Dry process electrically conductive composite formation

An energy storage device comprising an electrically conductive porous composite comprising:

• a thermally expanded polymer microsphere matrix binding a material composition having electrical conductivity properties to form an electrically conductive porous composite, the expanded microsphere matrix forming a three-dimensional interconnecting and interpenetrating pore network through which the bound material composition having electrical conductivity properties is distributed.

A method of forming a hollow electrode, the method comprising:

• placing a mixture of expandable polymer microspheres and a material composition having electrical conductivity properties in a tube-shaped confined volumetric space;
• and
• heating the mixture in the tube-shaped confined volumetric space to sufficiently expand the polymer microspheres to thereby bond the thermally-expanded polymer microspheres and the material composition having electrical conductivity properties within the tube-shaped confined volumetric space and form a hollow electrode comprising an electrically conductive porous composite.