Low Porosity Electrodes for Rechargeable Batteries

A positive electrode for a rechargeable battery comprising at least 95 wt % active cathode material with an electrode loading of at least 6 mg/cm2, and an electrode porosity of less than 2 vol %, wherein the active cathode material comprises a powder mixture.

A positive electrode for a rechargeable battery comprising at least 95 wt % active cathode material with an electrode loading of at least 25 mg/cm2, and having an electrode porosity of less than 10 vol %, wherein the active cathode material comprises a powder mixture.

A positive electrode for a rechargeable battery comprising at least 95 wt % active cathode material with an electrode loading of at least 30 mg/cm2, and having an electrode porosity of less than 12 vol %, wherein the active cathode material comprises a powder mixture.

A positive electrode for a rechargeable battery comprising at least 95 wt % active cathode material with an electrode loading of at least 40 mg/cm2, and having an electrode porosity of less than 14 vol %, wherein the active cathode material comprises segregated powder particles.

A positive electrode for a rechargeable battery comprising at least 95 wt % active cathode material, the electrode being porous, and the pores in the electrode being filled with electrolyte, wherein the electrolyte content in the electrode is less than 6 wt % of the weight of the active material, and wherein the active cathode material comprises a powder mixture.

A positive electrode for a rechargeable battery in a charged state comprising an electrolyte and a cathode material comprising a powder mixture, wherein less than a critical amount of electrolyte is present in the positive electrode, said critical amount defined as the amount of electrolyte that can be fully combusted by oxygen that evolves when the cathode material collapses according to the formula Li1−xMO2→(1−x) LiMO2+x/3M3O4+x/3O2, wherein x is the amount of Lithium extracted from the cathode material, and wherein the valence of M is +3.

A positive electrode for a rechargeable battery in a charged state comprising an electrolyte and an active cathode material comprising a powder mixture, wherein a total mass of electrolyte is less than 18 wt %*A of the active cathode mass, where A=Q/280, and Q is the extracted charge in mAh per g of active cathode material compared to the fully discharged battery.