Multi-layer cathode for rechargeable batteries and method for making same

A rechargeable battery comprising:

• a lithium-containing anode;
• a stainless-steel cathode current collector;
• a two-layer cathode comprising (i) lithium iodide as an active cathode material, (ii) a first electrode layer in contact with the cathode current collector, wherein the first electrode layer comprises at least two adhesion promoting binders and at least two first conductive additives with an electrochemical surface area ≥800 m2/gm, and (iii) a second electrode layer coated over the first electrode layer, wherein the second electrode layer comprises at least one polymeric binder that participates in a complexation interaction with the lithium iodide active material and at least one second conductive additive with a conductivity ≥5 S/cm;
• and an electrolyte in contact with the anode and the cathode;
• a liquid electrolyte comprising at least one organic solvent and at least one ionic salt in contact with the anode and the cathode;
• and
• an oxidizing gas in contact with the anode, the cathode, and the liquid electrolyte.

A method of fabricating a multi-layer cathode for a rechargeable battery comprising:

• preparing a first slurry comprising at least one adhesion promoting binder and at least one first conductive additive with an electrochemical surface area ≥800 m2/gm;
• dosing at least one halogen or metal halide active material solubilized in water or alcohol into the first slurry;
• applying the first slurry with the active material to a cathode current collector to form a first electrode layer of a multi-layer cathode;
• preparing a second slurry comprising at least one polymeric binder and at least one second conductive additive with a conductivity ≥5 S/cm;
• and
• coating the second slurry over the first electrode layer to form a second electrode layer of the multi-layer cathode.

A method of fabricating a multi-layer cathode for a rechargeable battery comprising:

• preparing a first slurry comprising at least one adhesion promoting binder and at least one first conductive additive with an electrochemical surface area ≥800 m2/gm;
• applying the first slurry to a cathode current collector to form a first electrode layer of a multi-layer cathode;
• preparing a second slurry comprising at least one polymeric binder, at least one second conductive additive with a conductivity ≥5 S/cm, and at least one halogen or metal halide active material solubilized in water or alcohol;
• and
• coating the second slurry over the first electrode layer to form a second electrode layer of the multi-layer cathode.