Electrochemical double layer capacitor having carbon powder electrodes

A method of making an electrode structure for use in a double layer capacitor, comprising the steps of:

• applying a first slurry including conducting carbon powder and a binder to one side of a current collector plate;
• curing the applied first slurry to form a first primary coating;
• applying a second slurry that includes activated carbon powder, a solvent and a binder to the first primary coating;
• curing the applied second slurry to form a first secondary coating;
• applying the first slurry to another side of the current collector plate that is opposite of the one side of the current collector plate;
• curing the applied first slurry to form a second primary coating on the other side of the current collector plate;
• applying the second slurry to the second primary coating;
• curing the applied second slurry to form a second secondary coating on the second primary coating, thereby forming a first electrode.

A method of making an electrode structure for use in a double layer capacitor, comprising the steps of:

• providing a current collector plate having a length and a width wherein the length is greater than the width;
• applying a first slurry including conducting carbon powder and a binder to a current collector plate while moving the current collector plate lengthwise;
• curing the applied first slurry to form a primary coating;
• applying a second slurry that includes activated carbon powder, a solvent and a binder to the primary coating while moving the current collector plate lengthwise;
• and
• curing the applied second slurry to form a secondary coating, thereby forming a first electrode.