Abstract: A method of manufacturing a free-standing electrode film includes preparing a mixture including an electrode active material, a binder, and an additive solution or conductive paste, the additive solution or conductive paste being in an amount less than 5% by weight of the mixture and including a polymer additive and a liquid carrier, as well as a conductive material in the case of a conductive paste. The mixture may have total solid contents greater than 95% by weight. Preparing the mixture may include mixing the additive solution or conductive paste with the electrode active material to lubricate the electrode active material and subsequently adding and mixing in the binder. The method may further include 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.

Abstract: A manufacturing method for the formation of lithium, potassium, and/or calcium intercalation compounds on a negative electrode for a battery or capacitor cell is disclosed. The battery or capacitor cell is constructed with a negative electrode that may contain graphitic carbon, silicon, metal oxide, and/or complex metal oxides and a lithium, potassium, and/or calcium ion source supplemental electrode. After construction of the cell, a method of controlled electrical contact is applied between the positive electrode and negative electrode to accelerate and regulate a process of ion exchange between the supplemental metal ion source electrode and the negative electrode which results in the formation of intercalation compounds within the negative electrode, and produces a battery or capacitor with a higher working voltage, high cycle life, and long DC life.

Abstract: A method for producing an electrode for an energy storage device includes: forming a current collector from a conductive material; forming a primer layer on the current collector; injecting dry powder electrode materials into the primer layer, wherein the dry powder electrode materials injected into the primer layer form an electrode film in electrical contact with the current collector.