Dry-particle based adhesive and dry film and methods of making same

Abstract

Dry process based energy storage device structures and methods for using a dry adhesive therein are disclosed.

1 .- 40 . (canceled) 
     
     
         41 . A method of manufacturing an electrode film for an energy storage device, comprising:
 providing conductive particles;   providing binder particles;   intermixing the conductive and binder particles to form an electrode film mixture; and   forming an electrode film by compressing the electrode film mixture, wherein the method does not include heated drying of the electrode film after forming the electrode film.   
     
     
         42 . The method of  claim 41 , wherein the conductive particles comprise carbon. 
     
     
         43 . The method of  claim 42 , wherein the conductive particles comprise dry carbon. 
     
     
         44 . The method of  claim 42 , wherein the conductive particles comprise conductive carbon. 
     
     
         45 . The method of  claim 42 , wherein the conductive particles comprise graphite. 
     
     
         46 . The method of  claim 41 , wherein the binder particles comprise a fibrillizable binder. 
     
     
         47 . The method of  claim 46 , wherein the fibrillizable binder comprises a fluorinated polymer. 
     
     
         48 . The method of  claim 46 , wherein the fluorinated polymer comprises PTFE. 
     
     
         49 . The method of  claim 41 , wherein intermixing comprises forming the electrode film mixture comprising between about 50 to 99% activated carbon, 0% to 25% conductive carbon, and 0.5% to 20% binder particles by weight. 
     
     
         50 . The method of  claim 41 , wherein intermixing comprises milling the conductive particles and the binder particles. 
     
     
         51 . The method of  claim 41 , wherein forming the electrode film comprises compressing the electrode film mixture to a thickness of about 80 to 260 microns. 
     
     
         52 . The method of  claim 41 , wherein forming the electrode film comprises compressing the electrode film mixture to a density of at least about 0.3 gm/cm 3 . 
     
     
         53 . The method of  claim 41 , wherein forming the electrode film comprises forming a first film, wherein the method further comprises recycling a portion of the electrode film mixture to form a second film. 
     
     
         54 . The method of  claim 41 , wherein the electrode film is a battery electrode film. 
     
     
         55 . A method of manufacturing a battery, comprising placing the electrode film of  claim 41  into a battery housing. 
     
     
         56 . A system for manufacturing an electrode film for an energy storage device, comprising:
 a source container comprising an electrode film mixture, the electrode film mixture comprising conductive particles and binder particles;   a calender apparatus configured to receive the electrode film mixture from the source container, and compress the electrode film mixture to form an electrode film, wherein the system does not include a heated drier configured to dry the electrode film mixture.   
     
     
         57 . The system of  claim 56 , further comprising:
 a second source container comprising the conductive particles;   a third source container comprising the binder particles; and   a mixer configured to receive the conductive particles from the second source container, and receive the binder particles from the third source container, and mix the conductive particles and binder particles to form an electrode film mixture.   
     
     
         58 . The system of  claim 56 , further comprising a laminator apparatus comprising an electrically conductive substrate, wherein the laminator apparatus is configured to receive the electrode film from the calender apparatus and laminate the electrode film to the electrically conductive substrate. 
     
     
         59 . The system of  claim 57 , wherein the mixer is a miller. 
     
     
         60 . The system of  claim 58 , wherein the miller is selected from a jet miller, a pin miller, a roll miller, and a hammer miller.