Patent ID: 8591600

Claim:
A method for fabricating an electrode structure within channels of a honeycomb substrate, said method being particularly adapted for producing an ultracapacitor, and comprising the steps of: providing a honeycomb substrate having a plurality of channels, simultaneously feeding a current collector along a central portion of at least one of said channels while injecting a paste containing an electrode material such that the interior of said channel becomes completely filled with said electrode paste at substantially a same rate that said current collector is fed into said channel, wherein said electrode paste is extrudable, and said current collector and said electrode paste are simultaneously fed into said channel by the nozzle of a co-extrusion device, inserting said nozzle of said co-extrusion device to one end of said channel, commencing the feeding of said current collector and extrudable electrode paste from said nozzle, and withdrawing said nozzle from said channel at a same rate that said current collector and said extrudable electrode paste are fed into said channel, and plugging one end of said channel and inserting said nozzle into an opposite, unplugged end prior to commencing the feeding of said current collector and extrudable electrode paste, wherein said co-extrusion device has a plurality of nozzles, each of which is simultaneously inserted, and simultaneously actuated to feed said current collector and extrudable electrode paste into its respective channel, and then simultaneously withdrawn, such that an electrode structure is simultaneously produced in a plurality of channels.