

capacitor according to the invention;

FIG. 6 is a schematic left hand side view of the supereapacitor of FIG. 5;

FIG. 7 is a schematic right hand side view ofthe supereapaeitor of FIG. 5; lo

FIG. 8 is a schematic front view of a further alternative

supereapaeitor according to the invention;

FIG. 9 is a schematic side view of the supereapaeitor of

FIG. 8;

FIG. 10 is a schematic front view of another supercapaci- 15

tor according to the invention;

FIG. 11 is a schematic side view ofthe supereapaeitor of

FIG. 10;

FIG. IIA is a schematic cross sectional of the supereapaeitor of FIG. 10; 20

FIG. 12 is a graph ofthe gravimetrie FOM versus T for

specific examples of the invention;

FIG. 13 is a graph ofthe volumetrie FOM versus T for

specific examples of the invention;

FIG. 14 is a graph of the gravimetrie power maximum 25

versus time eonstant for the speeifie examples ofthe invention;

FIG. 15 is a graph of the volumetrie power maximum

versus time eonstant for specific examples ofthe invention;

FIG. 16 is a table illustrating the sealahility of the 30

invention;

FIG. 17 is a table illustrating parameters of supercapacitors of the present invention as well as some prior art

supercapacitors;

FIG. 18 is a schematic cross sectional view of a super- 35

capacitor according to another aspect ofthe invention;

FIG. 19 is a schematic cross sectional view of a supercapacitor according to a further aspect of the invention;

FIG. 20 is a Table illustrating further examples of supercapacitors made in aeeordanee with the invention;

FIG. 21 is a schematic cross section of a supereapaeitor

according to one embodiment of the invention;

FIG. 22 is a plan view ofa separator forthe supereapaeitor

of FIG. 21;

FIG. 23 is a schematic plan view of one ofthe eleetrodes 5

of the supereapaeitor of FIG. 21;

FIG. 24 is a schematic perspective view of an electrode

assembly ineluding the separator of FIG. 22 and the eleetrode of FIG. 23; and

FIG. 25 is a schematic perspective view ofthe assembly 50

of FIG. 24 nested within a like eleetrode to that shown in

FIG. 23.

DETAILED DESCRIPTION OF THE

INVENTION 55

According to a first aspect of the invention there is

provided a charge storage deviee ineluding:

a first electrode;

a second electrode being opposed to and spaced apart 60

from the first electrode;

a porous separator disposed between the eleetrodes;

a sealed paekage for containing the electrodes, the separator and an electrolyte in whieh the eleetrodes are

immersed; and 65

a first terminal and a second terminal being eleetrieally

connected to the first electrode and the seeond eleetrode

respeetively and both extending from the paekage to allow

external electrical connection to the respective electrodes,

wherein the gravimetrie FOM ofthe deviee is greater than

about 2.1 Watts/gram.

It will be appreeiated that the gravimetrie FOM is a figure

of merit more appropriate for use with energy storage

deviees intended for pulse power applications. That is, such

applications are by necessity frequency dependent and, as

such, the ealeulation of the figure of merit involves first

identifying the frequeney f at which the impedanee ofthe

storage deviee reaehes a 45° phase angle. A reeiproeal of

f then provides a characteristic response time T for the

storage deviee. The value of the imaginary part of the

impedanee Z" at f is used to calculate the energy E that the

device is able to provide at that frequency. More partieularly:

E = C P

where C=-f/(2 f Z") and V is the rated voltage of the

device. The gravimetric figure ofmerit is then ealeulated by

dividing E by the mass of the deviee and by T〇. That is,

gravimetric FOM=£ /(m. 7")

The gravimetrie figure of merit has been suggested by

John R. Miller in a paper entitled "Pulse Power Performance

of Eleetroehemieal Capacitors: Technical Status of Present

Commereial Devices'' for the "8th International Seminar on

Double Layer Capacitors and Similar Energy Storage

Deviees'', Deerfield Beaeh, Fla., Dec. 7-9, 1998. The teachings of and disclosure within that paper are ineorporated

herein by way of cross reference.

Also detailed in the Miller paper is the ealeulation of a

volumetric figure ofmerit (volumetric FOM) whieh is based

upon E divided by both ! and the volume of the deviee.

The volumetrie FOM is expressed in terms of Watts/em^.

These figures ofmerit provide a diflerent characterisation

of storage deviees whieh is more in keeping with the

frequeney dependent nature of pulse power and other such

applieations to which the devices are being applied. It should

also be noted that the perfbrmanee ofthe deviees ean not be

adequately explained by the hitherto utilised simple RC

model. Sueh simple models do not account for the frequeney

dependent nature of either pulsed or high power applications, whereas the FOM used to characterise the present

invention is a parameter directly relevant to such applications.

Preferably, the first electrode ineludes a first substrate and

a first carbon layer supported by the substrate, and the

seeond electrode ineludes a second substrate and a second

carbon layer supported by the seeond substrate, wherein the

first and second carbon layers are opposed and include a

surface area of at least 400 m^/gram and the gravimetrie

FOM of the deviee is greater than about 1 Watts/gram.

It will be appreeiated that measurements herein ofsurface

area that are expressed in m^/gram are obtained from Nitrogen BET teehniques.

More preferably, the surfaee area ofthe earbon layers are

at least 1200 m^/gram. Even more preferably, at least one of

the earbon layers contains more than one type of carbon.

Even more preferably, the earbon layers are a mixture of

particles of high surface area carbon and highly conductive

carbon in a ratio of about 2.5:1 combined with a suspension

of protonated earboxy methyl eellulose (CMC). It will be

appreeiated, however, that other embodiments make use of

other binders. For example, another such binder is sodium

CMC.

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17

Referring now to FIG. 1, there is illustrated one embodiment of an energy storage deviee aeeording to the invention

in the form of a supercapacitor 1. Supercapacitor 1 is

packaged in a cylindrical housing 2 which extends axially

between a first end 3 and a second spaced apart end 4. In

other embodiments differently eonfignred housing are used.

The housing has a cylindrical sidewall 6 and, disposed

adjaeent to respective ends 3 and 4, a circular top 7 and base

8. All adjacent edges of the base, sidewall and top are

sealingly engaged. In this embodiment housing 2 is formed

from metal and top 7 and base 8 are sealingly adhered to

sidewall 6.

Top 7 includes two diametrically spaced apart ports 9 and

10 for sealingly receiving respeetive terminals 11 and 12.

The terminals extend from within housing 2 where they are

eleetrieally connected to respective ones or sets ofelectrodes

of supercapacitor 1. Although a large number of possible

eleetrodes are used in various embodiments ofthe invention,

the most preferred will be diseussed more detail below.

Terminals 11 and 12 are sealingly retained within the

respeetive ports by rubber seals 13 and 14.

