Cathode with a composite nickel structure and method to manufacture the same

A battery cell including an electrode with a composite nickel structure, the battery cell comprising:

• a single cathode defining the electrode with the composite nickel structure, the single cathode including:
• a single current collector including a first side and a second side;
• a first cathode electrode coating the first side of the single current collector such that the first cathode electrode is in direct contact with the first side of the single current collector, wherein the first cathode electrode includes a first concentration of nickel;
• and
• a second cathode electrode coating the second side of the single current collector such that the second cathode electrode is in direct contact with the second side of the single current collector, wherein the second cathode electrode is a nickel-free cathode electrode;
• a single anode facing the single cathode, wherein the single anode includes a first current collector having a first anode electrode coating one side of the first current collector and a second anode electrode coating another side of the first current collector;
• a single separator separating the single anode from the single cathode;
• and
• an electrolyte configured to provide a lithium-ion conduction path through the single separator such that ion transfer is enabled between the single anode and the single cathode via the lithium-ion conduction path of the electrolyte.

A method for manufacturing a cathode with a composite nickel structure, the method comprising:

• applying a first cathode electrode material to a first side of a cathode current collector within the cathode, wherein the first cathode electrode material directly contacts the first side of the cathode current collector;
• drying the first cathode electrode material to the cathode current collector;
• calendaring the first cathode electrode material and the cathode current collector;
• applying a second cathode electrode material to a second side of the cathode current collector such that the second cathode electrode material directly contacts the second side of the cathode current collector;
• drying the second cathode electrode material to the cathode current collector;
• and
• calendaring the first cathode electrode material, the second cathode electrode material, and the cathode current collector;
• wherein the first cathode electrode material is a nickel-based active material including a first nickel concentration, and wherein the second cathode electrode material is nickel-free active material devoid of nickel material.