Particle based electrodes and methods of making same

1. A method of making a slurry coated electrode, the method comprising:

dry blending dry carbon particles and dry binder to form a dry mixture comprised of the dry carbon particles and the dry binder;

liquefying the dry mixture with a solution to form a slurry;

applying the slurry to a current collector;

drying the slurry; and compacting the current collector and slurry.

2. The method of claim 1 , wherein the step of blending comprises a step of dry fibrillizing the mixture.

3. The method of claim 2 , wherein the dry fibrillizing step comprises milling the mixture.

4. The method of claim 2 , wherein the dry fibrillizing step comprises subjecting the mixture to high shear forces.

5. The method of claim 2 , wherein the dry fibrillizing step utilizes a high-pressure gas.

6. The product of claim 5 , wherein the high-pressure gas comprises a pressure of more than 60 PSI.

7. The product of claim 5 , wherein the gas comprises a water content of no more than 20 PPM.

8. The method of claim 1 , further comprising the step of treating the current collector prior to applying the slurry to improve adhesion between the current collector and slurry.

9. The method of claim 8 , wherein the step of treating the current collector further comprises coating the current collector with a bonding agent prior to applying the slurry.

10. The method of claim 8 , wherein the step of treating the current collector further comprises roughening a surface of the current collector prior to applying the slurry.

11. The method of claim 1 , wherein the dry binder comprises a fluoropolymer.

12. The method of claim 11 , wherein the fluoropolymer particles comprise PTFE.

13. The method of claim 11 , wherein the mixture comprises approximately 0% to 25% conductive carbon.

14. The method of claim 11 , wherein the mixture comprises approximately 0.5% to 20% fluoropolymer particles.

15. The method of claim 11 , wherein the mixture comprises approximately 80% to 95% activated carbon, approximately 0% to 15% conductive carbon, and approximately 3% to 15% fluoropolymer.

16. The method of claim 1 , wherein the mixture comprises conductive particles.

17. The method of claim 1 , wherein the mixture comprises activated carbon particles.

18. The method of claim 1 , wherein the mixture comprises approximately 50% to 99% activated carbon.

19. The method of claim 1 , wherein the solution comprises deionized water.

20. The method of claim 1 , wherein the current collector comprises aluminum.

21. The method of claim 1 , wherein the step of applying the suspension comprises coating the current collector with the slurry using a doctor blade, a slot die, or a direct or reverse gravure process.