A first preferred eleetrode eonfiguration is illustrated in

FIG. 2. More partieularly, in this embodiment, supereapaeitor 1 includes a plurality of first sheet eleetrodes 21 having

respective first tabs 22 extending therefrom. A plurality of

like seeond sheet eleetrodes 23 are alternated with eleetrodes

21 and have respeetive seeond tabs 24 extending therefrom.

A plurality of porous sheet separators 25 is disposed

between the adjaeent eleetrodes. As deseribed with referenee

to FIG. 1, housing 2 contains electrodes 21 and 23, separators 25 and an electrolyte (not shown). Tabs 22 are eleetrieally connected to terminal 11 and tabs 24 are eleetrieally

connected to terminal 12 to allow external electrical connection to the respective electrodes.

It will be appreeiated that although in FIG. 2 there are

illustrated two electrodes 21 and two electrodes 23, the

aetual embodiment ineludes a far greater number of such

sheet electrodes whieh are all interconnected to provide a

predetermined eapaeitanee. The invention, in this form, is

particularly advantageous in that the modular unit of capacitance one eleetrode 21, one eleetrode 23 and an intermediate separator 25— easily mass produced and combined

with a plurality of like units to provide the neeessary

capacitance for a particular application. Accordingly, a

supercapacitor having specific performance characteristics

is able to be produced easily and in small numbers at a unit

cost not dissimilar to that of a large run. In some embodiments a different size housing is required. The relative eost

of the housing, however, is not substantive.

Tabs 22 and 24 include respeetive eentrally disposed

apertures 27 and 28. These apertures reeeive respeetive

eonduetive rods 29 and 30 for electrically interconnecting

like tabs. The rods are, in turn, electrically connected within

housing 2 to respective electrodes 11 and 12.

In some embodiments two adjacent electrodes 21 and 23

are folded together to reduce one dimension of the eleetrodes. This is partieularly advantageous in circumstances

where the packaging requirements are very specific,

although a known capacitance is required.

In another embodiment, a similar eflect is achieved

through use oftwo or more sheet eleetrodes, and one ormore

intermediate separators, which are wound together in a

spiral. The two sheet eleetrode are longitudinally elongate

and transversely offset sueh that their opposed edges define

the respeetive tabs. In this embodiment, the length of the

sheet eleetrodes is tailored for the speeifie eapaeitanee

requirements. The manufaeture of a supercapacitor of this

18

kind will now be deseribed in more detail. In other embodiments, sueh as that described with reference to FIG. 1, a

similar preparation and coating technique is used. However,

as will be appreeiated by the skilled addressee, the sheet

eleetrodes of FIG. 1 are staeked rather than wound.

The supereapaeitor is ofthe double layer type and, for the

spiral wound configuration, one preforred embodiment

makes use of aluminium sheet eleetrodes that are 2500 mm

long and 85 mm wide. The first step is the preparation ofthe

eoating mixture that contains:

high surface area carbon;

conductive carbon;

binder;

a surfactant; and

water.

Although the coating process makes use of a wire-bar

technique it will be appreeiated by those skilled in the art

that other suitable teehniques sueh as reverse roll, doctor

blade or the like are also available.

Immediately after the eoating procedure is finished, the

electrode spools are plaeed in an oven to remove any

remaining water and to cure the binder. This also prevents

eorrosion ofthe aluminium. The oven temperature is maintained in the range of 110° C. to 140° C. and preferably

under a fan forced nitrogen atmosphere. The latter is to

minimise oxidation. The euring time is at least 5 hours,

although in some eireumstanees it is left longer, such as

twelve hours, without any detriment. Prior to removing the

eleetrodes, the oven should be allowed to cool to room

temperature to minimise oxidation.

It is more eonvenient to coat the full width of the

aluminium foil electrode and then slit to the desired width

ratherthan coat narrow widths offoil. In some embodiments

an uncoated edge is utilised and the earbon layer is applied

aeeordingly.

Although the sheet eleetrode has only been eoated on one

side, in other embodiments it ineludes a coating on both

sides. However, in other embodiments, rather than coating

both sides, two sheets with a single sided eoating are plaeed

in a back to back configuration to define a double sided

eleetrode. That is, the foil electrodes are adhered or otherwise seeure together such that the respeetive earbon layer

are outwardly facing and opposed to the earbon layers on

adjacent electrodes.

An offset is required between the two electrodes so that

each end connection will only make eontaet with one

eleetrode.

In embodiments where the terminal is formed by spraying

with aluminium, a flat edge is used to bend the opposed free

edges of each electrode over at 90°. This stops penetration

of aluminium spray used in the formation of the terminal.

This bending is eonveniently performed using the flat end of

a 20 cm spatula while the element is turning. In preforred

embodiments approximately 1 to 2 mm of the edge of the

eleetrodes are bent over. When looking at the element down

the long axis, no gaps between eleetrodes should be visible.

A more detailed deseription of the aluminium spraying

process is found in eo-pending PCT applieation number

PCT/AU98/00406 the details of which are incorporated

herein by way of cross reference.

Briefly, however, it will be noted that the aluminium metal

spray is used to make eleetrieal cormection with the windings. Beeause of the very high temperature of the flame a

steady movement ofthe gun aeross the elements used, with

no more than about 1 to 2 seconds on each element at a

distance of about 20 cm from the tip of the gun. This

movement is repeated three times before the elements are

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turned and the remaining side sprayed. This proeess is

repeated as often as required until an nnintermpted alnmininm surface is produced, interspersed with cooling periods if the elements are hot to touch. It will he appreeiated

that the eertain separators have a low softening temperature

and will shrink in the eross direetion above that temperature.

Onee enough aluminium is huih up, the ends are ground

until a smooth flat area is obtained suffieient for the terminals to be attaehed. As a large amount of heat is generated

during grinding care is taken not to overheat the eapaeitor.

This flat area need not be as large as the whole end but is

different for each end. The bottom end, that is the end

intended to be disposed furthest from top 7, is provided with

an electrode which is welded with a flat tab that radially

extends from the eore. Aeeordingly, the flat area that is at

least 10 mm wide and which has a smooth surface is needed

from the eore to the edge. The top end terminal is welded

tangentially midway between the eore and the edge and so

requires about one third or one half ofthe end to be smooth.

Laser welding ofthe terminal tabs is then undertaken. The

equipment was a Lasag Nd:YAG laser rated at 500 W

continuous. At least two 8 mm rows of welds ~3 mm apart

were produeed on each tab. The beam is moved at about 140

mm/min, and pulsed at 10 Hz with an energy of 29.5

Joules/pulse.

Prior to the final placing of the now formed eapaeitor

element into the paekage, which is in the form of a metal

can. Teflon insulators are plaeed between the terminals and

the top sprayed aluminium face to stop the terminal from the

bottom touching the top face and producing a short circuit.

