Description:FIELD OF INVENTION
[0001] The subject matter of the present disclosure broadly relates to the field of
batteries. Particularly, the present disclosure relates to a process of preparing an
electrode composite. Additionally, the present disclosure relates to an electrode
5 comprising the electrode composite, an electrochemical cell comprising the
electrode, and use thereof.
BACKGROUND OF THE INVENTION
[0002] The increasing interest in lithium-ion batteries (LIBs) arises from their
10 widespread use in modern electronic devices, attributed to their high energy
density, extended cycle life, and low self-discharge rate. These attributes make
LIBs indispensable across a range of applications, including portable electronics,
electric vehicles, and grid energy storage systems.
[0003] In LIBs, the cathode active material (CAM) plays a vital role in achieving
15 high energy density and enhancing battery capacity. Advancements in cathode
design are key to improving overall performance and safety. To ensure optimal
functionality, the electrode must maintain uniform CAM distribution and
mechanical stability. This highlights the importance of refining active materials and
electrode architecture to meet energy and safety standards.
20 [0004] In recent years, there has been increasing interest in developing dry cathode
manufacturing processes as an alternative to conventional slurry-based methods.
Dry cathode fabrication offers potential advantages such as reduced processing
steps, lower environmental impact, and improved energy efficiency.
[0005] However, dry cathodes often face challenges related to electrical
25 conductivity and resistance, which can negatively affect the rate performance of the
battery. Higher resistance leads to increased voltage drop during high-rate charge
and discharge, limiting the power output and energy efficiency of the cell. Reducing
electrical resistance in dry cathodes remains a significant challenge.
[0006] Therefore, there is a dire need to develop a process for preparing an
30 electrode composite that can overcome the above-mentioned drawbacks and
delivers electrochemically efficient performance.
2
SUMMARY OF THE INVENTION
[0007] In an aspect of the present disclosure, there is provided a process for
preparing an electrode composite, the process comprising: i) mixing an active
5 material with a first part of a first conducting carbon, and a second conducting
carbon, to obtain a first mixture; ii) blending a cohesive binder with the first mixture
to obtain a second mixture; followed by addition of a second part of the first
conducting carbon with the second mixture to obtain a third mixture; iii) blending
a fibrillating binder with the third mixture to obtain a fourth mixture, followed by
10 addition of a third part of the first conducting carbon with the fourth mixture to
obtain a fifth mixture; and iv) subjecting the fifth mixture to high shear mixing at a
tip speed in a range of 25 to 35 m/s, at temperature in a range of 65 to 75°C, and
subsequently cooling to a temperature in a range of 0 to 19℃ to obtain the
composite.
15 [0008] In another aspect of the present disclosure, there is provided an electrode
comprising the electrode composite prepared by the process as disclosed herein,
wherein the electrode is a cathode.
[0009] In one another aspect of the present disclosure, there is provided an
electrochemical cell comprising: a. the electrode as disclosed herein; b. an anode,
20 and c. an electrolyte.
[0010] In yet another aspect of the present disclosure, there is provided the use of
the electrode as disclosed herein, or the electrochemical cell as disclosed herein, for
the manufacture of a battery.
[0011] These and other features, aspects, and advantages of the present subject
25 matter will be better understood with reference to the following description. This
summary is provided to introduce a selection of concepts in a simplified form. This
summary is not intended to identify key features or essential features of the claimed
subject matter, nor is it intended to be used to limit the scope of the claimed subject
matter.
30
BRIEF DESCRIPTION OF THE DRAWINGS
3
[0012] The following drawings form a part of the present specification and are
included to further illustrate aspects of the present disclosure. The disclosure may
be better understood by reference to the drawings in combination with the detailed
description of the specific embodiments presented herein.
5 [0013] Figure 1 depicts the scanning electron microscopy (SEM) microstructure
images of (a) cathode C1, (b) cathode C2, (c) cathode C3, (d) comparative cathode
CP1, (e) comparative cathode CP2, and (f) comparative cathode CP3, in accordance
with an embodiment of the present disclosure.
