Particle packaging systems and methods

• US 20050250011A1
• Filed: 04/27/2005
• Published: 11/10/2005
• Est. Priority Date: 04/02/2004
• Status: Abandoned Application

• Current Assignee: Tesla Inc.
• Original Assignee: Maxwell Technologies Incorporated (Tesla Inc.)
• Inventors: Mitchell, Porter, Xi, Xiaomei, Zhong, Linda, Zou, Bin
• Application Number:
  US11/116,882
• Publication Number:
  US 20050250011A1
• Time in Patent Office: Days
• US Class Current: 429/217
• CPC Class Codes: H01G 11/22 Electrodes
• CPC Class Codes: H01G 11/32 Carbon-based
• CPC Class Codes: H01G 11/34 characterised by carbonisation or activation of carbon
• CPC Class Codes: H01G 11/38 Carbon pastes or blends; Binders or additives therein
• CPC Class Codes: H01G 11/42 Powders or particles, e.g. composition thereof
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 4/02 Electrodes composed of, or comprising, active material
• CPC Class Codes: H01M 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/0409 by a doctor blade method, slip-casting or roller coating
• CPC Class Codes: H01M 4/0416 involving impregnation with a solution, dispersion, paste or dry powder H01M4/0438 takes precedence
• CPC Class Codes: H01M 4/0435 Rolling or calendering
• CPC Class Codes: H01M 4/1391 of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 4/1393 of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/50 of manganese
• CPC Class Codes: H01M 4/58 of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy; of polyanionic structures, e.g. phosphates, silicates or borates
• CPC Class Codes: H01M 4/583 Carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/587 for inserting or intercalating light metals
• CPC Class Codes: H01M 4/62 Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
• CPC Class Codes: H01M 4/621 Binders
• CPC Class Codes: H01M 4/622 being polymers
• CPC Class Codes: H01M 4/8668 : Binders
• CPC Class Codes: H01M 4/886 : Powder spraying, e.g. wet or dry powder spraying, plasma spraying
• CPC Class Codes: H01M 4/8896 : Pressing, rolling, calendering membrane electrode assemblies H01M8/1004
• CPC Class Codes: H01M 4/9083 : on carbon or graphite
• CPC Class Codes: H01M 4/926 : on carbon or graphite
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/13 : Energy storage using capacitors
• CPC Class Codes: Y02E 60/50 : Fuel cells

Abstract

A dry process-based particle packaging method and system is disclosed where a matrix of dry fibrillized binder is formed so as to support one or more type of particle. Reliable and inexpensive products, including films, sheets, electrodes, batteries, capacitors, fuel cells, and/or medical devices can be thus manufactured.

Claims

8. An electrochemical energy product, comprising:

an electrode, the electrode including a structure formed of a plurality of particles, wherein the structure comprises substantially no processing additives.

1. A product, comprising:

a plurality of particles supported in a matrix of dry fibrillized binder.

2. The product of claim 1, wherein the product comprises a compacted structure.

3. The product of claim 2, wherein the compacted structure is coupled to a substrate.

4. The product of claim 3, wherein the compacted structure is substantially free of processing additives.

5. The product of claim 4, wherein the processing additives include hydrocarbons, high boiling point solvents, antifoaming agents, surfactants, dispersion aids, pyrrolidone mineral spirits, ketones, naphtha, acetates, alcohols, glycols, toluene, xylene, and Isopars™

.

6. The product of claim 3, wherein the substrate comprises a collector.

7. The product of claim 1, wherein the dry fibrillized binder is dry fibrillized by pressure.

9. The product of claim 8, wherein the structure comprises a capacitor structure.

10. The product of claim 8, wherein the structure comprises a battery structure.

11. The product of claim 8, wherein the structure comprises a fuel-cell structure.

12. The product of claim 8, wherein at least some of the particles comprise conductive carbon.

14. The product of claim 8, wherein at least some of the particles comprise activated carbon.

15. The product of claim 8, wherein at least some of the particles comprise activated carbon and conductive carbon.

16. The product of claim 8, wherein the processing additives include hydrocarbons, high boiling point solvents, antifoaming agents, surfactants, dispersion aids, pyrrolidone mineral spirits, ketones, naphtha, acetates, alcohols, glycols, toluene, xylene, and Isopars™

.

17. The product of claim 8, wherein at least some of the particles comprise a metal oxide.

18. The product of claim 8, wherein at least some of the particles comprise a fibrillizable particle.

19. The product of claim 8, wherein at least some of the particles comprise thermoplastic.

20. The product of claim 8, wherein at least some of the particles comprise catalyst impregnated carbon.

21. The product of claim 8, wherein at least some of the particles comprise graphite.

22. The product of claim 8, wherein at least some of the particles comprise manganese dioxide.

23. The product of claim 8, wherein at least some of the particles comprise a metal.

24. The product of claim 8, wherein at least some of the particles comprise graphite and intercalated carbon.

25. The product of claim 8, wherein at least some of the particles comprise graphite and intercalated carbon.

26. The product of claim 8, wherein the structure is in the form of a sheet.

11-1. The product of claim 8, wherein at least some of the particles comprise carbon.

27. A structure, comprising:

one or more particle fibrillized by a pressurized gas; and

one or more other particle supported by the one or more fibrillized particle.