Supercapacitor electrode having highly oriented and closely packed expanded graphite flakes and production process

摘要

Provided is a process for producing a supercapacitor electrode, comprising: (a) preparing a deformable mass of multiple flakes of exfoliated graphite worms or expanded graphite dispersed in or impregnated by a liquid or gel electrolyte; and (b) subjecting the deformable mass to a forced assembling and orientating procedure, forcing the deformable mass to form the electrode, wherein these fakes are spaced by thin electrolyte layers, having an electrolyte layer thickness from 0.4 nm to 10 nm, and the flakes are substantially aligned along a desired direction, and wherein the electrode has a physical density from 0.5 to 1.7 g/cm³ and a specific surface area from 50 to 3,300 m²/g, when measured in a dried state of the flakes without the electrolyte. This process leads to a supercapacitor having a large electrode thickness, high active mass loading, high tap density, and exceptional energy density.