IP Library › Granted Patent US 12,626,929
Granted Patent B2
US 12,626,929 · App. 19/192,711 · Granted May 12, 2026

Ultra-high molecular weight polyethylene (UHMWPE) particles and filled articles produced therewith

Inventors: Guy A. Sbriglia (Christiana, PA); Jeffrey A. Knopf (Wilmington, DE); Mark D. Edmundson (Rancho Palos Verdes, CA); Shunsuke Takaki (Okayama, JP); Shailesh P. Vidhate (Malvern, PA); Ryuta Yamamoto (Okayama, JP); Joseph W. Henderson (Elkton, MD)
Assignees: W. L. Gore & Associates, Inc.; W. L. Gore & Associates G.K.
H01M4/622C08F10/02H01M4/0435
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Quick Facts
Patent No.
US 12,626,929
App. No.
19/192,711
Granted
May 12, 2026
Kind
B2
Abstract

Apparatuses, systems, materials, and methods for preparing polyethylene electrodes for use in energy storage and transfer via dry electrode processing is described herein. Ultra-high molecular weight polyethylene (UHMWPE) particles and filler particles are used to form a blended composition. With shear, the UHMWPE fibrillates to durably enmesh the filler particles. The blended composition with the fibrillated UHMWPE particles may, in turn, be used to form an article, such as an electrode. The blended composition may contain less than 10% by weight of the UHMWPE. The UHMWPE has a molecular weight of at least about 2,000,000 g/mol, a bulk density from about 0.04 g/mL to about 0.25 g/mL, and a melt enthalpy of at least 190 J/g. In some embodiments, the UHMWPE may be conditioned to alter the size and/or shape of the particles. The median diameter of the conditioned UHMWPE particles is from 5 microns to 300 microns.

Claims (14)

1 . A blended particle composition comprising:

filler particles; and

fibrillatable ultra-high molecular weight polyethylene (UHMWPE) particles, wherein the UHMWPE particles are used as a binder, the UHMWPE particles having:

a molecular weight of at least about 2,000,000 g/mol,

a bulk density from about 0.04 g/ml to about 0.25 g/ml, and

a melt enthalpy of at least 190 J/g,

wherein the UHMWPE particles are formed of agglomerations of fine particles having an average diameter greater than or equal to 10 nm and less than or equal to 2000 nm, and

wherein the blended particle composition contains therein about 1% by weight to about 10% by weight of the UHMWPE binder particles.

2 . The blended particle composition of claim 1 , wherein the blended particle composition contains therein about 1% by weight to about 5% by weight of the UHMWPE binder particles.

3 . The blended particle composition of claim 1 , wherein the filler particles include filler material comprising at least one of carbon particles, conductive carbon particles, activated carbon particles, graphite particles, carbon black particles, and lithium compound particles.

4 . The blended particle composition of claim 1 , wherein the UHMWPE particles also have a percent (%) compressibility of at least 20% at 15 kPA normal stress as measured using powder rheometer at 22° C.

5 . The blended particle composition of claim 4 , wherein the UHMWPE particles also have cohesion of at least 3 kPa as measured using a powder rheometer at 22° C.

6 . The blended particle composition of claim 4 , wherein the UHMWPE particles also have unconfined yield stress (UYS) of at least 10 kPA as measured using a powder rheometer at 22° C.

7 . The blended particle composition of claim 4 , wherein the UHMWPE particles also have an angle of internal friction (AIF) of at least 25° as measured using a powder rheometer at 22° C.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Aug 11, 2025
From: SBRIGLIA, GUY A.; KNOPF, JEFFREY A.; EDMUNDSON, MARK D.; VIDHATE, SHAILESH P.; HENDERSON, JOSEPH W.
To: W. L. GORE & ASSOCIATES, INC.
Reel/Frame 071987/0141 →
Continuity (4)
Continuation 19099410
Provisional Application 63396402 · Aug 9, 2022
Provisional Application 63396407 · Aug 9, 2022
Related Publication 20250266460A1 · Aug 21, 2025
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