Co-extrusion method of fabricating electrode structures in honeycomb substrates and ultracapacitor formed thereby

Abstract

A method for fabricating electrode structures within a honeycomb substrate having a plurality of elongated channels is provided that is particularly adaptable for producing an ultracapacitor. In this method, the nozzle of a co-extrusion device simultaneously feeds a current collector along a central axis of one of the channels while simultaneously injecting a paste containing an electrode material so that the interior of the channel becomes completely filled with electrode paste at the same rate that the current collector is fed. Such co-extrusion as performed simultaneously at both sides of the ceramic substrate to rapidly form electrode structures within substantially all the channels of the substrate. The resulting ultracapacitor is capable of storing large amounts of electrical energy per unit volume in a structure which is relatively quick and easy to manufacture.

1 . 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, and   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.   
   
   
       2 . The method defined in  claim 1 , 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. 
   
   
       3 . The method defined in  claim 2 , further comprising the steps of 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. 
   
   
       4 . The method defined in  claim 1 , wherein said current collector is a wire formed from an electrically conductive material. 
   
   
       5 . The method defined in  claim 1 , wherein the electrode paste includes particulate carbon. 
   
   
       6 . The method defined in  claim 1 , wherein the honeycomb structure is formed from a dielectric and thermally stable ceramic material. 
   
   
       7 . The method defined in  claim 3 , further including the step of 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. 
   
   
       8 . The method defined in  claim 7 , 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. 
   
   
       9 . The method defined in  claim 8 , wherein said co-extrusion device has first and second sets of nozzles disposed on opposite sides of said honeycomb substrate, the total number of nozzles being the same or nearly the same as the total number of channels in the honeycomb substrate, and wherein said first and second sets of nozzles are simultaneously inserted, actuated, and withdrawn such that an electrode structure is simultaneously formed in substantially all of the channels. 
   
   
       10 . The method defined in  claim 1 , wherein the honeycomb substrate is formed from one of the group consisting of cordierite, mullite, aluminum titanate, silicon carbide, alumina and silicone alumina. 
   
   
       11 . A method for forming electrode structures within a dielectric honeycomb substrate, said method being particularly adapted for producing an ultracapacitor, and comprising the steps of:
 providing a honeycomb substrate having a plurality of elongated channels, and   simultaneously feeding a wire-like current collector along a central axis of at least one of said channels while injecting a paste containing an electrode material such that the interior of the channel becomes completely filled with said electrode paste at a same rate that said current collector is fed into said channel.   
   
   
       12 . The method defined in  claim 11 , wherein said electrode paste is extrudable, and said wire-like current collector and said electrode paste are simultaneously fed into said channel by the nozzle of a co-extrusion device. 
   
   
       13 . The method of  claim 11 , wherein the electrode paste includes activated particulate carbon. 
   
   
       14 . The method of  claim 13 , wherein the surface area of the activated particulate carbon is between about 1000 to 3000 m 2 /gm. 
   
   
       15 . The method of  claim 11 , wherein the current collector is a wire formed from a conductive metal. 
   
   
       16 . The method of  claim 11 , wherein the current collector is a wire having a diameter of between about 0.10 and 0.30 mm. 
   
   
       17 . The method of  claim 12 , further including the step of plugging one end of said at least one channel and inserting said nozzle into an opposite, unplugged end prior to commencing the feeding of said current collector and extrudable electrode paste. 
   
   
       18 . The method of  claim 12 , 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. 
   
   
       19 . The method of  claim 18 , wherein said co-extrusion device has first and second sets of nozzles disposed on opposite sides of said ceramic honeycomb structure, the total number of nozzles being the same or nearly the same as the total number of channels in the ceramic substrate, and wherein said first and second sets of nozzles are simultaneously inserted, actuated, and withdrawn such that an electrode structure is simultaneously formed in substantially all of the channels. 
   
   
       20 . The method of  claim 11 , wherein the channel density of said honeycomb substrate is between about 400 and 2000 per square inch. 
   
   
       21 . An ultracapacitor, comprising:
 a dielectric ceramic honeycomb substrate having a plurality of elongated channels, wherein at least one channel contains an electrode structure including a current collector disposed along a central axis of the channel, and wherein the balance of said channel is completely filled with electrode paste such that substantially no air voids are present within said channel.   
   
   
       22 . The ultracapacitor of  claim 21 , wherein said current collector is formed from a wire of electrically conductive material, and said honeycomb structure has a channel density of between about 400 and 2000 per square inch. 
   
   
       23 . The ultracapacitor of  claim 21 , wherein said electrode paste includes activated particulate carbon having a surface area of between about 1000 to 3000 m 2 /gm. 
   
   
       24 . The ultracapacitor of  claim 21 , wherein a plurality of said channels include said electrode structure, and wherein said current collector of each electrode has a portion that extends beyond one end of its respective channel. 
   
   
       25 . The ultracapacitor of  claim 24 , wherein the channels of said dielectric honeycomb structure are plugged in a checkerboard pattern at either end of said structure such that each channel has one plugged end and one open end, and wherein substantially all of said channels include said electrode structure, and further comprising conductive plates on either end of said structure that electrically connect said extending portions of said current collectors.