The present disclosure is directed to an improved fibrillated matrix- type active layer for an electrode of improved strength and durability and capable of operation at high current density with enhanced resistance to mechanical failure, and to a process for producing such improved active layers. The process is characterized by alternately or simultaneously producing two components; combining the components; shear blending (fibrillating) the mixture; drying; chopping to a fine powder form, and rolling into a self-sustaining, coherent shear form. Alternatively, the active layer can be formed by wet deposition of the powder on a filter paper or like medium.PPThe term "matrix" as used herein means that the active carbon particles are present within an unsintered network of carbon black/PTFE (fibrillated) material.
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