[0014] Figure 2 depicts the scanning electron microscopy (SEM) morphological
10 images of at varying resolutions (a) cathode C1, (b) cathode C2, and (c)
comparative cathode CP2, in accordance with an embodiment of the present
disclosure.
[0015] Figure 3 depicts (a) representation of specific discharge capacity versus
different C-rates for cathode C1, cathode C2, and comparative cathode CP2, and
15 (b) charge -discharge plot of cathode C1, cathode C2, and comparative cathode CP2
at 3C rate, in accordance with an embodiment of the present disclosure.
[0016] Figure 4 depicts the cycle life of electrochemical cells independently
comprising cathode C1, cathode C2, and comparative cathode CP2, in accordance
with an embodiment of the present disclosure.
20
DETAILED DESCRIPTION OF THE INVENTION
[0017] Those skilled in the art will be aware that the present disclosure is subject
to variations and modifications other than those specifically described. It is to be
understood that the present disclosure includes all such variations and
25 modifications. The disclosure also includes all such steps, features, compositions,
and compounds referred to or indicated in this specification, individually or
collectively, and any and all combinations of any or more of such steps or features.
Definitions
[0018] For convenience, before further description of the present disclosure, certain
30 terms employed in the specification, and examples are delineated here. These
definitions should be read in the light of the remainder of the disclosure and
4
understood as by a person of skill in the art. The terms used herein have the
meanings recognized and known to those of skill in the art, however, for
convenience and completeness, particular terms and their meanings are set forth
below.
5 [0019] The articles “a”, “an” and “the” are used to refer to one or to more than one
(i.e., to at least one) of the grammatical object of the article.
[0020] The terms “comprise” and “comprising” are used in the inclusive, open
sense, meaning that additional elements may be included. It is not intended to be
construed as “consists of only”.
10 [0021] Throughout this specification, unless the context requires otherwise the
word “comprise”, and variations such as “comprises” and “comprising”, will be
understood to imply the inclusion of a stated element or step or group of elements
or steps but not the exclusion of any other element or step or group of element or
steps.
15 [0022] The term “including” is used to mean “including but not limited to”.
“Including” and “including but not limited to” are used interchangeably.
[0023] The term “w/w” means the percentage by weight, relative to the weight of
the total composition, unless otherwise specified.
[0024] The term “active material” refers to the active constituent of an electrode,
20 which comprises the particles that undergo oxidation or reduction, resulting in
reversible ion storage. For the purpose of the present disclosure the active material
is nickel manganese cobalt oxide. (NMC). The nickel manganese cobalt has a
bimodal distribution with a single crystal size in a range 2 to 3.5 µm and a
polycrystal size in a range 5 to 15 µm.
25 [0025] The term “first conducting carbon” refers to the high surface area
amorphous carbon-based additive used in an electrode to enhance the conductivity
of the electrode. For the purposes of the present disclosure, the first conducting
carbon is selected from amorphous carbon, carbon black, Ketjen Black, super P, or
combinations thereof. The first conducting carbon has a surface area in a range of
30 1300 to 1400 m2/g.
5
[0026] The term “second conducting carbon” refers to the low surface area based
crystalline carbon-based additive used in an electrode to enhance the conductivity
of the electrode. For the purposes of the present disclosure, the second conducting
carbon is selected from graphene, KS6L, single walled carbon nanotube (SWCNT),
5 or combinations thereof. The second conducting carbon has a surface area in a range
of 17 to 20 m2/g.
[0027] The term “cohesive binder” refers to a polymeric substance that provides
cohesion, adhesion, and mechanical integrity to the active material when loaded on
a current collector, to obtain an electrode. For the purpose of the present disclosure,
10 the cohesive binder is selected from polyvinylidene fluoride (PVDF),
polyvinylidene fluoride hexafluoropropylene copolymer (PVDF-HFP),
polyvinylidene fluoride-vinylidene fluoride copolymers (PVDF-VF2),
polyvinylidene fluoride copolymers (PVDF-copolymers), or combinations thereof.
