Method for manufacturing a porous electrode, and battery containing such an electrode

A method for manufacturing an electrochemical device, the method comprising:

• forming a porous electrode by:
• (a) providing a substrate and a colloidal suspension or a paste comprising aggregates or agglomerates of monodisperse primary nanoparticles of at least one active electrode material, the monodisperse primary nanoparticles having an average primary diameter of between 2 nm and 60 nm, said aggregates or agglomerates having an average diameter of between 100 nm to 200 nm, wherein the substrate is a substrate acting as an electric current collector or an intermediate substrate,
• (b) depositing a layer is from said colloidal suspension or said paste provided on at least one face of said substrate using one of:
• electrophoresis, ink-jet printing, flexographic printing, doctor blade coating, roll coating, curtain coating, dip-coating, or slot-die coating,
• (c) drying the deposited layer, before or after separating said layer from the intermediate substrate, then heat treating the dried layer under an oxidizing atmosphere, and then consolidating the heat treated layer by pressing and/or heating to obtain a mesoporous layer,
• (d) depositing a coating of an electronically conductive material on and inside the pores of said mesoporous layer,
• wherein the meoporous layer is free of binder and has a porosity of between 20% and 60% by volume, preferably between 25% and 50%, and pores with an average diameter of less than 50 nm.

A method for manufacturing a lithium ion battery having a capacity greater than 1 mAh, the method comprising:

• forming a porous electrode by:
• (a) providing a substrate and a colloidal suspension or a paste comprising aggregates or agglomerates of monodisperse primary nanoparticles of at least one active electrode material, the monodisperse primary nanoparticles having an average primary diameter of between 2 nm and 60 nm, said aggregates or agglomerates having an average diameter of between 100 nm to 200 nm, wherein the substrate is a substrate acting as an electric current collector or an intermediate substrate,
• (b) depositing a layer is from said colloidal suspension or said paste provided on at least one face of said substrate using one of:
• electrophoresis, ink-jet printing, flexographic printing, doctor blade coating, roll coating, curtain coating, dip-coating, or slot-die coating,
• (c) drying the deposited layer, before or after separating said layer from the intermediate substrate, then heat treating the dried layer under an oxidizing atmosphere, and then consolidating the heat treated layer by pressing and/or heating to obtain a mesoporous layer,
• (d) depositing a coating of an electronically conductive material on and inside the pores of said mesoporous layer,
• wherein the meoporous layer is free of binder and has a porosity of between 20% and 60% by volume, preferably between 25% and 50%, and pores with an average diameter of less than 50 nm.