Patent ID: 8904626

Claim:
A method of forming an electrode, comprising the steps of: (a) providing a mixture of carbon particles and water and shearing the mixture to form a dispersion of the carbon particles in the water; (b) adding non-fibrillated POLY(TETRAFLUOROETHYLENE) to the dispersion to provide a resultant mixture comprising 2-10% by dry weight of POLY(TETRAFLUOROETHYLENE), 0-30% by dry weight of a conducting material, and 60-98% by dry weight of carbon particles, wherein a ratio by weight between the water and a total of the POLY(TETRAFLUOROETHYLENE), the conducting material and the carbon particles in the resulting mixture is in a range of 3:2 to 4:1, and shearing the resultant mixture until at least a portion of the POLY(TETRAFLUOROETHYLENE) has been fibrillated; (c) processing the resultant mixture into a sheet; and (d) attaching the sheet to a current collector.