This insulator is a 1 mm thick Teflon disk with a 3 mm hole

punehed in the eenter with a radial slit from this hole to the

edge. This hole loeatos the insulator on the eenter terminal

and prevents this terminal from touching the aluminium end

connection. A circular disk of Teflon is also placed in the

package to insulate the bottom ofthe element from the ean.

In most cases, polypropylene foam is disposed in the base of

the ean to hold the element in plaee. In other embodiments,

however, use is made of a formed plastie locater.

Once the eapaeitive element is in the ean, a final drying

step is earned out to remove any moisture. This is earned out

in a vacuum oven at a maximum temperature of 80° C. This

low temperature avoids softening of the separator. The low

temperature drying is carried out for about 12 hours using a

rotary vacuum pump, capable of producing a vacuum of

better than 150 Pa.

Electrolyte is then added to the ean so that the eapaeitive

element, exeluding the upwardly extending terminals, are

eompletely eovered. The pressure in the oven is gradually

reduced to about 53 Pa such that air trapped in the carbon

pores is removed. When the initial degassing has subsided,

the vaeuum is increased to 8 Pa. This process is facilitated

by warming the oven to 60° C. After about 30 minutes

degassing should have substantially stopped and the oven is

brought to atmospheric pressure with nitrogen. Thereafter

the eapaeitors are removed from the oven. More eleetrolyte

is added and the proeess repeated until no more eleetrolyte

is taken up. It is usual for 2 or 3 cycles to be eompleted.

Finally, any excess eleetrolyte is removed.

The eapaeitor is then eompleted by mounting the top on

the terminals. In this embodiment the top is made of

Bakelite, although in other embodiments other materials are

used. The top edge ofthe ean is curled over the periphery of

the top using a sealing tool in a small drill press at ~100 rpm.

Preferably, two types of carbon are used in the eapaeitor.

First, a high surface area or active carbon and, secondly, a

carbon such as a conductive carbon black.

20

The electrodes are preferably aluminium foil.

The eleetrolyte, in this embodiment, eonsists of a 1.0 M

solution of tetraethylammonium tetrafluoroborate

(TEATFB) dissolved in propylene earbonate (PC). That is,

217 grams ofTEATFB in 1 litre of solution. The amount of

water in the eleetrolyte is kept to an absolute minimum and

preferably less than 50 ppm. Accordingly, anhydrous PC is

used, such as that produced by SigmaAldrich. Moreover, the

TEATFB is exhaustively dried prior to use. This drying is

achieved by vaeuum oven drying at 160° C. for about six

hours or such time that is sufficient to adequately reduee the

moisture eontent.

The TEATFB is slow to dissolve, and at roomtemperature

it is not unusual to allow 24 hours for it to fully dissolve. The

present preferred method, however, reduces this time by

warming the solution to 50° C. To keep the moisture eontent

low, the preparation of electrolyte is performed inside a dry

nitrogen glove box.

The separator has desirable porosity, strength and thinness

for use in the present invention.

An alternative embodiment ofthe invention is illustrated

in FIG. 3 and FIG. 4. In this embodiment, the basie capacitive unit includes of two like sheet eleetrodes 35 and 36

which, as best shown in FIG. 4, are folded together. Each

sheet eleetrode is reetangular and includes four adjacent

edges 37, 38, 39 and 4 . Extending outwardly from edge 40

are two symmetrically spaced apart tabs 41 and 42 having

respective apertures 43 and 44. These tabs function similarly

to tabs 22 and 24 of FIG. 2 in that they are eonneeted

together with a plurality of like tabs and collectively electrical joined to a terminal 11 or 12 of capacitor 1.

In use, each of electrodes 35 and 36 are eentrally folded

about an axis 45 which is parallel to edges 37 and 39. As

shown in FIG. 4, each electrode is interleaved with the other

such that edge 39 of each electrode lies adjaeent to axis 45

ofthe other electrode. Also included between each adjacent

portion of the eleetrodes is a porous separator 46. It will be

appreeiated that the FIG. 4 illustration is schematically

represented to assist an understanding ofthe eonfiguration of

this embodiment. In praetiee the adjaeent eleetrodes and

separators are immediately adjaeent eaeh other rather than

the spaeed apart configuration shown in FIG. 4.

Electrodes 35 and 36 include on each side a layer of

activated carbon that is applied as described above. However, as would now be appreeiated by those skilled in the art

the winding step ofthe above method would be substituted

with a folding and then a stacking of a predetermined

plurality of capacitive elements to provide supereapaeitor 1

with the desired eleetrieal characteristics.

Where use is made of a plurality of capacitive elements,

a porous separator is disposed between adjaeent elements to

prevent eleetrieal shorting.

In some embodiments eleetrodes 35 and 36 are initially

coextensively abutted with a separator and then folded

together.

In other embodiments edge 40 of one eleetrode lies

adjaeent to edge 38 ofthe other electrode sueh that tabs 41

and 42 extend away from each other. In some sueh embodiments eaeh eleetrode is folded together with the other, and

the intermediate separator, along a plurality of axes, eaeh of

which is parallel and spaced apart from axis 45. In still

further embodiments the eleetrodes are folded along one or

more axes whieh is or are normal to axis 45. In alternative

embodiments eleetrodes 35 and 36 are folded along at least

one axis parallel to axis 45 and at least one axis normal to

axis 45.

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To further illustrate the invention and its applications it is

useful to look at the theoretieal and practical underpinnings

ofsupercapacitor development. More partieularly, it will be

appreeiatod that the supereapaeitor of the invention are

eapahle of being used in high power applications. The

characteristics of such supercapacitor dictate the effieieney,

size and mass required for the applieation. For a given mass

or volume and capacitance it is the characteristic of electrical resistance (known as the equivalent series resistanee or

esr) which distinguishes high from low efficiency supercapacitors. That is, for high power applications a low esr is

desired to minimise fosses.

For any capacitor the electrical resistance ean he lowered

by inereasing mass and volume. However, the desired result

is a simultaneous decrease in resistance, mass and volume

while maintaining capacitance.

The factors that contribute to electrical resistance inelude:

the intrinsie eleetrieal conductivity ofthe carbon, for carbon

based supereapaeitors; the interfaeial resistance; the metallie

electrode and connection resistance; and the electrolyte and

separator resistance. Attempts have been made to minimise

these faetors to achieve high efficiency operation.

