Energy storage device product

Abstract

A compressible and deformable layer is densified and laminated to a layer of a material that is relatively resistant to stretching. The densification and bonding take place in a single step. As used in fabrication of electrodes, for example, electrodes for double layer capacitors, a deformable and compressible active electrode film is manufactured from activated carbon, conductive carbon, and a polymer. The electrode film may be bonded directly to a collector. Alternatively, a collector may be coated with a wet adhesive layer. The adhesive layer is subsequently dried onto the foil. The dried adhesive and foil combination may be manufactured as a product for later sale or use, and may be stored as such on a storage roll or other storage device. The active electrode film is overlayed on the metal foil, and processed in a laminating device, such as a calender. Lamination both densifies the active electrode film and bonds the film to the metal foil. Spreading of the active electrode film in the plane parallel to the plane of the metal foil is reduced or eliminated during lamination, because of the adhesion between the film and the foil.

1 . An energy storage device product, comprising:
 a collector; and a dry adhesive adhered on the collector.   
     
     
         2 . The product of  claim 1 , wherein the collector and dried adhesive are stored as the product. 
     
     
         3 . The product of  claim 1 , wherein the product further comprises an electrode film and the electrode film is adhered to the collector by the dried adhesive. 
     
     
         4 . The product of  claim 3 , wherein the electrode film is formed of a plurality of dry fibrillized particles. 
     
     
         5 . The product of  claim 3 , wherein the electrode film is formed from an extruded slurry. 
     
     
         6 . The product of  claim 3 , wherein the electrode film and the dried adhesive are calendared together. 
     
     
         7 . The product of  claim 3 , wherein the collector comprises an aluminum. 
     
     
         8 . The product of  claim 7 , wherein the product is a capacitor. 
     
     
         9 . The product of  claim 8 , wherein the product is a double-layer capacitor. 
     
     
         10 . The product of  claim 3 , wherein the electrode film comprises a length, a width, and a thickness, wherein the electrode film is constrained by the dried adhesive such that when a force is applied to the film perpendicular to the length and width of the film the electrode film substantially maintains its width and length. 
     
     
         11 . The product of  claim 3 , wherein the particles comprise carbon and PTFE particles.