Dry Particle Based Adhesive Electrode and Methods of Making Same

Abstract

A dry process based capacitor and method for a self-supporting dry adhesive electrode film for use therein is disclosed.

1 . An apparatus for manufacture of an energy device electrode, comprising: 
 one or more feeder, wherein each feeder provides dry carbon and binder particles for use by the apparatus.    
     
     
         2 . The apparatus of claim  57 , wherein the apparatus includes at least two rollers, and wherein the at least two rollers are disposed to receive the particles from the feeders to form a dry film from the particles.  
     
     
         3 . The apparatus of claim  57 , wherein the apparatus includes a compactor, wherein the compactor is disposed to receive the particles to form a dry film from the particles, and wherein the dry film is self-supporting after one pass-through the compactor.  
     
     
         4 . The apparatus of claim  58 , wherein the dry film comprises a density of about 0.50 to 0.70 gm/cm 2 .  
     
     
         5 . The apparatus of claim  58 , wherein the dry film is a long self supporting film.  
     
     
         6 . The apparatus of claim  58 , wherein the dry film comprises an intermixed dry film, wherein some of the dry carbon and dry binder particles are intermixed within the dry film with a first gradient, wherein some of the dry carbon and dry binder particles are intermixed within the dry film with a first gradient, wherein the first gradient of particles provides electrode functionality, and wherein the second gradient of particles provides adhesive functionality.  
     
     
         7 . The apparatus of claim  57 , wherein the apparatus includes at least two heated rollers, and wherein the at least two rollers are disposed to receive the particles to form a dry electrode film from the mixture.  
     
     
         8 . The apparatus of claim  63 , wherein the apparatus is disposed to receive a current collector and to calendar the dry electrode film directly to the current collector.