Fabrication processes for electrodes for electrochemical devices, and electrochemical device fabrication process

1. A process for fabricating an electrode for electrochemical devices, said electrode comprising an active substance and a binder on a support carrier, the process comprising:

providing an electrode-formation coating material comprising said active substance, said binder and a binder solvent,

coating said coating material on said support carrier to form a coating film for said electrode, and then

removing the binder solvent remaining in said coating film by treating with carbon dioxide (CO 2 ) in a supercritical state without using a low-boiling solvent, wherein the low-boiling solvent has a boiling point from 30 to 180° C.

2. A process for fabricating an electrode for electrochemical devices, said electrode comprising an active substance and a binder on a support carrier, the process comprising:

providing an electrode-formation coating material comprising said active substance, said binder and a binder solvent,

coating said coating material on said support carrier to form a coating film for said electrode, and then

treating said coating film with carbon dioxide (CO 2 ) in a supercritical state while a low-boiling solvent remains deposited to said coating film, thereby removing the binder solvent remaining in said coating film,

wherein the low-boiling solvent (i) has a boiling point from 30 to 180° C., (ii) is compatible with the binder solvent, and (iii) has the boiling point lower than that of the binder solvent.

3. The process for fabricating an electrode for electrochemical devices according to claim 2 , wherein said coating film has been dipped in said low-boiling solvent, said coating film is lifted up therefrom while said low-boiling solvent remains deposited to said coating film, after which said coating film is treated with carbon dioxide in a supercritical state.

4. A process for fabricating an electrode for electrochemical devices, said electrode comprising an active substance and a binder on a support carrier, the process comprising:

providing an electrode-formation coating material comprising said active substance, said binder and a binder solvent,

coating said coating material on said support carrier to form a coating film for said electrode, and then

dipping the coating film in a low-boiling solvent and treating said coating film with carbon dioxide (CO 2 ) in a supercritical state while said coating film remains dipped in the low-boiling solvent, thereby removing the binder solvent remaining in said coating film,

wherein the low-boiling solvent (i) has a boiling point from 30 to 180° C., (ii) is compatible with the binder solvent, and (iii) has the boiling point lower than that of the binder solvent.

5. The process for fabricating an electrode for electrochemical devices according to claim 1 , wherein said active substance is a carbonaceous material having a specific surface area of 30 m 2 /g or greater.

6. The process for fabricating an electrode for electrochemical devices according to claim 2 , wherein said active substance is a carbonaceous material having a specific surface area of 30 m 2 /g or greater.

7. The process for fabricating an electrode for electrochemical devices according to claim 4 , wherein said active substance is a carbonaceous material having a specific surface area of 30 m 2 /g or greater.

8. The process for fabricating an electrode for electrochemical devices according to claim 5 , wherein said carbonaceous substance is an activated charcoal.

9. The process for fabricating an electrode for electrochemical devices according to claim 6 , wherein said carbonaceous substance is an activated charcoal.

10. The process for fabricating an electrode for electrochemical devices according to claim 7 , wherein said carbonaceous substance is an activated charcoal.

11. The process for fabricating an electrode for electrochemical devices according to claim 1 , wherein said electrode for electrochemical devices is an electrode for electric double-layer capacitors, an electrode for lithium ion secondary batteries, or an electrode for hybrid capacitors.

12. The process for fabricating an electrode for electrochemical devices according to claim 2 , wherein said electrode for electrochemical devices is an electrode for electric double-layer capacitors, an electrode for lithium ion secondary batteries, or an electrode for hybrid capacitors.

13. The process for fabricating an electrode for electrochemical devices according to claim 4 , wherein said electrode for electrochemical devices is an electrode for electric double-layer capacitors, an electrode for lithium ion secondary batteries, or an electrode for hybrid capacitors.

14. An electrochemical device fabrication process, wherein:

an electrode for electrochemical devices, comprising an active substance and a binder on a support carrier, is fabricated by a process for fabricating an electrode for electrochemical devices comprising:

providing an electrode-formation coating material comprising said active substance, said binder and a binder solvent,

coating said coating material on said support carrier to form a coating film for said electrode, and then

removing the binder solvent remaining in said coating film by treating with carbon dioxide (CO 2 ) in a supercritical state without using a low-boiling solvent, wherein the low-boiling solvent has a boiling point from 30 to 180° C., and thereafter,

assembling the fabricated electrode for electrochemical devices, a separator, an electrolyte and a housing into the electrochemical device.

15. An electrochemical device fabrication process, wherein:

an electrode for electrochemical devices, comprising an active substance and a binder on a support carrier, is fabricated by a process for fabricating an electrode for electrochemical devices comprising:

providing an electrode-formation coating material comprising said active substance, said binder and a binder solvent,

coating said coating material on said support carrier to form a coating film for said electrode, and then

treating said coating film with carbon dioxide (CO 2 ) in a supercritical state while a low-boiling solvent remains deposited to said coating film, thereby removing the binder solvent remaining in said coating film,

wherein the low-boiling solvent (i) has a boiling point from 30 to 180° C., (ii) is compatible with the binder solvent, and (iii) has the boiling point lower than that of the binder solvent, and thereafter,

assembling the fabricated electrode for electrochemical devices, a separator, an electrolyte and a housing into the electrochemical device.

16. An electrochemical device fabrication process, wherein:

an electrode for electrochemical devices, comprising an active substance and a binder on a support carrier, is fabricated by a process for fabricating an electrode for electrochemical devices comprising:

providing an electrode-formation coating material comprising said active substance, said binder and a binder solvent,

coating said coating material on said support carrier to form a coating film for said electrode, and then

dipping the coating film in a low-boiling solvent and treating said coating film with carbon dioxide (CO 2 ) in a supercritical state while said coating film remains dipped in the low-boiling solvent, thereby removing the binder solvent remaining in said coating film,

wherein the low-boiling solvent (i) has a boiling point from 30 to 180° C., (ii) is compatible with the binder solvent, and (iii) has the boiling point lower than that of the binder solvent, and thereafter,

assembling the fabricated electrode for electrochemical devices, a separator, an electrolyte and a housing into the electrochemical device.

17. The process according to claim 15 , wherein said coating film has been dipped in said low-boiling solvent, said coating film is lifted up therefrom while said low-boiling solvent remains deposited to said coating film, after which said coating film is treated with carbon dioxide in a supercritical state.

18. The process according to claim 1 , wherein a content of the binder solvent that remains in the coating film after the removing is 500 ppm or less.

19. The process according to claim 14 , wherein the electrolyte is selected from the group consisting of triethylmethylammonium borofluoride (TEMA.BF 4 ) and tetraethylammonium borofluoride (TEA.BF 4 ) dissolved in a solvent or a polymer electrolyte.

20. The process according to claim 1 , wherein when N-methyl-2-pyrrolidinone is used as the binder solvent, and the low-boiling solvent is acetone, methylene chloride, or an alcohol.