In a traditional capacitor, the current flow is between two

flat electrodes separated by a dielectric. Although carbon

based capacitors appear to be eonstmeted in a similar

fashion, the material between the metallie eleetrodes is not

the dialeetie, but the high surfaee area carbon, electrolyte

and separator (the aetive materials). The dieleetrie is the

nanometer thin layer ofsolvent at the earbon surface. As the

eurrent flows from the metallie eleetrodes through these

materials, their resistance must be minimised to reduce the

esr of the eapaeitor. This is achieved by reducing the

thickness ofthe active materials, for example by inereasing

the density ofthe earbon coating or using thinner coatings.

Another approach along these lines is to use thinner separators. The reduetion ofthickness also reduces the resistive

component ofthe eleetrolyte by minimising the path through

which the current must flow.

Another means of reducing the resistance of the aetive

materials is to use more eonduetive earbons and electrolytes.

The eombination of more eonduetive aetive materials with

thinner design allows higher powers to be aehieved while

maintaining or reducing the mass and/or volume.

The produet of resistance and capacitance (RC), commonly referred to as the time eonstant, is frequently used to

characterise capacitors. In an ideal capacitor, the time eonstant is frequency independent. However, in carbon based

supercapacitors, both R and C are frequeney dependent. This

arises from the mieroporous eharaeteristies of high surface

area carbons, and the nature ofcharge build up at the electric

double layer on the earbon surface. The traditional method

ofmeasuring R and C for supercapacitors is to use a constant

current charge or discharge and to measure the voltage jump

at the start or finish ofthe eyele, and the rate of change of

voltage during the eyele respeetively. This however effectively provides the R at high frequency and the C at low

frequency. Another more suitable method is to measure the

frequeney response ofthe eomplex impedanee and to model

a simple RC element to the data. This provides an estimate

of R and C across the frequeney range that may or may not

correlate with those measured using eonstant cart techniques. Clearly, the use ofRC time constant as a measure of

capacitor suitability is subject to a large uneertainty. Amore

useful teehnique has recently been proposed in whieh R and

C are measured at the frequeney at which the phase angle of

current and voltage is 45°. The reeiproeal ofthis frequency

is the "response time" and is more elearly defined than other

22

methods. Further, the eapaeitanee at this frequency ean then

be used to calculate the energy and provide a Figure ofMerit

(FOM) when normalised with mass or volume.

The theoretieal maximum power available from any

capacitor is the quotient of the voltage squared over four

times the esr. When normalised to mass or volume this

provides the theoretieal maximum power density in W/kg.

Clearly the maximum power can be inereased by either

decreasing the resistanee (as shown above), increasing the

operating voltage, or both. Increases in operating voltage

ean be aehieved, without any change in the composition of

the supereapaeitor materials, by maximising the voltage

window in which the capacitor operates. In a supereapaeitor

with symmetrical carbon based electrodes, the voltage is

equally distributed aeross both electrodes. During operation,

the maximum capacitor voltage is limited by the breakdown

voltage ofthe weakest eleetrode. A higher operating voltage

ean be aehieved by tailoring the eapaeitanee of each electrode to fully utilise the available voltage window. This is

conveniently aehieved by using different earbon loadings on

each electrode.

Aspeets of the invention described in this specification

allow targeted energy and power densities to be aehieved by

a novel supereapaeitor design and the assoeiated manufacturing process. One result is an extremely thin, high power

capacitor suitable for mobile telecommunication applications. Another is suitable for load-leveling in hybrid electric

vehicle. Specific examples ofthese will be further illustrated

by the following description.

EXAMPLES

Example 1

As sehematieally shown in FIGS. 5 to 7, a supereapaeitor

51 includes a first electrode in the form of a first plurality of

spaced apart rectangular aluminium sheets 52. A second

eleetrode in the form of a second plurality of spaced apart

rectangular aluminium sheets 53 are interleaved with and

opposed to sheets 52. A plurality ofporous separators 54 are

interposed between the adjaeent she 52 and 53. Arectangular

sealed plastie package 55 contains electrodes 52 and 53,

separators 54 and an electrolyte 56 in whieh the eleetrodes

are immersed. In this embodiment the eleetrolyte is aeetonitrile with TEATFB. A rectangular tab 57 and a rectangular

tab 58 are integrally formed with and upwardly end from

respective ones of sheets 52 and 53. Tabs 57 are abutted

together and electrically connected to a terminal 59, while

tabs 58 are abutted together and electrically connected to a

terminal 6 . This electrical connection is affected in this

embodiment with ultrasonie welding. Both terminals 59 and

60 extend from package 55 to allow external electrical

cormection to the respective electrodes.

Eaeh of sheets 52 and 53 have a width of about 70 mm,

a height of about 170 mm and a thickness of about 20

microns. In this particular embodiment use is made of fifty

of each of sheets 52 and 53, in that there are 100 sheets in

total. This provides a total electrode area of 5950 cm~.

As shown in the drawings, sheets 52 and 53 are eaeh

eoated on a single side only with an activated carbon layer

62, as described with reference to the earlier embodiments.

Where appropriate two like sheets are abutted baek to back

to provide outwardly facing activated carbon layers that are

opposed by like earbon layers on the other ofthe sheets. In

this embodiment layer 62 is substantially uniform across tho

sheets and has a thickness of about 36 microns.

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Package 55 has a rectangular prismatic form made from

ABS having external dimensions of about 17 mm hy 110

mm hy 190 mm. Where terminals 59 and 60 extend through

the paekage appropriate sealant 61 is used to prevent egress

of electrolyte 56 from package 55 or, also importantly, the

ingress of air, moisture or other contaminants into package

55.

As will be appreciated by those skilled in the art separator

54 maintains the opposed layers 62 in a spaced apart

configuration to prevent eleetrieal conduction therebetween.

However, separators 52 do allow movement of the ions

within the eleetrolyte between layers 62. In this particular

embodiment separators 54 are folded around back to back

pairs of sheets 53.

Supereapaeitor 51 is rated at 2.5 Volts and provides a

nominal capacitance of 270 Farads. Importantly, however,

the overall weight, ineluding the eleetrolyte and packaging,

is 295 grams. Utilising these figures, in eombination with a

measured T of 1 second provides a gravimetric FOM of 2.2

Watts/gram and a volumetric FOM of 1.6 Watts/cm^.

When utilising the simple RC model the equivalent series

resistanee is about 1 mQ and the RC time eonstant is about

280 ms.

Example 2

Another specific example of a supereapaeitor 71 made in

aeeordanee the invention is schematically illustrated in

FIGS. 8 and 9. In these Figures corresponding features are

denoted by eorresponding referenee numerals.

Each of sheets 52 and 53 have a width of about 40 mm,

a height of about 40 mm and a thickness of about 20

microns. In this particular embodiment use is made offorty

of each of sheets 52 and 53, in that there are eighty sheets

in total. This provides a total electrode area of 640 cm%

In this embodiment layer 62 is again substantially uniform

across the sheets and has a thickness of about 36 microns.

