# US 10,770,725 B2 · Alkaline battery cathode structures incorporating multiple carbon materials and orientations > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,770,725 B2 - Document ID: US10770725B2 - Status: Granted - Kind: B2 - Application number: 16/203,297 - Filed: 2018-11-28 - Published: 2019-03-28 - Granted: 2020-09-08 - Earliest claimed: 2016-08-10 - Assignees: Energizer Brands, LLC - Applicants: Energizer Brands, LLC - Inventors: Weiwei Huang - Web page: https://patentgrep.com/patent/US10770725B2 ## CPC - H01M 4/502: {for non-aqueous cells (H01M4/505 takes precedence)} - H01M 4/0402: {Methods of deposition of the material} - H01M 4/0411: {by extrusion} - H01M 4/0433: {Molding} - H01M 4/0485: {Casting} - H01M 4/06: Electrodes for primary cells - H01M 4/26: Processes of manufacture - H01M 4/381: {Alkaline or alkaline earth metals elements (H01M4/40 takes precedence)} - H01M 4/382: {Lithium (H01M4/405 takes precedence)} - H01M 4/624: {Electric conductive fillers} - H01M 4/625: {Carbon or graphite} - H01M 10/24: Alkaline accumulators - H01M 2004/028: {Positive electrodes} - Y02E 60/10: Energy storage using batteries - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract Cathode active materials for alkaline cells are disclosed. In particular, the cathode structures encompass conductive carbons introduced to the cathode so as to have a specific spatial orientation and/or a multi-carbon structure. The overall intent is to leverage the conductor(s) provided to the cathode structure to improve electronic and ionic conductance and, by extension, improve battery discharge performance. ## Claims ### Claim 1 A method of making a cathode structure for an alkaline battery comprising: a first mixing step including dispersing a first conductive material in a particulate active material and forming agglomerates in which the first conductive material is entrained within the agglomerates, wherein the active material comprises manganese dioxide; and a second mixing step including adhering a second conductive material with at least a portion of a surface of the agglomerates; and wherein the second conductive material comprises particles of a larger size in comparison to particles of the first conductive material. ### Claim 2 (depends on 1) The method according to claim 1, wherein the forming of agglomerates comprises compacting the dispersed first conductive material and particulate active material. ### Claim 3 (depends on 1) The method according to claim 1, wherein the manganese dioxide consists of at least 90 wt. % of the cathode structure. ### Claim 4 (depends on 1) The method according to claim 1, wherein the first conductive material comprises synthetic graphite. ### Claim 5 (depends on 4) The method according to claim 4, wherein the second conductive material comprises at least one selected from the group consisting of: unexpanded graphite, expanded graphite, graphene, graphite tubes, and graphite rods. ### Claim 6 A method of making a cathode structure for an alkaline battery comprising: a first mixing step including dispersing a first conductive material in a particulate active material and forming agglomerates in which the first conductive material is entrained within the agglomerates; a second mixing step including adhering a second conductive material with at least a portion of a surface of the agglomerates; and orienting the first conductive material to align the first conductive material in a common direction within the cathode structure; and wherein the second conductive material comprises particles of a larger size in comparison to particles of the first conductive material. ### Claim 7 (depends on 6) The method according to claim 6, wherein the orienting of the first conductive material includes at least one of: stretching, freeze casting, co-extrusion, and magnetic orientation. ### Claim 8 A method of making a cathode structure for an alkaline battery comprising: a first mixing step including dispersing a first conductive material in a particulate active material and forming agglomerates in which the first conductive material is entrained within the agglomerates; a second mixing step including adhering a second conductive material with at least a portion of a surface of the agglomerates; and forming the cathode structure produced by the second mixing step into a tubular cylinder; and wherein the second conductive material comprises particles of a larger size in comparison to particles of the first conductive material. ### Claim 9 (depends on 8) The method according to claim 8, wherein the forming the cathode structure is achieved by ring molding or impact molding. ### Claim 10 (depends on 6) The method according to claim 6, wherein the forming of agglomerates comprises compacting the dispersed first conductive material and particulate active material. ### Claim 11 (depends on 6) The method according to claim 6, wherein the first conductive material comprises synthetic graphite. ### Claim 12 (depends on 11) The method according to claim 11, wherein the second conductive material comprises at least one selected from the group consisting of: unexpanded graphite, expanded graphite, graphene, graphite tubes, and graphite rods. ### Claim 13 (depends on 6) The method according to claim 6, wherein the active material comprises manganese dioxide. ### Claim 14 (depends on 8) The method according to claim 8, wherein the forming of agglomerates comprises compacting the dispersed first conductive material and particulate active material. ### Claim 15 (depends on 8) The method according to claim 8, wherein the first conductive material comprises synthetic graphite. ### Claim 16 (depends on 15) The method according to claim 15, wherein the second conductive material comprises at least one selected from the group consisting of: unexpanded graphite, expanded graphite, graphene, graphite tubes, and graphite rods. ### Claim 17 (depends on 8) The method according to claim 8, wherein the active material comprises manganese dioxide. ### Claim 18 (depends on 1) The method according to claim 1, further comprising orienting the first conductive material to align the first conductive material in a common direction within the cathode structure. ### Claim 19 (depends on 8) The method according to claim 8, further comprising orienting the first conductive material to align the first conductive material in a common direction within the cathode structure.