[0028] The term “fibrillating binder” refers to a type of the binder constituent of an
15 electrode, which has the property to form small fibrils under the application of shear
force. The fibrillating binder provides the mechanical integrity of the electrode
during manufacturing and provide optimal dispersion and adhesion of the active
material and conducting carbon to the current collector. For the purpose of the
present disclosure, the fibrillating binder is selected from polytetrafluoroethylene
20 (PTFE), polytetrafluoroethylene copolymers (PTFE-copolymer), or combinations
thereof.
[0029] The term “first mixture” refers to the mixture obtained by mixing an active
material with a first part of a first conducting carbon, and a second conducting
carbon.
25 [0030] The term “second mixture” refers to the mixture obtained by blending the
first mixture with a cohesive binder.
[0031] The term “third mixture” refers to the mixture obtained by addition of a
second part of the first conducting carbon with the second mixture.
[0032] The term “fourth mixture” refers to the mixture obtained by blending a
30 fibrillating binder with the third mixture to obtain a fourth mixture.
6
[0033] The term “fifth mixture” refers to the mixture obtained by addition of a third
part of the first conducting carbon with the fourth mixture.
[0034] The term “current collector” refers to the electric bridging
component, which collects electrical current generated at the electrodes of
5 electrochemical devices and connect with external circuits. For the purpose of the
present disclosure, the current collector is selected from primer coated aluminum
foil, or bare aluminum foil.
[0035] The term “bimodal distribution” refers to a dataset or material characterized
by two distinct peaks or modes in its particle size distribution. In the context of
10 electrode materials, this indicates the presence of two dominant particle size ranges
namely, single crystals and polycrystals, which contribute to enhanced packing
density, mechanical strength, and electrochemical performance. A single crystal is
defined as a particle with a continuous and unbroken lattice structure, free of grain
boundaries, offering superior electrical conductivity and mechanical stability. In
15 contrast, a polycrystal consists of multiple smaller crystallites or grains, each with
its own orientation. The presence of grain boundaries in polycrystals can influence
conductivity and ion transport, while also improving structural integrity. For the
purpose of the present disclosure, the nickel manganese cobalt material exhibits a
bimodal particle size distribution, with a single crystal size range from 2 to 3.5 µm
20 and a polycrystal size range from 5 to 15 µm.
[0036] The term “peel strength” refers to the force required to separate the electrode
coating layer comprising active material, binder, and conducting carbon from the
current collector in a battery cell. It serves as a measure of the electrode’s
mechanical integrity and is indicative of the battery’s performance and durability.
25 For the purpose of the present disclosure, the electrode exhibits a peel strength on
single side coated cathode in a range of 1.1 to 2.0 N/25 mm.
[0037] The term “resistance” refers to the opposition that a material presents to the
flow of electric current. In the context of an electrode composite, electrical
resistance depends on the properties and proportions of the active material, first
30 conducting carbon, second conducting carbon, cohesive binder, and fibrillating
binder, as well as the structure and morphology of the composite itself. Lower
7
electrical resistance within the electrode composite enables more efficient electron
flow, which can enhance the overall performance of the battery by improving both
energy and power density. For the purpose of the present disclosure, the electrode
composite has resistance in a range of 0.2 to 0.7 Ω.
5 [0038] The term “electrical resistance” refers to the opposition that a material
presents to the flow of electric current. In the context of an electrode, electrical
resistance depends on the properties and proportions of the active material, first
conducting carbon, second conducting carbon, cohesive binder, and fibrillating
binder, as well as the structure and morphology of the composite, and the electrode
10 itself. Lower electrical resistance of electrode enables more efficient electron flow,
which can enhance the overall performance of the battery by improving both energy
and power density. For the purpose of the present disclosure, the electrode has an
electrical resistance in a range of 0.15 to 0.25 Ω.
