Dry electrode manufacture by temperature activation method

Abstract

A method of manufacturing a free-standing electrode film includes preparing a mixture including an electrode active material, a conductive material, and a binder, heating the mixture to 70° C. or higher, subjecting the mixture to a shear force, and, after the mixture has been subjected to the shear force, pressing the mixture into a free-standing film. The method may further include adding a solvent to the mixture. A resulting free-standing electrode film may include an amount of binder less than 4% by weight.

1 - 20 . (canceled) 
     
     
         21 . A free-standing electrode film comprising:
 an electrode active material; and   one or more binders totaling less than 4 percent by weight of the free-standing electrode film, the electrode active material having an exposed surface that is unblocked by the one or more binders.   
     
     
         22 . The free-standing electrode film of  claim 21 , wherein the one or more binders comprise polytetrafluoroethylene (PTFE). 
     
     
         23 . The free-standing electrode film of  claim 21 , wherein the one or more binders total 3.5 percent by weight of the free-standing electrode film. 
     
     
         24 . The free-standing electrode film of  claim 21 , wherein the electrode active material is in an amount 82-99 percent by weight of the free-standing electrode film. 
     
     
         25 . The free-standing electrode film of  claim 21 , wherein the electrode active material comprises one or more materials selected from the group consisting of activated carbon, graphite, hard carbon, and metal oxide. 
     
     
         26 . The free-standing electrode film of  claim 21 , further comprising a conductive material. 
     
     
         27 . The free-standing electrode film of  claim 26 , wherein the conductive material is in an amount less than 10 percent by weight of the free-standing electrode film. 
     
     
         28 . The free-standing electrode film of  claim 27 , wherein the conductive material is 3.5 percent by weight of the free-standing electrode film. 
     
     
         29 . The free-standing electrode film of  claim 21 , further comprising solvent in an amount less than 3 percent by weight of the free-standing electrode film. 
     
     
         30 . The free-standing electrode film of  claim 29 , wherein the solvent has a boiling point of less than 130° C. 
     
     
         31 . The free-standing electrode film of  claim 29 , wherein the solvent includes one or more chemicals selected from the group consisting of a hydrocarbon, an acetate ester, an alcohol, a glycol, ethanol, methanol, isopropanol, acetone, diethyl carbonate, and dimethyl carbonate. 
     
     
         32 . An electrode for use in an energy storage device, the electrode comprising:
 a current collector; and   an electrode film laminated on the current collector, the electrode film comprising an electrode active material and one or more binders totaling less than 4 percent by weight of the electrode film, the electrode active material having an exposed surface that is unblocked by the one or more binders.   
     
     
         33 . The electrode of  claim 32 , wherein the one or more binders comprise polytetrafluoroethylene (PTFE). 
     
     
         34 . The electrode of  claim 32 , wherein the one or more binders total 3.5 percent by weight of the electrode film. 
     
     
         35 . The electrode of  claim 32 , wherein the electrode active material is in an amount 82-99 percent by weight of the electrode film. 
     
     
         36 . The electrode of  claim 32 , wherein the electrode active material comprises one or more materials selected from the group consisting of activated carbon, graphite, hard carbon, and metal oxide. 
     
     
         37 . The electrode of  claim 32 , wherein the electrode film further comprises a conductive material. 
     
     
         38 . The electrode of  claim 37 , wherein the conductive material is in an amount less than 10 percent by weight of the electrode film. 
     
     
         39 . The electrode of  claim 38 , wherein the conductive material is 3.5 percent by weight of the electrode film. 
     
     
         40 . The electrode of  claim 32 , wherein the electrode film further comprises solvent in an amount less than 3 percent by weight of the electrode film.