High solids content paste formulations for secondary battery electrode

A high solids content paste formulated for fabricating a positive electrode of an electrochemical energy storage device, comprising:

• a solid phase mixing of a positive active material and a carbon material to form a solids mixture that is wetted to form a wetted solids mixture;
• one or more binder solids and an organic solvent combined with the binder solvents to form a viscous binder mixture, wherein the viscous binder mixture and the wetted active material are subsequently combined to form a paste;
• and
• a hyperdispersant added to the paste to form the high solids content paste for the positive electrode to control viscosity of the paste based on a particular coating tool and a composition configured for a shelf life having no separation, sedimentation, or coagulation of the high solids content paste and configured to maintain its deposited shape after coating until the high solids content paste has dried,
• wherein the high solids content paste has a viscosity in the range of 25,479 cP to 47,184 cP and a corresponding density of 2.72 to 2.73 g/cc.

A plurality of high solids content pastes formulated for fabricating electrodes of an electrochemical energy storage device, comprising:

• (i) a first high solids content paste for a positive electrode of the electrochemical energy storage device, including:
• a solid phase mixing of a positive active material and a carbon material to form a solids mixture that is wetted to form a wetted solids mixture;
• a binder solid and an organic solvent combined with the binder solid to form a viscous binder mixture, wherein the viscous binder mixture and the wetted solids mixture are subsequently combined to form a first paste;
• and
• a hyperdispersant added to the first paste to form the first high solids content paste for the positive electrode to control viscosity of the first high solids content paste based on a particular coating tool and a composition configured for a shelf life having no separation, sedimentation, or coagulation of the high solids content paste and configured to maintain its deposited shape after coating until the first high solids content paste has dried wherein the first high solids content paste has a viscosity in the range of 25,479 cP to 47,184 cP and a corresponding density of 2.72 to 2.73 g/cc;
• and
• (ii) a second high solids content paste for a negative electrode of the electrochemical energy storage device, including:
• a negative active material wherein the negative active material is wetted to form wetted negative active material;
• a binder and a water solvent combined with the binder to form a viscous binder mixture, wherein a low shear mixer is used to combine the viscous binder mixture and the wetted negative active material to form a second paste;
• and
• a hyperdispersant added to the second paste to form the first high solids content paste for the positive electrode to control viscosity of the second high solids content paste based on the particular coating tool and a composition configured for a shelf life having no separation, sedimentation, or coagulation of the high solids content paste and configured to maintain its deposited shape after coating until the second high solids content paste has dried,
• wherein the second high solids content paste has a viscosity in the range of 25,479 cP to 47,184 cP and a corresponding density of 2.72 to 2.73 g/cc.