[0039] The term “charge capacity” refers to the ability of an electrochemical cell
15 to store charge during the charging process. This parameter helps in evaluating the
performance of electrochemical cells. For the purpose of the present disclosure, the
electrode has a charge capacity in a range of 230 to 233 mAh/g.
[0040] The term “discharge capacity” refers to the ability of an electrochemical cell
to release charge during the discharging process. This is an important parameter for
20 evaluating the performance of electrochemical cells. For the purpose of the present
disclosure, the electrode has a discharge capacity in a range of 211 to 215 mAh/g.
[0041] The term “initial coulombic efficiency” (ICE) refers to a measure of the
efficiency of the first charge-discharge cycle of an electrochemical cell.
Specifically, it is the ratio of the discharge capacity to the charge capacity during
25 the first cycle, expressed as a percentage. A higher ICE indicates that a larger
proportion of the charge stored during the first cycle can be recovered during
discharge. It reflects longer battery life and better overall efficiency. For the
purpose of the present disclosure, the electrode has an initial coulombic efficiency
in a range of 92 to 94%.
30 [0042] The term “capacity retention” refers to the percentage of the initial capacity
that an electrochemical cell retains after a certain number of cycles. It is a measure
8
of an electrochemical cell’s ability to maintain its charge capacity over time and
through multiple charge-discharge cycles. For the purpose of the present disclosure,
the electrode has the at least 98% capacity retention up to 50 cycles.
[0043] The term “C-rate” refers to the rate at which an electrochemical cell is
5 charged or discharged relative to its capacity. It is the measurement of the rate at
which an electrochemical cell is charged or discharged relative to its maximum
capacity. It is crucial in determining the electrochemical cell’s energy retention and
overall performance. A 1C rate means the electrochemical cell will be fully charged
or discharged in one hour. Lower C-rates such as 0.2C, or 0.5C are generally better
10 for energy retention as they facilitate longer, safer charging cycles. These rates help
minimize thermal issues and mechanical stress, thereby extending the battery’s
lifespan. On the other hand, higher C-rates such as 2C, 3C can lead to faster
charging and discharging. For the purpose of the present disclosure, the electrode
has a specific capacity of at least 163 mAh/g at a 2C rate.
15 [0044] The term “bulk density (ρb)” refers to the mass of the electrode composite
powder divided by the total volume it occupies, including interparticle voids. It is
measured without applying any compaction and reflects the natural packing
behaviour of the powder. Bulk density influences the flowability of the electrode
composite during processing, which in turn affects manufacturing efficiency and
20 uniformity of electrode formation. For the purpose of the present disclosure, the
electrode composite exhibits a bulk density in a range of 1.2 to 1.6 g/cc.
[0045] The term “true density (ρtr)” refers to the density of the electrode composite
itself, excluding any pores or voids. It is defined as the mass of the composite
divided by its actual solid volume. True density provides insight into the intrinsic
25 material properties and structural compactness of the electrode composite, which
are critical for optimizing electrochemical performance. For the purpose of the
present disclosure, the electrode composite exhibits a true density in a range of 4.0
to 5.0 g/cc.
[0046] The term “tap density (ρtp)” refers to the bulk density of the electrode
30 composite after it has been compacted by tapping or vibration. It is measured by
filling a container with powder, tapping it a specified number of times, and then
9
recording the resulting volume and mass. Tap density reflects the packing
efficiency of the electrode composite and influences key parameters such as
electrode thickness, porosity, and ultimately the energy density of the battery. A
higher tap density generally leads to improved volumetric energy density. For the
5 purpose of the present disclosure, the electrode composite has a tap density in a
range of 1.0 to 3.0 g/cc.