Package 55 has a rectangular prismatic form made from

ABS having external dimensions of about 10 mm by 50 mm

by 50 mm.

Supereapaeitor 71 is rated at 2.5 Volts and provides a

nominal capacitance of 30 Farads. The overall weight,

ineluding the eleetrolyte and packaging, is 25 grams. Utilising these figures, in eombination with a measured T of

0.48 second provides a gravimetric FOM of2.71 Watts/gram

and a volumetric FOM of 2.71 Watts/cm°. When utilising

the simple RC model the equivalent series resistanee is

about 4 m 106 and the RC time eonstant is about 120 ms.

Example 3

Another specific example of a supereapaeitor made in

aeeordanee the invention is ofthe same eonstmetion ofthat

shown in FIGS. 8 and 9. However, in this embodiment use

is made oftwenty of each of sheets 52 and 53, in that there

are forty sheets in total. This provides a total electrode area

of 320 cm%

In this embodiment layer 62 is again substantially uniform

across the sheets and has a thickness of about 12 microns.

Package 55 has a rectangular prismatic form made from

ABS having external dimensions of about 5 mm by 50 mm

by 50 mm.

The supereapaeitor of this example is rated at 2.5 Volts

and provides a nominal capacitance of 10 Farads. The

overall weight, ineluding the eleetrolyte and packaging, is

17 grams. Utilising these figures, in eombination with a

24

measured T of 0.11 seconds provides a gravimetric FOM of

2.64 Watts/gram and a volumetric FOM of 3.00 Watts/cm^.

When utilising the simple RC model the equivalent series

resistanee is about 5 mQ and the RC time eonstant is about

50 ms.

Example 4

There is shown in FIGS. 10, 11 and llA a supereapaeitor

81, where eorresponding features are denoted by eorresponding reference numerals. As with the other examples

deseribed above, use is made of sheet eleetrodes. However,

these sheets are eontained within a package 82 the size of a

credit card or smart card.

Each of sheets 52 and 53 have a width of about 40 mm,

a height of about 65 mm and a thickness of about 20

microns. In this particular embodiment use is made ofthree

of each of sheets 52 and 53, in that there are six sheets in

total. This provides a total electrode area of 78 cm%

Again, layer 62 is substantially uniform across the sheets

and has a thickness of about 12 microns.

Package 55 has a rectangular prismatic form made from

PVC sheets and having external dimensions of about 2 mm

by 54 mm by 86 mm.

Supereapaeitor 81 is rated at 2.5 Volts and provides a

nominal capacitance of 0.3 Farads. The overall weight,

ineluding the eleetrolyte and packaging, is 12 grams. Utilising these figures, in eombination with a measured T of

0.037 seconds provides a gravimetric FOM of 1.27 Watts/

gram and a volumetric FOM of 1.68 Watts/cm% When

utilising the simple RC model the equivalent series resistanee is about 22.5 mQ and the RC time eonstant is about 6.3

ms.

Example 5

A multiple eharge storage deviee in the form of a supercapacitor 90 is schematically illustrated in FIG. 18. Supercapacitor 90 includes a first sheet electrode whieh is eolleetively defined by aluminium sheets 94 and 96. In other

embodiments a single folded sheet is used. It will be

appreeiated by those skilled in the art that a single sheet

eould also be used.

Both sheets 94 and 96 are eleetrieally connected to a first

terminal (not shown). Sheet 94 ineludes a first coating 95 on

one side thereof, while the opposite side ofsheet 96 ineludes

a second coating 97. The first coating is of a first predetermined thiekness and the seeond eoating is of a second

predetermined thiekness whieh is different from the first

thickness. A seeond sheet eleetrode 98 is eleetrieally connected to a second terminal 92 and is disposed adjaeent to

the one side of electrode 94. Also, electrode 98 ineludes a

third coating 199 on one side thereof of a third predetermined thiekness whieh is equal to the first predetermined

thiekness. Coating 199 is opposed to coating 95. A third

electrode 200 is eleetrieally connected to terminal 92 and is

disposed adjaeent to sheet 96. Eleetrode 200 ineludes a

fourth coating 201 on one side thereof which is of a fourth

predetermined thiekness. Moreover, coating 201 is opposed

to coating 97. As with other embodiments, a plurality of

porous separators are disposed between respeetive adjaeent

eleetrodes. Additionally, supereapaeitor 90 includes a package 91 for containing the eleetrodes, the one or more

separators and an electrolyte and through which the terminals extend to allow external electrical connection to the

respective electrodes.

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All the coatings of this emhodiment utilise the same

formulation. The diflering thieknesses, however, provide

supereapaeitor 90 with a multiple time eonstant given that

the two capacitive cells making up the supereapaeitor are in

parallel with eaeh other. In this case, a cells are defined by

the respective opposed and adjacent carbon coatings.

In other embodiments the thieknesses ofthe eoatings are

the same and the formulation ofthe eoating varies between

eells to provide a difference in eapaeitanee. This, in turn,

provides a multiple time eonstant supereapaeitor.

Example 6

An alternative multiple eharge storage deviee in the form

of supereapaeitor 99 is schematically illustrated in FIG. 19.

This supereapaeitor includes a first sheet electrode 100

whieh is eleetrieally connected to a first terminal (not

shown) and which includes a first coating 102 on one side

thereof having a first predetermined thiekness. A seeond

sheet eleetrode 103 is eleetrieally connected to a second

terminal (not shown) and is disposed adjaeent to electrode

100. The seeond electrode ineludes a second coating 106 on

one side thereof having a second predetermined thiekness.

As shown, coating 106 is opposed to coating 102.

A porous separator 54 is disposed between the adjaeent

eleetrodes for maintaining those eleetrodes in a fixed spaeed

apart configuration. Additionally, a package 105 contains the

eleetrodes, the separator and an electrolyte, whereby the

terminals (not shown) extend from the paekage to allow

external electrical connection to the respective electrodes.

This arrangement of a varying carbon thickness across the

separate eleetrodes also provides a multiple time eonstant

supereapaeitor.

For convenience, the electrode pair shown in FIG. 19 is

defined as a cell. In other embodiments, use is made of a

plurality of like eells staeked together and connected in

parallel to provide the desired eapaeitanee. Preferably, also,

the eells are staeked sueh that the thinner end and the thieker

end of one eell are juxtaposed to the respeetive thieker end

and the thinner end of at least one adjaeent eell.

In other embodiments use is made ofconstructions similar

to that of the above examples but with different physieal

parameters to provide different eharaeteristies. Some

examples ofsuch alternative physical parameters and resultant characteristics are shown in the Table of FIG. 17 and

FIG. 2 . For ease ofreferenee, FIG. 12 provides a graphical

representation of the gravimetric FOM versus T for the

examples of the invention listed in FIG. 17, where the

respeetive loeations ofthe supereapaeitors on the referenee

plane are represented by numerals corresponding to the item

number in the Table of FIG. 17. FIG. 13 provides a corresponding representation for the example supereapaeitors

showing volumetric FOM versus T〇.

