The Gillette Company

Duracell U.S. Operations, Inc.

Maya Stevanovic

Michael Pozin

Minkoo Kang

Fred Joseph Berkowitz

Lucyna M Pawlowska

Frank M Delnick

Dharmendra Rana

John J Weckesser

Christopher Boczer

Rosauro Del Rosario

Nikolai Nikolaevich Issaev

Bhupendra Kanchanial Patel

Steven Jeffrey Specht

George M Cintra

Yelena Kouznetsova

Ken Taylor

Zhiping Jiang

Rosario Del Rosauro

Barry D Josephs

Barry David Josephs

Yelena Valentinovna Kouznetsova

A cathode slurry comprising organic solvent, lithium iron phosphate, polymeric binder, and at least one conductive agent, and from about 30 wt. % to about 40 wt. % solids is prepared. The cathode slurry may be coated onto at least one side of a substrate to form a cathode coated substrate. The cathode coated substrate may be dried to form a cathode. An anode and cathode may be contained within a housing with electrolyte to form a lithium ion cell.

Method of making a cathode slurry and a cathode

A primary cell having an anode comprising lithium or lithium alloy and a cathode comprising iron disulfide (FeS) or a mixture of iron disulfide (FeS) and iron sulfide (FeS) and conductive carbon particles. A cathode slurry is prepared comprising the FeSor FeSplus FeS powder, conductive carbon, binder, and a solvent. The binder is preferably a styrene-ethylene/butylene-styrene (SEBS) block copolymer. There is an advantage discovered in utilizing a hydronaphthalene solvent to form the cathode slurry. The preferred solvent is 1,2,3,4-tetrahydronaphthalene or decahydronaphthalene and mixtures thereof. The slurry mixture is coated onto a conductive substrate and the solvent evaporated leaving a dry cathode coating on the substrate. Higher drying temperature may be used resulting in a dry cathode coating which resists cracking. The anode and cathode can be spirally wound with separator therebetween and inserted into the cell casing with electrolyte then added.

Method of preparing cathode containing iron disulfide for a lithium cell

A cathode includes a foil current collector including a coating containing iron disulfide on one side that covers less than 100% of the side.

Battery electrodes

This disclosure relates to methods of making a cathode for a lithium battery. The batteries include: (a) treating a cathode current collector with flame or corona; (b) coating a slurry containing iron disulfide, a first solvent, and a binder onto the cathode current collector obtained from step (a) to form a coated cathode current collector, in which the slurry contains about 73-75% by weight solids and the binder contains a polymer selected from the group consisting of linear di- and tri-block copolymers, linear tri-block copolymers cross-linked with melamine resin, ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, tri-block fluorinated thermoplastics, hydrogenated nitrile rubbers, fluoro-ethylene-vinyl ether copolymers, thermoplastic polyurethanes, thermoplastic olefins, and polyvinylidene fluoride homopolymers; and (c) drying the coated cathode current collector obtained from step (b) to provide a cathode, in which the cathode contains no more than 0.5% by volume of the first solvent and is capable of being bent to 180&#xb0;. This disclosure also relates to methods of making a lithium battery.

Flexible cathodes

A primary cell having an anode comprising lithium or lithium alloy and a cathode comprising iron disulfide (FeS), iron sulfide (FeS) and carbon particles. The electrolyte comprises a lithium salt dissolved in a solvent mixture. A cathode slurry is prepared comprising iron disulfide (FeS) powder, iron sulfide (FeS) powder, carbon, binder, and a liquid solvent. The mixture is coated onto a conductive substrate and solvent evaporated leaving a dry cathode coating on the substrate. The anode and cathode can be spirally wound with separator therebetween and inserted into the cell casing with electrolyte then added.

Lithium cell with cathode including iron disulfide and iron sulfide

A primary cell having an anode comprising lithium and a cathode comprising iron disulfide (FeS) and carbon particles. The electrolyte comprises a lithium salt dissolved in a nonaqueous solvent mixture which contains an additive, preferably iodine, suppressing voltage delay. A cathode slurry is prepared comprising iron disulfide powder, carbon, binder, and liquid solvent. The mixture is coated onto a conductive substrate and solvent evaporated leaving a dry cathode coating on the substrate. The anode and cathode can be spirally wound with separator therebetween and inserted into the cell casing with electrolyte then added.

Lithium cell

This disclosure relates to methods of making a cathode for a lithium batter. The methods include: (a) treating a cathode current collector with flame or corona; (b) coating a slurry containing iron disulfide, a first solvent, and a binder onto the cathode current collector obtained from step (a) to form a coated cathode current collector, in which the slurry contains about 73-75% by weight solids and the binder contains a polymer selected from the group consisting of linear di- and tri-block copolymers, linear tri-block copolymers cross-linked with melamine resin, ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, tri-block fluorinated thermoplastics, hydrogenated nitrile rubbers, fluoro-ethylene-vinyl ether copolymers, thermoplastic polyurethanes, thermoplastic olefins, and polyvinylidene fluoride homopolymers; and (c) drying the coated cathode current collector obtained from step (b) to provide a cathode, in which the cathode contains no more than 0.5% by volume of the first solvent and is capable of being bent to 180&#xb0;. This disclosure also relates to methods of making a lithium battery.

Method of making cathode including iron disulfide

A primary lithium battery can include a current collector that includes aluminum, a cap that includes aluminum, or both. The current collector can be coated with a cathode material The aluminum battery components can have high mechanical strength and low electrical resistance.

Methods of making coated battery components

A cathode for a lithium battery is described. The cathode includes: (a) a current collector including aluminum foil; and (b) an active cathode material including: (i) manganese dioxide; (ii) conductive materials; and (iii) a binder selected from the group consisting of linear di- and tri-block polymers, linear tri-block polymers cross-linked with melamine resin, ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, tri-block fluorinated thermoplastics, hydrogenated nitrile rubbers, fluoro-ethylene-vinyl ether copolymers, thermoplastic polyurethanes, thermoplastic olefins, and polyvinylidine fluoride homopolymers.

Applying materials, e.g. electrolytes and other materials, in the form of a spray during battery manufacture, particularly using a vibratory nebulizer to produce a small droplet, low velocity spray.

Growing community of inventors

Danbury, CT, United States of America

Maya Stevanovic