Patent ID: 7419745

Claim:
A method of forming an electrode structure, comprising: (a) providing a carbon having a surface area determined using the Brunauer, Emmett, Teller (BET) method of 500 to 2,500 m 2 /g and a pore size distribution with at least one peak at a pore size of between 0.1 to 5.0 nm measured using the Horvath-Kawazoe method and at least one second peak at a pore size between 2.0 and 50.0 nm measured using the Barrett-Joyner-Halenda method; (b) providing an aluminum foil current collector; (c) depositing a porous electrode on a current collector by spraying onto the current collector a mixture comprising: (i) the carbon; and (ii) a binder; wherein the mixture is a powder and wherein the mixture comprises 50 to 85 wt % carbon; and, (d) heating the product of (c) to a temperature above a glass transition temperature of the binder for 2 to 120 minutes to cure the binder.