The supereapaeitor shown as Item 12 in FIG. 17 ineludes

a parallel eombination of pairs of capacitive cells that are

connected in series. Accordingly, the nominal operational

voltage is 5 Volts. In other embodiments more than two

capacitive cells are connected in series to provide a higher

operating voltage.

It is also useful to characterise the capacitors of the

present invention with criteria more eommonly used in the

field. More partieularly, the maximum power available from a supereapaeitor has been ealeulated with the

formula:

% = 4R

26

where V is the maximum operating voltage ofthe eapaeitor

and R is the resistanee determined from the simple RC

model of the eapaeitor.

The Pmax values for the examples in FIG. 17 have been

ealeulated and divided, on the one hand by the mass of the

respeetive deviees to provide a gravimetric and, on the

other hand, by the volume of the respeetive deviees to

provide a volumetric These values have then been

plotted in FIGS. 14 and 15 respectively again time constants.

As particularly illustrated FIGS. 12 to 15 inclusive, the

supereapaeitors described in the examples above provide

extremely advantageous pulse power load characteristics.

That is, a low response time T and time eonstant ensures

good transient response to high frequency loads, as are

eneountered in applieations where switehing or pulsing of

the load occurs. This, in combination with the high gravimetric FOM and * and the high volumetrie FOM and

P provided in the examples, allow the invention to be

applied to a broad range of applications. To illustrate this

point, the supereapaeitor ofExample 1 is intended primarily

for high power automotive applieations to facilitate regenerative breaking and the provision of high torque over short

time periods, and the neeessity for correspondingly high

current loads. The supereapaeitor ofExample 4, however, is

primarily intended to be used in parallel with a mobile

telephone battery.

The graphs of FIGS. 12 to 15 each include two unbroken

lines, whieh extend aeross the upper regions of the ranges

shown. In each case the lines represent the theoretical upper

limit of the various parameters being illustrated for the

examples 3 and 12 shown in FIG. 17. For a given eombination of features and the given formulation of the earbon

coating, there will be a theoretical maximum where the

volume or mass contribution ofthe packaging to the overall

device is small. For other formulations the theoretieal maximum will differ.

With the benefit of the teaehing herein the skilled

addressee would appreciate that the invention is also advantageous in that various parameters ofthe supereapaeitor are

easily tailored to meet the speeifie requirements of any

particular application. That is, the invention is particularly

suited to scaling. By way ofexample, FIG. 16 shows various

calculated characteristics for a number of other embodiments of the invention. This illustrates that for a given

formulation, thinner layers higher provide higher power

densities and figures of merit, as well as lower time eonstants and response times.

It will be understood that the unbroken lines ineluded in

the Figures represent the limit for the two given formulations. However, there are other formulations which provide

an extended range of operability and allow higher figures of

merit and power densities, as well as lower time eonstants,

to be aehieved.

The ealeulations in FIG. 16 are based on the resistanee of

the deviees being eomprised of the resistanee of:

1. the terminals;

2. the aluminium electrodes;

3. the eleetrode/earbon interface;

4. the earbon inter-particle interface;

5. the electrolyte in the earbon layer; and

6. the eleetrolyte in the separator.

The present invention makes use ofthis model to optimise

the various resistances while still providing a high capacitance, high figures of merit, high power densities and a

desired response time.

The gravimetrie FOM is expected to scale as the gravimetric power density, and the volumetrie FOM is expeeted

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to scale as the volumetric power density. These latter quantities are proportional to: V% 1/R and either 1/mass or

lA^lume. Thus, for a given voltage optimised for the

applieation, an increase in FOM eomes through decreasing

R, decreasing mass and decreasing volume. For a given

formulation and given thiekness of coating R is essentially

proportional to the inverse ofthe eleetrode area. Forminimal

packaging mass or volume, the mass and volume are proportional to the eleetrode area. Thus making a "bigger"

device will only marginally increase the FOM due to less

paekaging. Hence, for a given size of device, the resistance

is minimised by decreasing the thickness of the eoating

consistent with the time eonstant or response time desired

for the deviee. The eapaeitanee ofthe deviee is then determined by the seleetion of the mix of carbons and the

formulation of the eoating material.

The inventors also believe that the superior performance

of supercapacitors ofthe present invention is contributed to

by the improved eonduetivity between individual carbon

particles resulting from the use of the mixture of carbon

particles and protonated earboxy methyl eellulose (CMC).

Without wishing to be bound by theory, it is believed that

such improved eonduetivity is the result of a number of

factors such as increased packing density of individual

carbon particles; increased migration of electrolyte into

intra-molecular spaces on the surfaee of the individual

carbon particles; and an overall reduction in the size ofthe

interfaee region between the earbon particles and electrolyte. It is believed that a mixture ofhigh surface area carbon

and highly conductive carbon optimises these effeets.

Further, the relative insolubility of protonated CMC eontributes to an increased overall life ofthe supereapaeitors of

the present invention.

It will be appreeiated that the term "immersed" or like

terms, unless explieitly noted otherwise, when used in

referenee to the disposition ofthe eleetrodes in the eleetrolyte is intended to include not only those supereapaeitors

where an excess of electrolyte is used, but also those where

the quantity of electrolyte is suffieient to only wet the

eleetrodes. That is, the quantity of electrolyte need be

suffieient to allow operation of the supereapaeitor.

It will also be appreeiated that although the above

examples are primarily concerned with discrete eells, the

invention is also applicable to bipolar configurations.

Moreover, it will be appreeiated that the term "organic

eleetrolyte" or like terms refer to an electrolyte in an organic

solvent.

For comparative purposes FIG. 17 provides a Table

showing parameters ofsupereapaeitors ofthe present invention as well as some prior art supereapaeitors.

Referring to FIG. 21, a charge storage device 301 includes

a sealed prismatic housing 302. Two opposed folded reetangular aluminium electrodes 303 and 304 are disposed

within housing 302 and connected to respective metal terminals 305 and 306 for allowing external electrical connection to the electrodes. A SoluporTM sheet separator 307 is

disposed intermediate eleetrodes 303 and 304 for maintaining those eleetrodes in a fixed spaeed apart configuration. An

electrolyte (not shown) is also disposed intermediate the

eleetrodes.

Separator 307 is formed in a "pocket" eonfiguration,

wherein it is folded baek upon itself and the transverse ends

seeured together for providing an opening 308 between the

transverse ends. For ease of illustration, separator 307 is

shown as having two fold lines. In praetiee, however, a

single Ibid line is used as the separator is abutted direetly

28

against the opposed eleetrodes. The porous nature of the

separator allows the movement of ions in the eleetrolyte

between the eleetrodes.

