Large format ultracapacitors and method of assembly

1. A capacitor comprising:

a plurality of electrode substrates, each of the plurality of electrode substrates having a coated portion and an uncoated portion, the coated portion being coated with a coating material comprising:

an activated carbon material with high surface area;

a water soluble binder selected from the group consisting of poly vinyl alcohol, poly acrylic acid, polymethacrylic acid, polyethylene oxide, polyacrylamide, poly-N-isopropylearylamide, poly-N,N-dimethylacrylamide, polyethyleneimine, polyoxyethylene, polyvinylsulfonic acid, poly(2-methoxyethoxyethoxyethylene), butadiene-acrylonitrile, and combinations thereof; and

a water soluble thickener;

a separator inserted between adjacent substrates of the plurality of electrode substrates; and

an electrolyte.

2. The capacitor according to claim 1 , wherein the water soluble binder comprises poly acrylic acid.

3. The capacitor according to claim 1 , wherein the water soluble binder comprises polymethacrylic acid.

4. The capacitor according to claim 1 , wherein the water soluble binder comprises polyethylene oxide.

5. The capacitor according to claim 1 , wherein the water soluble binder comprises polyacrylamide.

6. The capacitor according to claim 1 , wherein the water soluble binder comprises poly-N-isopropylearylamide.

7. The capacitor according to claim 1 , wherein the water soluble binder comprises poly-N,N-dimethylacrylamide.

8. The capacitor according to claim 1 , wherein the water soluble binder comprises polyethyleneimine.

9. The capacitor according to claim 1 , wherein the water soluble binder comprises polyoxyethylene.

10. The capacitor according to claim 1 , wherein the water soluble binder comprises polyvinylsulfonic acid.

11. The capacitor according to claim 1 , wherein the water soluble binder comprises poly(2-methoxyethoxyethoxyethylene).

12. The capacitor according to claim 1 , wherein the water soluble binder comprises butadiene-acrylonitrile.

13. The capacitor according to claim 1 , wherein the activated carbon material comprises activated carbon nano foam.

14. The capacitor according to claim 1 , wherein the activated carbon material has a surface area between about 100 square meters per gram and about 2,500 square meters per gram.

15. The capacitor according to claim 1 , having a capacitance of above about 30 Farads.

16. The capacitor according to claim 1 , wherein the electrolyte comprises an aqueous medium.

17. The capacitor according to claim 1 , wherein the electrolyte comprises a non-aqueous medium.

18. The capacitor according to claim 1 , wherein the coating further comprises a conductive additive.

19. A method comprising the steps of:

a) forming a slurry comprised of:

a high surface area activated carbon material;

a water soluble binder selected from the group consisting of: poly vinyl alcohol, poly acrylic acid, polymethacrylic acid, polyethylene oxide, polyacrylamide, poly-N-isopropylearylamide, poly-N,N-dimethylacrylamide, polyethyleneimine, polyoxyethylene, polyvinylsulfonic acid, poly(2-methoxyethoxyethoxyethylene), butadiene-acrylonitrile, and combinations thereof;

a water soluble thickener; and

water;

b) coating a substrate with the slurry; and

c) drying the coating onto the substrate.

20. The method according to claim 19 , further comprising the steps of:

d) stacking a plurality of the substrates on top of each other, while separating adjacent substrates from each other with a micro porous separator material;

e) inserting the stack into a pouch; and

f) adding an electrolyte to the stack in the pouch.