Particle based electrodes and methods of making same

1. A blend of dry particles fibrillized for use in the manufacture of a coated electrode, comprising: a mixture of dry fibrillized dry carbon and dry binder particles.

2. The particles of claim 1 , wherein the dry binder particles comprise a polymer, and wherein the dry carbon particles comprise activated and conductive carbon.

3. The particles of claim 2 , wherein the binder comprises particles subjected to high shear forces.

4. The particles of claim 3 , wherein the high shear forces are applied by gas at more than about 60 PSI.

5. The particles of claim 3 , wherein the binder comprises milled polymer particles.

6. The particles of claim 3 , wherein the binder comprises jet milled polymer particles.

7. The particles of claim 3 , wherein the binder comprises hammer milled polymer particles.

8. The particles of claim 2 , wherein the binder comprises fluoropolymer particles.

9. The particles of claim 8 , wherein the binder comprises PTFE.

10. The particles of claim 8 , wherein the electrode is an energy storage device electrode.

11. The particles of claim 10 , wherein the energy storage device is a capacitor.

12. An electrode, comprising;

a dry blend of dry carbon particles and dry binder particles subjected to high shear forces.

13. The electrode of claim 12 , wherein the blend comprises approximately 50% to 99% activated carbon.

14. The electrode of claim 12 , wherein the blend comprises approximately 0% to 25% conductive carbon.

15. The electrode of claim 12 , wherein the blend comprises approximately 0.5% to 20% fluoropolymer.

16. The electrode of claim 12 , wherein the blend comprises approximately 80% to 95% activated carbon, approximately 0% to 15% conductive carbon, and approximately 3% to 15% fluoropolymer.

17. The electrode of claim 12 , wherein the electrode is a capacitor electrode.

18. The electrode of claim 17 , wherein the electrode is a double-layer capacitor electrode.

19. The electrode of claim 12 , wherein the electrode is a battery electrode.

20. The electrode of claim 12 , wherein the electrode is a fuel-cell electrode.

21. The electrode of claim 12 , further comprising a current collector, wherein the binder and carbon particles are in the form of a coated dried slurry, wherein the slurry is coupled to the current collector.

22. A capacitor product, comprising;

a dry fibrillized blend of dry particles subjected to high shear forces, the particles including binder and carbon particles; and

one or more current collector, wherein the blend of dry particles are disposed onto the one or more current collector as a coating.

23. The product of claim 22 , wherein between the one or more current collector and the dry particles is disposed a bonding layer.

24. The product of claim 22 , wherein the one or more current collector comprises aluminum.

25. The product of claim 24 , further comprising a housing, wherein the one or more current collector is shaped as a roll, wherein the roll is disposed within the housing.

26. The product of claim 25 , wherein within the housing is disposed an electrolyte.

27. The product of claim 26 , wherein the electrolyte comprises acetonitrile.

28. The product of claim 22 , wherein the capacitor is rated to operate at a voltage of no more than about 3.0 volts.

29. An energy storage device, comprising:

dry fibrillized electrode means for providing coated electrode functionality in an energy storage device.

30. A capacitor, the capacitor comprising:

a housing;

a cover;

a collector, the collector disposed in the housing, the collector comprising two ends, a first end coupled to the housing, a second end coupled to the cover;

a dried electrode slurry, the dried electrode slurry disposed as a coating onto the collector, the dried electrode slurry comprising a dry fibrillized blend of dry carbon and dry polymer, the dry fibrillized blend comprising of essentially no processing additive; and

an electrolyte, the electrolyte disposed in the housing.

31. The capacitor of claim 30 , wherein the capacitor comprises a capacitance of greater than 1 Farad.