Battery electrode and methods of making

1. A method, comprising:

mixing a solvent with a dry cathode mixture to form a slurry, the dry cathode mixture including a cathode active material, a conductive diluent, and a polymeric binder;

at least partially removing the solvent from the slurry to form a composition;

calendering, in a first calendering step, the composition to form a sheet having a first set of dimensions, calendering the composition including passing the composition between calender rollers;

baking the sheet at a temperature of 25° C. to 150° C. for at least 15 minutes to form a dry sheet;

cutting the dry sheet into coupons having a second set of dimensions different from the first set of dimensions;

calendering, in a second calendering step, the coupons to form pressed coupons having a third set of dimensions different from the second set of dimensions;

baking the pressed coupons to form cathodes by subjecting the pressed coupons to a temperature of 25° C. to 150° C. for at least one hour.

2. The method of claim 1 , wherein baking the sheet includes subjecting the sheet to a temperature of 25° C. to 150° C. for 15 minutes to 3 hours±15 minutes.

3. The method of claim 2 , wherein baking the sheet includes subjecting the sheet to a temperature of 80° C. to 150° C. for 1 hour to 2 hours.

4. The method of claim 3 , wherein baking the pressed coupons includes subjecting the pressed coupons to a temperature of 60° C. to 150° C. for 3-12 hours.

5. The method of claim 3 , wherein baking the pressed coupons includes subjecting the pressed coupons to a temperature of 80° C. to 150° C. for 3-9 hours.

6. The method of claim 3 , wherein:

the cathode active material comprises silver vanadium oxide;

the conductive diluent comprises graphite and carbon black;

the polymeric binder comprises polytetrafluoroethylene.

7. The method of claim 3 , wherein, during mixing a solvent with the dry cathode mixture to form a slurry, the amount of solvent mixed with the dry cathode mixture is 55 to 75 wt % of the total weight of the slurry.

8. The method of claim 3 , wherein the slurry has a first solvent to powder weight ratio, and

wherein at least partially removing the solvent from the slurry is performed such that after the solvent removal, solvent to powder weight ratio is reduced to 15 wt % to 25 wt % of the first solvent to powder weight ratio.

9. The method of claim 1 , wherein:

baking the sheet includes subjecting the sheet to a temperature of 60° C. to 150° C. for 15 minutes to 3 hours; and

baking the pressed coupons includes subjecting the pressed coupons to a temperature of 60° C. to 150° C. for 3-12 hours.

10. The method of claim 1 , wherein:

baking the sheet includes subjecting the sheet to a temperature of 80° C. to 150° C. for 1 hour to 2 hours; and

baking the pressed coupons includes subjecting the pressed coupon to a temperature of 80° C. to 150° C. for 3-9 hours.

11. The method of claim 1 , wherein the slurry has a first solvent to powder weight ratio, wherein the first solvent to powder weight ratio is a 1.2 liquid to 1.0 solid weight ratio and wherein the solvent is a liquid paraffin.

12. The method of claim 1 , wherein calendering the composition to form the sheet comprises feeding the composition into a plastic tube and calendering the plastic tube using a calender machine comprising the calender rollers, wherein the diameter of the calender rollers is 4 inches or smaller, calendering the plastic tube including passing the plastic tube between the calender rollers.

13. The method of claim 1 , wherein calendering the composition to form a sheet comprises feeding the composition into a plastic tube and calendering the plastic tube using a calender machine that includes calender rollers with a diameter of 1.5 inches.

14. The method of claim 1 , wherein:

the solvent includes a liquid paraffin;

mixing the solvent with the dry cathode mixture includes adding to the dry cathode mixture the liquid paraffin so as to form an electrode active mixture having a 1.2 liquid to 1.0 solid weight ratio; and

mixing the electrode active mixture to disperse the binder;

at least partially removing the solvent from the slurry to form the composition comprises reducing the solvent to powder weight ratio to form a paste, wherein the paste is substantially 22% solvent by weight; and

calendering the composition to form the sheet comprises:

feeding the paste into a plastic tube; and

calendering the plastic tube with the paste inside the tube so as to form a calendered paste.

15. The method of claim 14 , wherein calendering the plastic tube comprises calendering the plastic tube using calender rollers that are between 1 inch and 3 inches in diameter.

16. The method of claim 14 , wherein calendering the composition to form the sheet further comprises:

calendering the plastic tube a plurality of more times;

removing the plastic tube from the paste to form the sheet;

calendering the sheet;

cutting the sheet into a first sheet and a second sheet; and

stacking the first sheet and the second sheet to form a stacked sheet.

17. The method of claim 16 , wherein calendering the composition to form a sheet further comprises calendering the stacked sheet in a direction that is different from a direction in which the sheet was calendered.

18. The method of claim 14 , wherein calendering the composition to form the sheet further comprises:

removing the calendered paste from the plastic tube; and

calendering the calendered paste so as to form the sheet with a thickness of 0.04 to 0.012 inches.