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 energy storage device product, comprising: 
 a self-supporting film consisting of a dry mix of dry carbon and dry binder particles.    
     
     
         2 . The product of  claim 1 , wherein at least some of the dry mix is dry fibrillized.  
     
     
         3 . The product of  claim 1 , wherein the dry mix consists of no processing additive.  
     
     
         4 . An energy storage device product, comprising: 
 one or more self-supporting dry adhesive film comprising a dry mix of dry binder and dry carbon particles.    
     
     
         5 . The product of  claim 4 , wherein the self supporting dry adhesive film is a compacted film.  
     
     
         6 . The product of  claim 5 , wherein the dry adhesive film comprises a thickness of less than 250 microns.  
     
     
         7 . The product of  claim 4 , wherein the self-supporting dry adhesive film comprises a length of at least 1 meter.  
     
     
         8 . The product of  claim 4 , wherein the self-supporting dry adhesive film is coupled directly against a substrate.  
     
     
         9 . The product of  claim 8 , wherein the self-supporting dry adhesive film comprises no processing additive.  
     
     
         10 . The product of  claim 8 , wherein the substrate comprises a collector.  
     
     
         11 . The product of  claim 10 , wherein the collector comprises aluminum.  
     
     
         12 . The product of  claim 8 , wherein the product comprises a collector, and wherein the dry adhesive film is coupled directly against a surface of the collector.  
     
     
         13 . The product of  claim 12 , wherein the collector is untreated.  
     
     
         14 . The product of  claim 10 , wherein the collector comprises two sides, wherein one self supporting dry adhesive film is calendered directly against one side of the collector, and wherein a second self supporting dry adhesive film is calendered directly against a second side of the collector.  
     
     
         15 . The product of  claim 14 , wherein the collector is treated.  
     
     
         16 . The product of  claim 14 , wherein the collector is formed to comprise a roll.  
     
     
         17 . The product of  claim 16 , wherein the roll is disposed within a sealed aluminum housing.  
     
     
         18 . The product of  claim 17 , wherein within the housing is disposed an electrolyte, and wherein the product comprises a double-layer capacitor.  
     
     
         19 . The product of  claim 8 , wherein at least some of the dry binder comprises a fibrillizable fluoropolymer, and wherein the dry carbon particles comprise activated carbon particles and conductive carbon particles.  
     
     
         20 . The product of  claim 8 , wherein at least some of the dry binder comprises a thermoplastic, and wherein the dry carbon particles comprise conductive carbon particles.  
     
     
         21 . A capacitor, the capacitor comprising: 
 a collector; the collector having two sides; and    two electrode film layers, wherein a first electrode film layer is bonded directly onto a first surface of the collector, and wherein a second electrode film layer is bonded directly onto a second surface of the collector.    
     
     
         22 . The capacitor of  claim 21 , wherein the two electrode film layers consist of no processing additives.  
     
     
         23 . The capacitor of  claim 22 , wherein the two electrode layers comprise a thermoplastic.  
     
     
         24 . The capacitor of  claim 21 , wherein the film layers comprise substantially zero residues as determined by a chemical analysis of the layers before impregnation by an electrolyte.  
     
     
         25 . The capacitor of  claim 24 , wherein the residues comprise hydrocarbons, high boiling point solvents, antifoaming agents, surfactants, dispersion aids, water, pyrrolidone, mineral spirits, ketones, naphtha, acetates, alcohols, glycols, toluene, xylene, and Isopars™.  
     
     
         26 . The capacitor of  claim 23 , wherein the layers are impregnated with an electrolyte.  
     
     
         27 . The capacitor of  claim 26 , wherein the capacitor comprises a double-layer capacitor.  
     
     
         28 . An energy storage device, comprising: 
 one or more continuous self supporting intermixed film structure comprising dry carbon particles and dry binder particles, the film structure comprising about zero parts per million processing additive.    
     
     
         29 . The energy storage device of  claim 28 , wherein the additive is selected from the group consisting of hydrocarbons, high boiling point solvents, antifoaming agents, surfactants, dispersion aids, water, pyrrolidone, mineral spirits, ketones, naphtha, acetates, alcohols, glycols, toluene, xylene, and Isopars™.  
     
     
         30 . The energy storage device of  claim 28 , wherein the film structure comprises a dry adhesive binder.  
     
     
         31 . The energy storage device of  claim 28 , wherein the film structure comprises a dry conductive carbon.  
     
     
         32 . The energy storage device of  claim 28 , wherein the film structure comprises dry activated carbon, dry conductive carbon, and dry adhesive binder.  
     
     
         33 . The energy storage device of  claim 28 , wherein the film structure is coupled to a collector.  
     
     
         34 . The energy storage device of  claim 28 , wherein the intermixed film structure comprises two intermixed film structures coupled to a collector, wherein a first of the film structures is coupled to a first side of the collector, and wherein a second of the film structures is coupled to a second side of the collector.  
     
     
         35 . The energy storage device of  claim 28 , wherein the intermixed film structure is an electrode film.  
     
     
         36 . The energy storage device of  claim 35 , wherein the electrode film is an energy storage device electrode film.  
     
     
         37 . The energy storage device of  claim 36 , wherein the electrode film comprises a capacitor electrode film.  
     
     
         38 . A capacitor structure, comprising 
 a collector; and    a plurality of dry processed particles coupled to the collector, wherein the particles define a long integral dry electrode film.    
     
     
         39 . The structure of  claim 38 , wherein the film comprises dry conductive carbon and dry adhesive materials.  
     
     
         40 . The structure of  claim 38 , wherein the film comprises one or more blend of dry particles.  
     
     
         41 . The structure of  claim 40 , wherein a first of the particles comprises activated carbon, conductive carbon, and a fibrillizable binder; and wherein a second of the particles comprises conductive carbon and adhesive binder.  
     
     
         42 . An energy storage device electrode, the electrode comprising: 
 adhesive binder particles; and    carbon particles, the carbon particles comprising a surface,    wherein a plurality of the carbon particles are coupled to each other by the adhesive binder particles, and wherein a plurality of the carbon particles make direct carbon particle to carbon particle contact.