Composite electrode and method for fabricating same
First Claim
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1. An energy storage device comprising:
- a current collector comprising a first surface and a second surface, the first surface of the current collector being uneven; and
a first film of active electrode material, the first film comprising dry carbon and binder particles, the first film comprising a third surface adjacent to the first surface of the current collector, the third surface of the first film being attached directly to the first surface of the current collector;
wherein the first and third surfaces are bonded directly to each other causing the first surface to adhere to the third surface.
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Abstract
Composite electrodes are constructed with pressure-bonding techniques instead of an adhesive. A current collector is made from aluminum foil roughed on both surfaces. The surfaces of the collector can be treated to enhance adhesion to the surfaces. Layers of film that includes active electrode material, such as activated carbon, are fabricated and pressure-bonded to the current collector using a calender with heated rollers. The resulting composite sheet is then processed to shape electrodes, which can be used in electrical energy storage devices, including double layer capacitors.
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Citations
12 Claims
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1. An energy storage device comprising:
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a current collector comprising a first surface and a second surface, the first surface of the current collector being uneven; and a first film of active electrode material, the first film comprising dry carbon and binder particles, the first film comprising a third surface adjacent to the first surface of the current collector, the third surface of the first film being attached directly to the first surface of the current collector; wherein the first and third surfaces are bonded directly to each other causing the first surface to adhere to the third surface. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method of manufacturing an electrode, comprising:
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providing a current collector comprising a first surface and a second surface; roughing the first and second surfaces of the current collector; providing a first film of active electrode material comprising a third surface; providing a second film of active electrode material comprising a fourth surface; bringing the first surface in direct contact with the third surface; bringing the second surface in direct contact with the fourth surface; pressing the first film, the current collector, and the second film together to cause the first surface to adhere to the third surface, and the second surface to adhere to the fourth surface; and wherein the film comprises a dry fibrillized blend of carbon and binder particles. - View Dependent Claims (9, 10, 11)
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12. A method of manufacturing an electrode, comprising:
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providing a current collector comprising a first surface and a second surface; roughing the first and second surfaces of the current collector; providing a first film of active electrode material comprising a third surface; providing a second film of active electrode material comprising a fourth surface; bringing the first surface in direct contact with the third surface; bringing the second surface in direct contact with the fourth surface; pressing the first film, the current collector, and the second film together to cause the first surface to adhere to the third surface, and the second surface to adhere to the fourth surface; and wherein said step of pressing comprises a step of processing the first film, the current collector, and the second film in a calender to cause the first surface of the current collector to adhere to the third surface of the first film, and to cause the second surface of the current collector to adhere to the fourth surface of the second film; and wherein the film comprises a dry fibrillized blend of carbon and binder particles.
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Specification