DRY PARTICLE BASED ADHESIVE ELECTRODE AND METHODS OF MAKING SAME

• US 20080102371A1
• Filed: 11/13/2007
• Published: 05/01/2008
• Est. Priority Date: 07/09/2003
• 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:
  US11/939,494
• Publication Number:
  US 20080102371A1
• Time in Patent Office: Days
• US Class Current: 429/231.8
• CPC Class Codes: C04B 2235/77 Density
• CPC Class Codes: C04B 35/52 based on carbon, e.g. graphite
• CPC Class Codes: C04B 35/522 Graphite C04B35/536 takes precedence
• CPC Class Codes: C04B 35/634 Polymers C04B35/636 takes precedence
• CPC Class Codes: C04B 35/63488 Polyethers, e.g. alkylphenol polyglycolether, polyethylene glycol [PEG], polyethylene oxide [PEO]
• CPC Class Codes: H01G 11/22 Electrodes
• 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: H01G 9/00 Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors

Abstract

A dry process based capacitor and method for a self-supporting dry adhesive electrode film for use therein is disclosed.

Claims

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.