[0047] The term “Brunauer–Emmett–Teller (BET) plot” refers to a graphical
representation used to analyse the surface area of materials. This plot helps
determine the specific surface area of a material by measuring the amount of gas
10 adsorbed on its surface at various pressures. The BET plot is used to measure the
effective surface area of first conducting carbon, second conducting carbon, and
electrode composite. For the purposes of the present disclosure, the first conducting
carbon has a surface area in a range of 1300 to 1400 m2/g, the second conducting
carbon has a surface area in a range of 17 to 20 m2/g, and the electrode composite
15 exhibits a specific surface area in a range of 10 to 13 m2/g.
[0048] The term “calendaring” refers to a mechanical process used to compress,
smooth, and control the thickness of an electrode material. The calendaring process
involves passing a mixture, which typically comprises active materials, conducting
carbons, and binders, through a series of rollers under controlled pressure and
20 temperature. The rollers exert significant force to compress the mixture, reducing
its thickness to a desired level while ensuring uniformity and improving its
mechanical properties. For the purpose of present disclosure, the electrode
composite is calendared to form an electrode film, which is subsequently laminated
onto a current collector.
25 [0049] The term “lamination” refers to the process in which a film or sheet is
applied to a substrate by exerting specific pressure or force under elevated
temperature conditions. For the purpose of the present disclosure, the electrode
composite is calendared to form an electrode film, which is subsequently laminated
onto a current collector.
30 [0050] The term “electrode density (ρe)” refers to the mass of the finished electrode
per unit volume, including the active material, binder, and conducting carbon. It is
10
measured after coating, drying, and calendaring, and is used to calculate the void
ratio of the electrode, which reflects its porosity. Electrode density is defined as the
ratio of the mass of the electrode layer to its volume, where the mass includes only
the coating of the electrode composite (excluding the current collector). The volume
5 of the electrode layer is calculated as the product of the coated area and the
thickness of the electrode composite layer.
[0051] The term “aspect ratio” refers to the ratio of the length of the fibrillated
binder to the particle size or diameter of the active material. It depends on the shape
and dimensional properties of the fibrillated binder. The aspect ratio influences the
10 crack resistance, mechanical flexibility, and powder flowability of the electrode
composite or the resulting electrode.
[0052] The term “void ratio-electrode composite” refers to a measure of porosity
within the electrode structure, quantifying the volume of voids (empty spaces)
relative to the volume of solid material in the electrode composite. This parameter
15 plays a critical role in determining ion transport, electrolyte diffusion, mechanical
integrity, energy density, and internal resistance of the electrode. The void ratio of
the electrode composite can be calculated using either bulk density or the tap
density in relation to the true density of the electrode composite. When based on
bulk density, the void ratio is given by Equation 1:
𝑉𝑜𝑖𝑑 𝑟𝑎𝑡𝑖𝑜 %=(1−
𝜌𝑏
𝜌𝑡𝑟
20 ) × 100…………………………………………….1
where ρb is the bulk density and ρtr is the true density. Alternatively, when based on
tap density, the void ratio is given by Equation 2:
𝑉𝑜𝑖𝑑 𝑟𝑎𝑡𝑖𝑜 %=(1−
𝜌𝑏
𝜌𝑡𝑝
)× 100 ……………………………………………2
where ρb is the bulk density and ρtp is the tap density. These equations provide
25 insight into the packing efficiency and porosity of the electrode composite, which
are essential for optimizing electrochemical performance.
[0053] The term “void ratio-electrode” refers to a measure of porosity within the
final electrode structure after coating, drying, and calendaring. It quantifies the
volume of voids present in the electrode layer relative to the volume of solid
30 material, and directly influences ion transport, electrolyte accessibility, mechanical
11
integrity, and electrochemical performance. The void ratio of the electrode is
calculated using the electrode density and the true density of the electrode
composite, as shown in Equation 3:
𝑉𝑜𝑖𝑑 𝑟𝑎𝑡𝑖𝑜 %=(1−
𝜌𝑒
𝜌𝑡𝑟
)×100 ……………………………………………...3
5 where ρe is the electrode density and ρtr is the true density of the electrode
composite. A well-optimized void ratio of electrode ensures a balance between
energy density and ion transport efficiency.
