Dry electrode manufacture with lubricated active material mixture

A method of manufacturing a free-standing electrode film, the method comprising:

• preparing a mixture including an electrode active material, a binder, and a conductive paste, the conductive paste being in an amount less than 5% by weight of the mixture and including a polymer additive, a liquid carrier, and a conductive material, the mixture having total solid contents greater than 95% by weight, said preparing comprising mixing the conductive paste with the electrode active material to lubricate the electrode active material and subsequently adding the binder;
• subjecting the mixture to a shear force;
• and,
• after the mixture has been subjected to the shear force, pressing the mixture into a free-standing film.

A powdery mixture for use in manufacturing a free-standing electrode film, the powdery mixture comprising:

• an electrode active material;
• a binder;
• and
• an additive solution in an amount less than 5% by weight of the powdery mixture, the additive solution including a polymer additive and a liquid carrier,
• wherein the powdery mixture has total solid contents greater than 95% by weight.