Eaeh electrode is formed from a single like aluminium

sheet having at least one tab 309 which is eleetrieally

engaged with the respeetive terminals 305 and 306. The

eleetrodes are folded into the overlapping and nested eonfiguration shown in the drawing. Again, it will be appreeiated that for ease ofillustration electrode 304 is shown with

two fold lines. In praetiee, however, a single fold is made as

this electrode is abutted direetly against separator 307.

Electrode 303 is reeeived within opening 308 and enveloped by separator 307 such that only tab 309 extends from

the "pocket" or pouch. This electrode and separator combination is then inserted into the folded eleetrode 304 to

complete a single eapaeitive cell. While in this embodiment

only a single eell is illustrated, in other embodiments use is

made of two or more sueh eells. The eleetrode area of the

eleetrodes is about 102 cm^ which provides a nominal

capacitance of about 28 Farads at 2.5 Volts.

Each of electrodes 303 and 304 includes a high surface

area coating 310 of activated carbon. This coating is of a

predetermined thiekness and includes a binder to facilitate

intimate engagement between the carbon and the eleetrodes.

As terminals 305 and 306 extend from the inside to the

outside of housing 302 they are sealingly engaged intermediate their respective ends with the housing. In this embodiment the sealing engagement is efleeted by two rubber

grommets 311 and 312. In other embodiments use is made

of grommets eonstmeted from other materials or combinations of materials. For example, some deviees make use of

silicon sealing compounds and adhesives.

Eleetrode 303 and 304 will now be deseribed in more

detail with reference to FIGS. 22 to 24. More partieularly,

and as best shown in FIG. 23, electrode 303 is substantially

rectangular and includes two rectangular sub-sheets 315 and

316. fhe sub-sheets are integrally formed and symmetrical

about a fold line 317 which defines a common edge 318.

Sheets 315 and 316 include respeetive integrally formed

reetangular sub-tabs 319 and 320 which, as shown in FIG.

24, abut to collectively define tab 309.

Sheet 315 includes two spaced apart and parallel edges

321 and 322 which extend away normally from edge 318. A

further edge 323 extends between edges 321 and 322. As

also shown in FIG. 23, tab 319 extends from away from edge

323 adjaeent to where that edge meets with edge 322.

Similarly, sheet 316 ineludes two spaced apart and parallel

edges 325 and 326 which extend away normally from edge

318. A further edge 327 extends between edges 325 and 326.

Similarly also, tab 320 extends from away from edge 327

adjaeent to where that edge meets with edge 326.

Eleetrode 303 is eoated on one side only with the aetivated carbon and then folded about line 317 sueh that the

eoated side is outwardly facing, as shown in FIG. 21.

Electrode 304 is the same as electrode 303 only that it is

interleaved in the opposite sense so that the respeetive tabs

309 are spaeed apart. This wifi be deseribed in further detail

below. For convenience, corresponding features ofthe eleetrodes wifi be designated with eorresponding referenee

numerals.

Separator 307 is shown, not to scale, in plan in FIG. 22

and includes two rectangular sub-sheets 331 and 332 which

are integrally formed along a common edge 333. This edge

also defines a fold line 334. Sheet 331 also includes two

spaced apart and parallel edges 335 and 336 which extend

away normally from edge 333. A free edge 337 extends

between edges 335 and 336. Similarly, sheet 332 ineludes

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two spaced apart and parallel edges 339 and 340 which

extend away normally from edge 333. A free edge 341

extends between edges 339 and 34 .

During mannfactnre, electrode 303 is folded about line

317 sueh that the eoated sides of sheets 315 and 316 are

opposed and outwardly facing. Additionally, tabs 319 and

320 are abutted. Separately, separator 307 is folded about

line 334 sueh that edges 335 and 339 are parallel and abutted

together, edges 336 and 340 are parallel abutted together and

edges 337 and 341 are parallel and adjacent to one another.

Thereafter, edges 335 and 339 are joined together and edges

336 and 340 are joined together. In some embodiments this

is aehieved with adhesive, while in other embodiments heat

welding or other heat treatment is utilised. In still further

embodiments the edges are not joined.

As best illustrated in FIG. 24, eleetrode 303 is then nested

within the "pouch" or "pocket" formed by separator 307. As

shown, the separator envelopes substantially all of electrode

303 and, as will be deseribed below, maintains electrodes

303 and 304 in a spaced apart configuration. Tab 309 extends

outwardly beyond adjacent edges 337 and 341 to allow its

electrical connection to terminal 305. For ease of illustration, in FIG. 24 the separator 307 is shown with edges 336

and 340 joined by way ofheat welding, while edges 335 and

339 are adjaeent, although not yet joined.

Eleetrode 304 is then formed by folding a like eoated

sheet to that which forms electrode 303. More partieularly,

the fold is made along fold line 318 sueh that that the eoated

sides ofsheets 315 and 316 are opposed sad inwardly facing.

Additionally, tabs 319 and 320 are adjacent to each other and

opposed. The assembly of FIG. 24 is then nested within

eleetrode 304, as best illustrated in FIG. 25, sueh that the

respeetive tabs 309 of the eleetrodes are spaeed apart. Tabs

319 and 320 of electrode 304 are then abutted and secured

to terminal 306 to allow external electrical connection with

the electrode.

The eleetrode assembly of FIG. 25 is referred to as s

single eell and, as would be appreeiated by a skilled

addressee from the teaehing herein, a plurality of the eells

are able to be eonneeted in parallel to proportionally

increase the capacitance of supercapacitor 301. In other

embodiments, a plurality of the eells are staeked in parallel

sueh that the respeetive tabs 309 for like eleetrodes 303 and

304 form two spaced apart stacks of like tabs. The tabs in

each staek are then elamped together and the stacks eleetrieally connected to respective terminals 305 and 306.

The preferred embodiments of the invention use a nonaqueous electrolyte to achieve high energy densities. Surprisingly, however, they are also able to achieve high power

densities and FOM's in spite ofthe eonventional wisdom to

the eontrary for this type of electrolyte. This result is

aehieved in the preferred embodiments through a concerted

effort to reduce the overall resistance ofthe supereapaeitor.

The use of the following foatures contribute to this result:

a thin highly porous separator to minimise the length of

the eurrent path, and hence the resistanee, offered by

the eleetrolyte;

thin layers of high surface area carbon (less than about

100 microns thick) for providing a short current path

through the earbon to the aluminium electrode while

still providing a high capacitance per unit volume;

a blend of carbons including conductive carbon black for

improving the eonduetivity of the earbon layer; and

an electrolyte including a high concentration ofsalt (in the

order of 1.0 Molar).

