Processes and systems for supercapacitor stack fabrication

A process for fabricating an n-cell supercapacitor stack, comprising:

• a step of providing
• at least n+1 identical, or substantially identical, electrically inert conductive sheets having a defined perimeter;
• n identical, or substantially identical, ion-permeable insulating sheets having a defined perimeter;
• n identical, or substantially identical, first electrodes having a defined perimeter;
• n identical, or substantially identical, second electrodes having a defined perimeter;
• and
• at least n matching dielectric frames, each having an inner perimeter, which is smaller than the perimeter of the conductive sheet, and/or the perimeter of the insulating sheet, and which is larger than the perimeter of the first electrode and the perimeter of the second electrode, each of the dielectric frames further having an outer perimeter, which is larger than the perimeter of the conductive sheet and the perimeter of the insulating sheet;
• a step of assembling the supercapacitor stack, comprising:
• assembling n units each on top of the other, wherein each unit comprises a conductive sheet, a first electrode, an insulating sheet, a second electrode, and at least one frame, wherein the first electrode is disposed between and aligned with the conductive sheet and the insulating sheet and the second electrode is disposed between and aligned with the insulating sheet and a conductive sheet of the adjacent unit, and wherein the at least one frame extends beyond the edge of the conductive sheet throughout the entire perimeter of the conductive sheet;
• disposing an additional conductive sheet on top of the nth second electrode;
• and
• a step of attaching adjacent units onto one another, such that at least one of the frames within each unit is attached to at least one of the frames within each respective unit adjacent thereto,
• wherein n is an integer from 1 to 100.