Solvent-free dry powder process to incorporate ceramic particles into electrochemical cell components

A method of making an electrode for an electrochemical cell without solvents, the method comprising:

• forming a plurality of coated particles each having a surface coating disposed over a core region by processing a plurality of first particles comprising an electroactive material, a plurality of second particles comprising a ceramic material, and a plurality of third particles comprising a carbon-containing material in a dry-coating device comprising a rotatable vessel defining a cavity with a rotor disposed within the cavity, by rotating the rotatable vessel at a first speed in a first direction and rotating the rotor at a second speed greater than the first speed in a second direction opposite to the first direction, wherein the core region comprises a portion of the plurality of the first particles and the surface coating comprises a portion of the plurality of the second particles and a portion of the plurality of the third particles;
• mixing the plurality of coated particles with a plurality of binder particles in a planetary and centrifugal mixer that rotates about a first axis and revolves about a second axis to form a mixture in which a portion of the plurality of binder particles surrounds each of the plurality of coated particles;
• dry spraying the mixture onto a current collector;
• and
• consolidating the mixture by applying heat and pressure to form a porous electrode comprising the plurality of first particles comprising an electroactive material having a coating comprising a ceramic and a carbon-containing material distributed in a matrix of the binder.