Method of making a cathode

1. A method of making a battery cathode, comprising:

mixing electrochemically active cathode material, graphite, water and an aqueous based binder to provide a mixture;

extruding the mixture continuously into a cathode;

removing water from the cathode; and

cutting the cathode into individual cathodes, wherein the aqueous based binder is present in amount of less than 3%.

2. The method of claim 1 wherein the water is removed by heating the cathode.

3. The method of claim 2 wherein the water is removed by heating the cathode between about 20 C. and 500° C.

4. The method of claim 2 wherein at least 50% by weight of the water is removed from the cathode by heating.

5. The method of claim 1 wherein the electrochemically active cathode material is selected from the group consisting of manganese oxide, manganese dioxide, electrolytic manganese dioxide (EMD), chemical manganese dioxide (CMD), high power electrolytic manganese dioxide (HP EMD), lambda manganese dioxide, and mixtures thereof.

6. The method of claim 1 wherein the aqueous based binder comprises hydroxypropylethylcellulose.

7. The method of claim 1 wherein the cathode has a cross-sectional configuration selected from the group consisting of circular, semicircular, star, multi-lobed, crescent, pie, partial ring and annulus.

8. The method of claim 1 wherein the cathode is extruded in at least two longitudinal pieces which are combined to form the equivalent of one longitudinally extruded cathode.

9. The method of claim 1 wherein the cathode further comprises potassium hydroxide.

10. The method of claim 9 wherein the binder is insoluble in the potassium hydroxide at potassium hydroxide concentrations less than 7%.

11. The method of claim 1 wherein the cathode further comprises a surfactant.

12. The method of claim 1 wherein the binder has a swelling of no more than 10% in water.

13. The method of claim 1 wherein the linear cathode shrinkage is less than 5.0%.

14. The method of claim 1 wherein the cross-sectional cathode shrinkage is less than 5.0%.

15. The method of claim 1 wherein the mixture has at least one peak from 20 Nm to 200 Nm at a time between 1 second and 10 seconds.

16. The method of claim 1 further comprising a conditioning step wherein the mixture is extruded prior to extruding the mixture into a cathode.

17. The method of claim 1 wherein the cathode has a dry bending strength of at least 0.5 N/mm 2 .

18. A method of making a battery, comprising:

i) making a cathode by:

a) mixing electrochemically active cathode material, graphite, water and an aqueous based binder to provide a mixture;

b) extruding the mixture into a cathode;

c) removing water from the cathode,

d) cutting the cathode into individual cathodes, wherein the aqueous based binder is present in amount of less than 3%;

ii) inserting the cathode in a can;

iii) inserting a separator in the can;

iv) inserting a current collector in the can;

v) inserting an anode in the can;

vi) inserting an electrolyte in the can; and

vii) sealing the can.

19. The method of claim 18 wherein the electrochemically active cathode material is selected from the group consisting of manganese oxide, manganese dioxide, electrolytic manganese dioxide (EMD), chemical manganese dioxide (CMD), high power electrolytic manganese dioxide (HP EMD), lambda manages dioxide, and mixtures thereof.

20. A mixture for making a battery cathode comprising EMD, graphite, and an aqueous binder and optionally comprising surfactants, electrolytes and additional binders wherein the mixture is characterized by a plastogram having at least one torque peak ranging from 20 to 80 Nm and a second peak occurring in time after the first peak ranging from 20 to 160 Nm.

21. The method of claim 1 , wherein the extruded cathode is not affixed onto a support substrate during the extruding, removing water, and cutting steps.

22. The method of claim 18 , wherein the extruded cathode is not affixed onto a support substrate during the extruding, removing water, and cutting steps.