Recyclable dry-particle based adhesive electrode and methods of making same
A dry process based capacitor and method for using one or more recyclable electrode film structure is disclosed.
1. A dry method of making an energy storage device electrode film, the dry method comprising:
forming a first dry electrode film from a first plurality of dry particles, wherein no solvents are used for forming the first dry electrode film, wherein the first dry electrode film consists of a fibrillizable fluoropolymer dry binder, activated carbon particles and conductive carbon particles, and wherein the first plurality of dry particles consist of a fibrillizable fluoropolymer dry binder, activated carbon particles, and conductive carbon particles; and
recycling at least a portion of the first dry electrode film to form a second dry electrode film, wherein the recycling is a dry recycling process in which no solvents are used in any portion of the process, wherein the dry recycling process consists of:
reducing in size the portion of the first dry electrode film to form a second plurality of homogeneous dry particles, wherein the second plurality of homogeneous dry particles consist of a free flowing powder of a fibrillizable fluoropolymer dry binder, activated carbon particles and conductive carbon particles; and
calendering a composition, wherein the composition consists of the second plurality of homogeneous dry particles, to form the second dry electrode film;
wherein calendering the second dry electrode film is performed directly after forming the second plurality of homogeneous dry particles; and
wherein at least one of the first and second dry electrode films is self-supporting.
2. The dry method of claim 1 , further comprising coupling a first side of the second dry electrode film to a collector.
3. The dry method of claim 1 , wherein the fibrillizable fluoropolymer dry binder comprises polytetrafluoroethylene.
4. The dry method of claim 1 , wherein the first dry electrode film is self-supporting.
5. The dry method of claim 1 , wherein the second dry electrode film is self-supporting.
6. The dry method of claim 1 , wherein the first and second dry electrode films are heated dry films.
7. The dry method of claim 1 , wherein the second dry electrode film comprises a density of about 0.50 to 0.70 gm/cm3.
8. The dry method of claim 1 , wherein the first dry electrode film comprises between about 80% to 95% activated carbon, between about 0% to 15% conductive carbon, and between about 3% to 15% fluoropolymer.
9. The dry method of claim 1 , wherein the second dry electrode film comprises a length of at least one meter.
10. The dry method of claim 1 , wherein the second dry electrode film comprises a self-supporting dry intermixed film structure.
11. The dry method of claim 1 , wherein the second dry electrode film is both conductive and adhesive.
12. The dry method of claim 11 , wherein the second dry electrode film is coupled directly to a current collector.
13. The dry method of claim 1 , wherein the reducing step comprises one or more processing steps selected from the group consisting of dry fibrillizing, dry blending, and dry milling.
14. The dry method of claim 13 , wherein the reducing step comprises jet-milling.
15. A method of making a battery comprising:
making at least one energy storage device electrode using the method of claim 1 ;
inserting the at least one energy storage device electrode into a housing;
covering the housing with a cover; and
adding electrolyte into the housing.
16. The dry method of claim 1 , wherein calendering the second dry electrode film is performed within 10 minutes after forming the second plurality of homogeneous dry particles.
17. A dry method of making an energy storage device electrode film, the dry method comprising:
forming a first dry electrode film solely from a first dry free flowing powder, wherein the first dry free flowing powder consists of fibrillizable fluoropolymer dry binder particles, dry activated carbon particles and dry conductive carbon particles; and
recycling at least a portion of the first dry electrode film to form a second dry electrode film, wherein the recycling is a dry recycling process in which no solvents are used in any portion of the process, the dry recycling process consists of:
collecting an unused portion of the first dry electrode film, wherein the unused portion of the first dry electrode film consists of fibrillizable fluoropolymer dry binder particles, dry activated carbon particles, and dry conductive carbon particles;
reprocessing the unused portion of the first dry electrode film to form a second dry homogeneous free flowing powder, wherein the second dry homogeneous free flowing powder and the unused portion of the first electrode film consists of fibrillizable fluoropolymer dry binder particles, dry activated carbon particles, and dry conductive carbon particles; and
calendering a composition, wherein the composition consists of the second dry homogeneous free flowing powder to form the second dry electrode film;
wherein calendering the second dry electrode film is performed directly after forming the second dry homogeneous free flowing powder; and wherein at least one of the first and second dry electrode films is self-supporting.
18. The dry method of claim 17 , wherein the fibrillizable fluoropolymer dry binder particles comprise polytetrafluoroethylene.
19. The dry method of claim 17 , further comprising coupling a first side of the second dry electrode film to a collector.
20. The dry method of claim 17 , wherein the first dry electrode film is self-supporting.
21. The dry method of claim 17 , wherein the second dry electrode film is self-supporting.
22. The dry method of claim 17 further comprising heating the first and second dry electrode films.
23. The dry method of claim 17 , wherein the first dry electrode film comprises between about 80% to 95% activated carbon, between about 0% to 15% conductive carbon, and between about 3% to 15% fibrillizable fluoropolymer dry binder particles.
24. The dry method of claim 17 , wherein the second dry electrode film comprises a self-supporting dry intermixed film structure.
25. The dry method of claim 17 , wherein the second dry electrode film is both conductive and adhesive.
26. The dry method of claim 17 , wherein reprocessing further comprises one or more processing steps selected from the group consisting of dry fibrillizing, dry blending and dry milling.
27. The dry method of claim 26 , wherein the processing step comprises jet-milling.
28. A method of making a battery comprising making at least one energy storage device electrode using the method of claim 17 ;
inserting the at least one energy storage device electrode into a housing;
covering the housing with a cover; and
adding electrolyte into the housing.
29. The dry method of claim 17 , wherein calendering the second dry electrode film is performed within 10 minutes after forming the second dry homogeneous free flowing powder.