In some embodiments the thiekness of each carbon coating, including the binder, is less than 100 microns. For the

30

examples shown in FIGS. 17 and 20 the respeetive earbon

coating thicknesses are specified. With the exception ofthe

6 mieron eoating, the earbon particle diameter is a nominal

6 to 8 microns. However, for the 6 mieron coating use is

made of similar size partieles that are ground to a nominal

diameter of 2 microns. In embodiments where use is made

ofsmaller nominal diameter carbons, the coatings are thinner again.

The eonventional wisdom has been to utilise relatively

thiek earbon coatings to provide a greater capacitance per

unit volume. Such coatings are in the order of about 150

microns or greater. However, it has been diseovered that

thinner coatings, as used in the deseribed embodiments,

allows a reduced esr as the length ofthe eurrent path through

the earbon coating is small. The thin eoatings also have a

positive eontribution to a high FOM's as they oeeupy less

volume than the thieker eoatings employed in prior art

devices. Surprisingly, however, the deviees aeeording to the

preferred embodiments of the invention still provide relatively high eapaeitanee as the available surfaee area remains

relatively high due to the use of an activated carbon and a

protonated binder.

While not wishing to be limited by theory, it is presently

understood, when thinner coatings are used, that another

mechanism comes into play. More particularly, the activated

carbon used in the preferred embodiments results in interpartiele voids in the earbon coating. These voids are typieally labrinthine in character. For prior art coatings having

a thickness which is significantly greater than the carbon

particle size, the impedance ofthe eoating is high. However,

for the eoatings of the preferred embodiments, where the

eoating thickness is the same order of magnitude as the

earbon particle size, the effect of the interpartiele voids is

minimal on the impedanee. That is, it has been diseovered

that there is a strong relationship between the size of the

aetive carbon particle, the thickness ofthe earbon layer and

the resultant impedance provided by that layer.

Preferred embodiments of the invention make use of

thinner carbon coatings to take advantage ofthis relationship

and thereby aehieve greater capacitances per unit volume,

and hence high FOM'S.

The volume and mass measurements for determining

FOM's take into account the paekaging in which the eleetrodes, the separator and electrolyte are eontained. The high

FOM's aehievable with the deseribed embodiments of the

invention are also contributed to by the paekaging itself and

the eompaet method of disposing the separate eomponents

within the paekaging.

For the larger supercapacitors constructed in accordance

with the invention it is known to use heavier and bulkier

packaging than is absolutely necessary and still achieve

relatively high FOM's. For example, in eases where it is

desirable to have highly robust packaging for operation in

hostile environments some eompromise in FOM is tolerated.

However, forthese larger devices, the relatively high FOM's

are still possible due to the packaging contributing proportionally less to the overall volume or weight ofthe deviee.

For some of the smaller devices, the high FOM's are

aehieved, in part, through use offlexible multi-layer plastics

paekaging. Examples of such packing are disclosed in the

eo-pending International Patent Application no. PCT/AU99/

00780 in the name ofthe present applieants. The diselosure

within that PCT application is incorporated herein by way of

cross reference.

Although the invention has been deseribed with referenee

to specific examples it will be appreciated by those skilled

in the art that it may be embodied in many other forms.

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Case 2:23-cv-00334 Document 1-3 Filed 07/14/23 Page 37 of 38 PageID #: 72
US 7,382,600 B2

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The invention elaimed is:

1. A eharge storage deviee eomprising:

a first electrode;

a second electrode being opposed to and spaced apart

from the first electrode;

a porous separator disposed between the eleetrodes;

a sealed paekage for containing the electrodes, the separator and an electrolyte in whieh the eleetrodes are

immersed; and

a first terminal and a second terminal being eleetrieally

connected to the first electrode and the second eleetrode respeetively and both extending from the paekage to allow external electrical connection to the

respective electrodes, wherein the gravimetrie FOM

of the deviee is greater than abont 2.1 Watts/gram.

2. A device aeeording to claim 1 including a gravimetric

FOM in one of the following ranges:

about 2.5 Watts/gram to 3 Watts/gram; or

about 3 Watts/gram to 3.5 Watts/gram; or

about 3.5 Watts/gram to 5 Watts/gram; or

greater than about 5 Watts/gram.

3. A device according to claim 1 wherein the first electrode and the seeond eleetrode form a capacitive cell and the

device includes a plurality of like cells disposed within the

paekage, eaeh cell being eleetrieally connected in parallel

with at least one other cell in the package.

4. A device according to claim 1 wherein the first electrode and the seeond electrode form a capacitive cell and the

device includes a plurality of like eells disposed within the

paekage, eaeh eell being eleetrieally connected in series with

at least one other cell in the package.

5. A device according to claim 1 wherein the first electrode and the seeond electrode form a capacitive cell and the

device includes a plurality of like eells disposed within the

paekage, eaeh eell being eleetrieally connected with at least

one other cell in the package, wherein the connects are a

combination of parallel and series eonneets.

6. A deviee aeeording to claim 1 wherein the first electrode and the seeond electrode inelude a first carbon coating

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and a second carbon coating respectively wherein the surface area of carbon used in the eoatings is greater than 20

m^/gram.

7. A device aeeording to claim 1 wherein the first electrode ineludes a first substrate and a first carbon layer

supported by the first substrate, and the seeond electrode

ineludes a second substrate and a second carbon layer

supported by the seeond substrate, wherein the first and

second carbon layers are opposed and includes a surface

area of at least 400 m^/gram and the gravimetrie FOM ofthe

deviee is greater than about 1 Watts/gram.

8. A device according to claim 7 wherein the surface area

of the earbon layers are at least 1200 m^/gram.

9. A device aeeording to claim 8 wherein at least one of

the earbon layers contains more than one type of carbon.

10. A device according to claim 9 wherein the carbon

layers are a mixture ofpartieles of high surface area carbon

and highly conductive carbon in a ratio of about 2.5:1

combined with a suspension of carboxy methyl eellulose

CMC .

11. A deviee aeeording to claim 1 wherein the maximum

operating voltage of the deviee is less than about 4 Volts.

12. A device according to claim 11 wherein the maximum

operating voltage of the deviee is less than about 3.5 Volts.

13. A device according to claim 12 wherein the maximum

operating voltage of the deviee is less than about 3 Volts.

14. A device according to claim 1 wherein the response

time T of the deviee is less than about 0.09 seconds.

15. A device according to claim 14 wherein the response

time T ofthe deviee is less than about lO"^ seconds.

16. A device according to claim 15 wherein the response

time T ofthe deviee is less than about 10~^ seconds.

17. A device according to claim 16 wherein the response

time T ofthe deviee is less than about ICL seconds.

18. A device according to claim 17 wherein the response

time T ofthe deviee is less than about 5xl〇~^ seconds.

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