Dry process electrically conductive composite formation

Abstract

An electrically conductive porous composite composed of an expanded microsphere matrix binding a material composition having electrical conductivity properties to form an electrically conductive porous composite is disclosed herein. An energy storage device incorporating the electrically conductive porous composite is also disclosed herein.

1 - 20 . (canceled) 
     
     
         21 . A solidified porous composite comprising:
 a thermally-expanded polymer matrix and a particulate filler material distributed through the polymer matrix, wherein the polymer matrix comprises compression and heat-bonded polymer microspheres having been thermally-expanded to fill a fixed volume cavity of a mold, the thermally-expanded polymer matrix having solidified and conformed to a shape of the fixed volume cavity,   wherein the solidified porous composite comprises a porosity of about 30% to about 90%.   
     
     
         22 . The solidified porous composite of  claim 21 , wherein the compression and heat-bonded polymer microspheres comprise spherical thermoplastic particles, at least some of the spherical thermoplastic particles comprising a thermoplastic polymer shell encapsulating a fluid. 
     
     
         23 . The solidified porous composite of  claim 21 , wherein at least a portion of the compression and heat-bonded polymer microspheres are ruptured. 
     
     
         24 . The solidified porous composite of  claim 21 , wherein the solidified porous composite comprises about 30 wt % to about 95 wt % of the particulate filler material. 
     
     
         25 . The solidified porous composite of  claim 21 , wherein the particulate filler material comprise at least one inorganic material. 
     
     
         26 . The solidified porous composite of  claim 25 , wherein the at least one inorganic material comprises at least one of zinc, nickel, or oxides thereof. 
     
     
         27 . The solidified porous composite of  claim 25 , wherein the at least one inorganic material comprises at least one of lithium intercalation compounds, lead, lead oxide, manganese dioxide, ruthenium oxide, tantalum oxide, silver, iron, iron oxide, metal hydrides, cobalt oxide, crystalline carbonaceous material, or amorphous carbonaceous material. 
     
     
         28 . The solidified porous composite of  claim 25 , wherein the particulate filler material comprises powders of the at least one inorganic material. 
     
     
         29 . The solidified porous composite of  claim 21 , wherein the particulate filler material exhibits an average particle size of about 3 μm to about 9 μm. 
     
     
         30 . The solidified porous composite of  claim 21 , wherein the solidified porous composite is rigid. 
     
     
         31 . The solidified porous composite of  claim 21 , wherein the solidified porous composite exhibits a cylindrical shape or a tube-like shape. 
     
     
         32 . The solidified porous composite of  claim 21 , wherein the solidified porous composite exhibits a sheet-like shape. 
     
     
         33 . The solidified porous composite of  claim 21 , wherein the solidified porous composite comprises an additive. 
     
     
         34 . The solidified porous composite of  claim 21 , further comprising at least one of polyvinylidene fluoride, polyvinylidene fluoride copolymer, polyethylene oxide, or polyacrylonitrile. 
     
     
         35 . The solidified porous composite of  claim 21 , further comprising at least one of a hydrogen-evolution inhibitor, an electrolyte-soluble pore former, an auxiliary binder, or a wettability-enhancing agent. 
     
     
         36 . The solidified porous composite of  claim 21 , further comprising a liquid disposed in pores defined by thermally-expanded polymer matrix and a particulate filler material. 
     
     
         37 . The solidified porous composite of  claim 21 , further comprising a mechanical reinforcement material. 
     
     
         38 . A method of forming the solidified porous composite of  claim 21 , the method comprising:
 placing a mixture of polymer microspheres and the particulate filler material in the fixed volume cavity of the mold; and   heating the mixture in the fixed volume cavity of the mold to sufficiently expand the polymer microspheres to form the compression and heat bonded polymer microspheres.   
     
     
         39 . The method of  claim 38 , wherein heating the mixture comprises heating the mixture to about 95° C. to about 200° C. 
     
     
         40 . An energy storage device comprising:
 a thermally-expanded polymer matrix and a particulate filler material distributed through the polymer matrix, wherein the polymer matrix comprises compression and heat-bonded polymer microspheres having been thermally-expanded to fill a fixed volume cavity of a mold, the thermally-expanded polymer matrix having solidified and conformed to a shape of the fixed volume cavity,   wherein the solidified porous composite comprises a porosity of about 30% to about 90%.