Process for fabrication of low basis weight electrode active blanks

A method for preparing an electrode, comprising the steps of:

• a) providing an electrode active material;
• b) mixing the electrode active material with a fluoro-polymeric material in a solvent to form an electrode admixture paste;
• c) removing the solvent from the electrode admixture paste to provide a solvent concentration of, by weight, about 15.7% to about 26%;
• d) calendering the filtered electrode admixture paste into a first sheet structure having a first thickness by subjecting the paste to at least one first calendering mill;
• e) calendering the first sheet structure into an electrode active structure having a second thickness less than the first thickness by contacting the first sheet structure in a second direction with at least one second calendering mill to thereby fibrillate the fluoro-polymeric material in other than a first direction used to form the first sheet structure from the pellet-shaped structures by the first calendering mill;
• and
• f) contacting the electrode active structure to at least one of a first and second major surfaces of a conductive substrate.

A method for preparing an electrode, comprising the steps of:

• a) providing an electrode active material;
• b) mixing the electrode active material with a fluoro-polymeric material in a solvent to form an electrode admixture paste;
• c) briquetting the electrode admixture paste into pellet-shaped structures;
• d) rolling the pellet-shaped structures into a first sheet structure having a first thickness by subjecting them to at least one first roll mill;
• e) rolling the first sheet structure into an electrode active structure having a second thickness less than the first thickness by contacting the first sheet structure in a second direction with at least one second roll mill to thereby fibrillate the fluoro-polymeric material in other than a first direction used to form the first sheet structure from the pellet-shaped structures by the first roll mill, wherein the first sheet structure is not folded from when it leaves the first roll mill to when it enters the second roll mill;
• and
• f) contacting the electrode active structure to at least one of a first and second major surfaces of a conductive substrate.