Solvent-free dry powder process to incorporate ceramic particles into electrochemical cell components

Abstract

Solvent-free methods of making a component, like an electrode, for an electrochemical cell are provided. A particle mixture is processed in a dry-coating device having a rotatable vessel defining a cavity with a rotor. The rotatable vessel is rotated at a first speed in a first direction and the rotor at a second speed in a second opposite direction. The particle mixture includes first inorganic particles (e.g., electroactive particles), second inorganic particles (e.g., ceramic HF scavenging particles), and third particles (e.g., electrically conductive carbon-containing particles). The dry coating creates coated particles each having a surface coating (including second inorganic particles and third particles) disposed over a core region (the first inorganic particle). The coated particles are mixed with polymeric particles in a planetary and centrifugal mixer that rotates about a first axis and revolves about a second axis. The polymeric particles surround each of the plurality of coated particles.