Dry-particle based adhesive and dry film and methods of making same

• US 20070122698A1
• Filed: 10/14/2005
• Published: 05/31/2007
• 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:
  US11/251,408
• Publication Number:
  US 20070122698A1
• Time in Patent Office: Days
• US Class Current: 429/217
• CPC Class Codes: H01G 11/28 arranged or disposed on a current collector; Layers or phases between electrodes and current collectors, e.g. adhesives
• CPC Class Codes: H01G 11/38 Carbon pastes or blends; Binders or additives therein
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• 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 4/131 Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• 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 4/366 as layered products
• CPC Class Codes: H01M 4/50 of manganese
• CPC Class Codes: H01M 4/505 of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy
• CPC Class Codes: H01M 4/525 of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
• 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 4/623 : fluorinated polymers
• CPC Class Codes: H01M 4/625 : Carbon or graphite
• CPC Class Codes: H01M 4/8668 : Binders
• CPC Class Codes: H01M 4/8673 : Electrically conductive fillers
• 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 4/9041 : Metals or alloys H01M4/92 takes precedence
• 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
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49108 : Electric battery cell making
• CPC Class Codes: Y10T 428/28 : Web or sheet containing structurally defined element or component and having an adhesive outermost layer
• CPC Class Codes: Y10T 428/2878 : including addition polymer from unsaturated monomer
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31678 : Of metal

Abstract

Dry process based energy storage device structures and methods for using a dry adhesive therein are disclosed.

Claims

1. An article used in the manufacture of an energy storage device, comprising:

a sheet of material;

a dry film, the dry film including dry conductive carbon particles and dry binder, the dry film coupled to the sheet of material.

2. The article of claim 1, wherein the dry binder comprises a thermoplastic.

3. The article of claim 2, wherein the dry binder is selected from a group consisting of polyethylene, polypropylene, polyolefin, and non-fibrillizable fluoropolymer particles.

4. The article of claim 1, wherein the binder comprises a thermoplastic, thermoset, and/or radiation set material.

5. The article of claim 2, wherein the sheet of material comprises an aluminum foil.

6. The article of claim 2, wherein the aluminum is corona treated.

7. The article of claim 2, wherein the sheet of material comprises a dry process based electrode film.

8. The article of claim 7, wherein the dry process based electrode film is a self-supporting dry film.

9. The article of claim 8, wherein the dry process based electrode film is a compacted dry fibrillized blend of binder and carbon particles.

10. The article of claim 2, wherein the sheet of material comprises an additive based electrode film.

11. A primer layer product, comprising:

a dry process based mix of dry particles, wherein the mix includes dry conductive carbon particles and dry binder.

12. The product of claim 11, wherein the binder is a thermoplastic.

13. The product of claim 11, wherein the product is an energy storage device primer layer product.

14. The product of claim 13, wherein the mix comprises substantially no processing additive.

15. An electrode, comprising:

a collector; and

a dry process based structure, wherein the structure is coupled to the collector, wherein the structure comprises dry carbon and dry binder particles, and wherein between the collector and the structure there exists only one distinct interface.

16. The electrode structure of claim 15, wherein the binder particles comprise a thermoplastic.

17. The electrode of claim 16, wherein the carbon particles comprise conductive carbon.

18. The electrode of claim 17, wherein the structure comprises no processing additive.

19. An energy storage device adhesive structure, the structure comprising:

dry adhesive binder; and

dry carbon particles, the dry carbon particles comprising a surface, wherein a plurality of the carbon particles are coupled to each by the dry adhesive binder, and wherein a plurality of the carbon particles make direct carbon particle to carbon particle contact.

20. The structure of claim 19, wherein the dry adhesive binder comprises a thermoplastic.

21. The structure of claim 20, wherein the dry adhesive binder is selected from a group consisting of polyethylene, polypropylene, polyolefin, and non-fibrillizable fluoropolymer particles.

22. The structure of claim 19, wherein the structure comprises substantially no processing additive.

23. An energy storage device, comprising:

dry process based adhesive means for providing adhesion and functionality in an energy storage device.

24. A capacitor structure, comprising

a collector;

and

a plurality of dry processed particles coupled to the collector, wherein the plurality of particles define a long intermixed film.

25. The structure of claim 24, wherein the film comprises conductive carbon and thermoplastic.

26. The structure of claim 24, wherein the structure comprises no processing additives.

27. A capacitor structure, comprising

a continuous compacted dry adhesive film comprising a dry mix of dry binder and dry carbon particles, the film coupled to a collector, the collector shaped into a roll and disposed within a sealed aluminum housing.

28. The structure of claim 27, wherein the dry adhesive film comprises no processing additive.

29. An energy storage device structure, comprising:

one or more dry electrode film, wherein the one or more dry electrode film is both conductive and adhesive, and wherein the one or more dry electrode film is coupled directly to a current collector.

30. The device of claim 29, wherein the dry electrode film comprises no processing additive.

31. The device of claim 29, wherein the dry electrode film comprises conductive particles.

32. The device of claim 31, wherein the conductive particles comprise a metal.

33. The device of claim 31, wherein the dry film comprises dry thermoplastic particles.

34. The device of claim 29, wherein the dry electrode film comprises conductive carbon particles and thermoplastic particles.

35. The device of claim 29, wherein the dry electrode film is coupled by application of heat.

36. A solventless method for manufacture of an energy storage device, comprising the steps of:

providing dry carbon particles;

providing dry binder particles; and

intermixing the dry carbon and dry binder particles without the substantial use of processing additives.

37. The method of claim 36, further comprising a step of applying the dry intermixed particles onto a substrate.

38. The method of claim 37, wherein the dry intermixed particles are applied directly onto a self-supporting electrode film.

39. The method of claim 38, wherein the self-supporting film is formed without the use of any processing additives.

40. The method of claim 37, wherein the substrate comprises a current collector.