Method for fabricating self-aligning electrode
First Claim
1. A method of manufacturing an electrode, the method comprising:
- providing a first film of active electrode material comprising a first film surface;
coating the first film surface with a first layer of wet adhesive binder; and
drying the first layer of wet adhesive binder to obtain a first dry binder coating on the first film surface.
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Accused Products
Abstract
Electrodes are constructed with pressure-bonding techniques that simplify alignment of various electrode components during lamination. In an exemplary embodiment, a current collector is made from aluminum foil that has been roughed or pitted on both surfaces. The surfaces of the current collector can be further treated to enhance adhesion properties of these surfaces. Layers of film that include active electrode material, such as activated carbon particles, are fabricated using non-lubricated techniques. Each film is coated on one side with an adhesive binder solution, such as a thermoplastic solution. The adhesive binder is dried, and the films are laminated to the current collector using a calender with heated rollers. The resulting electrode product is processed to shape electrodes, which can then be used in electrical energy storage devices, including double layer capacitors.
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Citations
25 Claims
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1. A method of manufacturing an electrode, the method comprising:
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providing a first film of active electrode material comprising a first film surface; coating the first film surface with a first layer of wet adhesive binder; and drying the first layer of wet adhesive binder to obtain a first dry binder coating on the first film surface. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
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24. A method of manufacturing an electrode, the method comprising:
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making a first sheet from active electrode material using a non-lubricated high-shear technique, the active electrode material comprising activated carbon particles, the first sheet comprising a first sheet surface; making a second sheet from the active electrode material using a non-lubricated high-shear technique, the second sheet comprising a second sheet surface;
coating the first sheet surface with a first layer of adhesive binder;coating the second sheet surface with a second layer of adhesive binder; providing a current collector comprising a first current collector surface and a second current collector surface; stacking the first sheet, the second sheet, and the current collector so that the first current collector surface is in contact with the first layer of adhesive binder and the second current collector surface is in contact with the second layer of adhesive binder, thereby obtaining a stacked product; and laminating the stacked product by pressing the current collector and the first and second sheets to cause the first sheet to bond to the first current collector surface and the second sheet to bond to the second current collector surface, thereby obtaining a laminated electrode product.
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25. A method of manufacturing an electrode, the method comprising:
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providing a first dry self supporting film of active electrode material formed from a dry powder material and comprising a first film surface; coating the first film surface with a first layer of wet adhesive binder; and drying the first layer of wet adhesive binder to obtain a first dry binder coating on the first film surface.
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Specification