Method of Producing Participate Electrode Materials for Alkali Metal Batteries

A method of producing anode particulates or cathode particulates for use in an alkali metal battery, said method comprising:

• a) preparing a slurry containing particles of an anode active material or cathode active material capable of reversibly absorbing and desorbing lithium ions or sodium ions, an electron-conducting material, and a lithium salt or sodium salt and an optional polymer dissolved in a volatile liquid medium, which is different in composition than a liquid solvent of an intended electrolyte for said battery;
• b) conducting a particulate-forming means to convert said slurry into multiple anode particulates or cathode particulates having a dimension from 10 nm to 300 μm, wherein an anode particulate or a cathode particulate is composed of (i) particles of said anode or cathode active material, (ii) said electron-conducting material, and (iii) said lithium salt or sodium salt, said optional polymer, and said volatile liquid medium, wherein said electron-conducting material forms a 3D network of electron-conducting pathways in electronic contact with said anode active material or cathode active material and said lithium salt or sodium salt is in ionic contact with said anode or cathode active material and wherein said anode particulate or cathode particulate has an electrical conductivity from about 10−7 S/cm to about 300 S/cm;
• and
• c) partially or completely removing said volatile liquid medium from said multiple anode particulates or cathode particulates.