[0054] Ratios, concentrations, amounts, and other numerical data may be presented
herein in a range format. It is to be understood that such range format is used merely
10 for convenience and brevity and should be interpreted flexibly to include not only
the numerical values explicitly recited as the limits of the range, but also to include
all the individual numerical values or sub-ranges encompassed within that range as
if each numerical value and sub-range is explicitly recited.
[0055] Unless defined otherwise, all technical and scientific terms used herein have
15 the same meaning as commonly understood by one of ordinary skill in the art to
which this disclosure belongs. Although any methods and materials similar or
equivalent to those described herein can be used in the practice or testing of the
disclosure, the preferred methods, and materials are now described. All publications
mentioned herein are incorporated herein by reference.
20 [0056] The present disclosure is not to be limited in scope by the specific
embodiments described herein, which are intended for the purposes of
exemplification only. Functionally equivalent products, compositions,
formulations, and methods are clearly within the scope of the disclosure, as
described herein.
25 [0057] As discussed in the background, there is a need for an effective dry electrode
composite that exhibits low resistance, enhanced conductivity, and strong particle-
to-particle adhesion. Conventional dry mixing methods often lead to
microstructural non-uniformities, such as carbon agglomerations and ribbon-like
structures, which compromise both conductivity and mechanical integrity. Dry
30 electrodes also experience rapid temperature rise at C rates above 2C and
12
demonstrate poor rate performance, due to elevated cell impedance. To address
these limitations, a process has been developed for preparing the electrode
composite through the sequential addition of conducting carbon and strategic binder
incorporation. This method employs a dual carbon system comprising high surface
5 area amorphous carbon (1300 to 1400 m2/g), and low surface area ultra-thin
graphite-based carbon (17 to 20 m2/g). The high surface area of the amorphous
carbon ensures a porous carbon coating, which facilitates better electrolyte
percolation and provides anchoring sites for the binder. In parallel, the ultra-thin,
flaky graphite imparts slipperiness, protecting both the roller and cathode active
10 material (CAM) particles during calendaring by allowing ceramic particles to skid
under shear during pressing. Together, the amorphous (first conducting carbon) and
graphite-based carbon (second conducting carbon) enable controlled processing
and smooth transitions from powder to film and film to film. Optimized mixing
parameters for the preparation of the first, through fifth mixtures include controlled
15 temperature, high shear activation, and gradual cooling. Sequential addition enables
controlled coating of both cohesive and fibrillating binders with conducting carbon,
reducing their insulating effects while preserving their functional properties. These
conditions promote uniform carbon coating, and binder dispersion, thereby
balancing the conductivity and mechanical strength. Additionally, incorporating the
20 first, second, and third parts of the first conducting carbon in a weight ratio range
of 1:0.3:0.3 to 1:1:1, results in a significant reduction in electrical resistance,
improved capacity at high discharge rates, enhanced thermal management, and
superior structural uniformity.
[0058] The present disclosure addresses the issue of poor particle-to-particle
25 cohesion in dry-processed electrodes, which result in low peel strength and reduced
conductivity. To overcome this challenge, a cohesive binder is introduced prior to
the addition of a fibrillating binder in the sequential mixing process. The cohesive
binder is selected based on specific criteria, including melting point between 138 to
152°C, melt viscosity between 12 to 39 Kp, secondary particle size of 3 to 10 µm,
30 and electrochemical stability. However, the fibrillating binder has primary particle
size of 180 to 280 nm, and a secondary particle size of 400 to 700 µm. The mixing
13
process ensures uniform binder distribution and improved adhesion. This optimized
binder combination enhances conductivity, reduces resistivity, and enables low-
temperature calendaring in dry electrode manufacturing. The process maintains
electrochemical stability, achieving over 98% capacity retention and up to 94%
5 coulombic efficiency. This innovation transforms dry electrode manufacturing into
a scalable, high-performance, and environmentally friendly solution.
