Patent ID: 6946007

Claim:
A method of making an electrode structure for use in a double layer capacitor, comprising the steps of: forming a plurality of electrodes, each of the plurality of electrodes comprising: a current collector plate; a primary coating formed on a portion of each side of the current collector plate as a slurry, the primary coating including conducting carbon powder and a binder; and a secondary coating formed on each primary coating as a slurry, the secondary coating including activated carbon powder, a solvent and a binder; positioning a respective separator between two adjacent electrodes of the plurality of electrodes while stacking the plurality of electrodes on top of each other such that the respective separator is juxtaposed against respective secondary coatings of adjacent ones of the plurality of electrodes, wherein the respective separator electrically insulates the adjacent ones of the plurality of electrodes from each other, whereby forming a stack of the plurality of electrodes with a respective separator positioned in between respective ones of the plurality of electrodes; and rolling the electrode stack starting at one end of the electrode stack into a cylindrical structure.