RECYCLABLE DRY-PARTICLE BASED ADHESIVE ELECTRODE AND METHODS OF MAKING SAME

• US 20080206446A1
• Filed: 03/05/2008
• Published: 08/28/2008
• Est. Priority Date: 07/09/2003
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Maxwell Technologies Incorporated (Tesla Inc.)
• Inventors: Mitchell, Porter, Xi, Xiaomei, Zhong, Linda
• Granted Patent: US 11,430,613 B2
• Time in Patent Office: Days
• US Class Current: 427/58
• 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: H01G 11/86 specially adapted for electrodes carbonisation or activation of carbon for the manufacture of electrodes H01G11/34
• 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 using one or more recyclable electrode film structure is disclosed.

Claims

1. A method of making an energy storage device electrode, the method comprising:

forming a first electrode film from a plurality of particles;

and reusing one or more of the plurality of particles to form a second film.

2. The method of claim 1, wherein the plurality of particles are dry fibrillized.

3. The method of claim 2, wherein the operation of reusing comprises dry fibrillizing the particles after the particles are used to make the first electrode film.

4. The method of claim 1, further comprising coupling a first side of the second film to a collector.

5. The method of claim 1, wherein the one or more of the plurality of particles reused to form the second film comprise fibrillizable fluoropolymer particles, activated carbon particles, and conductive particles.

6. The method of claim 5, wherein the binder comprises a fluoropolymer.

7. The method of claim 5, wherein the conductive particles comprise conductive carbon particles.

8. The method of claim 1, wherein the first film is self-supporting.

9. The method of claim 1, wherein the second film is self-supporting.

10. The method of claim 1, wherein the plurality of particles comprise conductive carbon particles and activated carbon particles.

11. The method of claim 1, wherein the first and second films are heated dry films.

12. The method of claim 1, wherein the second film comprises a density of about 0.50 to 0.70 gm/cm².

13. The method of claim 1, wherein the first film comprises between about 80% to 95% activated carbon, between about 0% to 15% conductive carbon, and between about 3% to 15% fibrillizable fluoropolymer.

14. The method of claim 13, wherein the first film further comprises a thermoplastic.

15. The method of claim 1, wherein the second film comprises a length of at least one meter.

16. The method of claim 1, wherein the first film comprises substantially no processing additive.

17. The method of claim 1, wherein reusing operation comprises forming the second film using substantially no processing additive.

18. The method of claim 17, wherein the processing additives include hydrocarbons, high boiling point solvents, antifoaming agents, surfactants, dispersion aids, water, pyrrolidone, mineral spirits, ketones, naphtha, acetates, alcohols, glycols, toluene, xylene, and/or isoparaffinic fluids.

19. The method of claim 1, wherein the one or more of the plurality of particles reused to form the second film comprise dry processed recycled binder particles and conductive particles.

20. The method of claim 1, wherein the second film comprises a self-supporting dry intermixed film structure comprised of reused carbon and binder particles.

21. The method of claim 20, wherein the reusing operation comprises forming the second film comprises with substantially no processing additive.

22. The method of claim 1, wherein the one or more of the plurality of particles reused to form the second film comprise dry processed recycled binder particles and activated carbon particles.

23. The method of claim 22, wherein the second film is both conductive and adhesive.

24. The method of claim 23, wherein the second film is coupled directly to a current collector.

25. A method of making an energy storage device electrode, the method comprising:

dry processing a dry mixture of binder particles, activated carbon particles and recycled conductive particles to form an electrode film.

26. The method of claim 25, wherein the binder particles comprise a thermoplastic.

27. The method of claim 25, wherein electrode film is coupled to a collector.

28. The method of claim 25, wherein the recycled conductive particles comprise recycled conductive carbon particles.

29. The method of claim 25, wherein the dry processing operation comprises fibrillizing the binder particles.

30. The method of claim 25, wherein the binder particles comprise fibrillizable fluoropolymer particles.

31. The method of claim 25, wherein the electrode film comprises a self-supporting film.

32. The method of claim 25, wherein the binder particles are recycled.

33. The method of claim 25, wherein the activated carbon particles are recycled.

34. The method of claim 25, wherein the dry processing operation comprises substantially no processing additive.

35. A method of making an energy storage device electrode, the method comprising:

dry processing a dry mixture of activated carbon particles and recyclable binder particles to form a self-supporting electrode film.

36. The method of claim 35, further comprising coupling the self-supporting electrode film to a collector.

37. The method of claim 35, wherein the electrode film comprises a capacitor electrode film.

38. The method of claim 35, wherein the dry processing operation comprises fibrillizing the recyclable binder particles.

39. The method of claim 35, wherein the recyclable binder particles comprise recyclable fibrillizable fluoropolymer particles.

40. The method of claim 35, wherein the recyclable binder particles are recycled.

41. The method of claim 35, wherein the activated carbon particles are recyclable.

42. The method of claim 41, wherein the recyclable activated carbon particles are recycled.

43. The method of claim 35, wherein the dry processing operation comprises substantially no processing additive.