Abstract: A cathode produced from a new process for manufacturing a cathode component from a free-standing sheet of cathode material, is described. The process comprises a first step of adjusting the particle size of the cathode active material to a useful size followed by mixing with binder and conductive additives suspended in a suitable solvent to form a paste. The paste is then fed into a series of roll mills to form the sheet material, or the paste can first be pelletized before the rolling step. The cathode sheet material is dried and punched into cathode plates having a myriad of geometric shapes suitable for cathode preparation by compressing a current collector between two plates of the cathode material.

Abstract: A new process for manufacturing a cathode component from a free-standing sheet of cathode material, is described. The process comprises a first step of adjusting the particle size of the cathode active material to a useful size followed by mixing with binder and conductive additives suspended in a suitable solvent to form a paste. The paste is then fed into a series of roll mills to form the sheet material, or the paste can first be pelletized before the rolling step. The cathode sheet material is dried and punched into cathode plates having a myriad of geometric shapes suitable for cathode preparation by compressing a current collector between two plates of the cathode material.

Abstract: An electrochemical cell having a serpentine-like electrode wherein electrode active material thereon is distributed for maximizing capacity and minimizing volume. The electrode active material extends along the length of the current collecting element of the electrode and terminates at a fold which defines an outer side of an outer section so that electrode active material is not positioned on this outer side where it would not be facing an opposite polarity electrode and where it may thus be generally ineffective for increasing battery capacity. The resulting savings in volume allows the thickness of the electrode active layer to be increased so that additional battery capacity may be achieved in the same battery volume.