Method of making a cathode for an electrochemical cell

DETAILED DESCRIPTION I claim: 1.
A method for constructing a large, highly active cathode electrode for use in an electrochemical cell comprising the steps of: forming a porous, semi-rigid dough of cathode material; drying the dough; breaking up the dried dough to form a mass of discrete porous conglomerates; and pressing a quantity of the conglomerates onto a rigid electrically conductive screen-like member so that the conglomerates substantially fill the interstices therein and are structurally supported by the interstice-defining members of the screen-like member.
2.
The method of claim 1 wherein the step of forming a porous, semi-rigid dough of cathode material includes mixing carbon black and an isopropanol solution to form a slurry.
3.
The method of claim 1 wherein the step of forming a porous, semi-rigid dough of cathode material includes dry-mixing carbon black and graphite.
4.
The method of claim 3 wherein an isopropanol solution is added to the resulting dry mixture to form a slurry.
5.
The method of claim 2 wherein a binder is added to the slurry to produce said dough.
6.
The method of claim 5 wherein the conglomerates are completely cured subsequent to their impressment onto the screen-like member.
7.
The method of claim 5 wherein the dough is extruded into a spaghetti-like shape prior to being dried and broken up into conglomerates.




Description:
FIELD OF THE INVENTION The present invention is related generally to electrochemical cells and is more particularly concerned with a novel construction for cells having high discharge capacities.
Cells with high discharge capacities are utilized for a wide variety of applications including portable lighting sources, communications equipment and the like.
Since such cells may be required to supply current over extended periods of time, it is desirable to provide the largest discharge capacity per unit volume, hereinafter referred to as energy density, and the highest possible rate capability.
One such electrochemical system characterized by a large energy density of approximately 600 watt-hrs