[0059] Accordingly, the present disclosure provides a process for preparing an
electrode composite, the process comprising: i) mixing an active material with a
first part of a first conducting carbon, and a second conducting carbon, to obtain a
10 first mixture; ii) blending a cohesive binder with the first mixture to obtain a second
mixture; followed by addition of a second part of the first conducting carbon with
the second mixture to obtain a third mixture; iii) blending a fibrillating binder with
the third mixture to obtain a fourth mixture, followed by addition of a third part of
the first conducting carbon with the fourth mixture to obtain a fifth mixture; and iv)
15 subjecting the fifth mixture to high shear mixing at a tip speed in a range of 25 to
35 m/s, at temperature in a range of 65 to 75°C, and subsequently cooling to a
temperature in a range of 0 to 19℃ to obtain the composite.
[0060] The present disclosure is not to be limited in scope by the specific
embodiments described herein, which are intended for the purposes of
20 exemplification only. Functionally equivalent products, compositions, and methods
are clearly within the scope of the disclosure, as described herein.
[0061] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite, the process comprising: i) mixing an active
material with a first part of a first conducting carbon, and a second conducting
25 carbon, to obtain a first mixture; ii) blending a cohesive binder with the first mixture
to obtain a second mixture; followed by addition of a third part of the first
conducting carbon with the second mixture to obtain a third mixture; iii) blending
a fibrillating binder with the third mixture to obtain a fourth mixture, followed by
addition of a second part of the first conducting carbon with the fourth mixture to
30 obtain a fifth mixture; and iv) subjecting the fifth mixture to high shear mixing at a
tip speed in a range of 25 to 35 m/s, at temperature in a range of 65 to 75°C, and
14
subsequently cooling to a temperature in a range of 0 to 19℃ to obtain the
composite.
[0062] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite, wherein subjecting the fifth mixture to high shear
5 mixing at a tip speed in a range of 25 to 35 m/s, at temperature in a range of 65 to
75°C, and subsequently cooling to a temperature in a range of 0 to 19℃ to obtain
the composite. In another embodiment of the present disclosure, subjecting the fifth
mixture to high shear mixing at a tip speed in a range of 28 to 33 m/s, at temperature
in a range of 68 to 73°C, and subsequently cooling to a temperature in a range of 5
10 to 18℃ to obtain the composite. In yet another embodiment of the present
disclosure, subjecting the fifth mixture to high shear mixing at a tip speed in a range
of 28 to 33 m/s, at temperature in a range of 69 to 72°C, and subsequently cooling
to a temperature in a range of 10 to 17℃ to obtain the composite.
[0063] In an embodiment of the present disclosure, there is provided a process for
15 preparing an electrode composite, as disclosed herein, wherein the first part of the
first conducting carbon, the second part of the first conducting carbon, and the third
part of the first conducting carbon are in a weight ratio range of 1:0.3:0.3 to 1:1:1.
In another embodiment of the present disclosure, the first part of the first conducting
carbon, the second part of the first conducting carbon, and the third part of the first
20 conducting carbon are in a weight ratio range of 1:0.3:0.3 to 1:0.9:0.9. In yet another
embodiment of the present disclosure, the first part of the first conducting carbon,
the second part of the first conducting carbon, and the third part of the first
conducting carbon are in a weight ratio range of 1:0.3:0.3 to 1:0.7: 0.7.
[0064] In an embodiment of the present disclosure, there is provided a process for
25 preparing an electrode composite, as disclosed herein, wherein the first conducting
carbon has a surface area in a range of 1300 to 1400 m2/g; and the second
conducting carbon has a surface area in a range of 17 to 20 m2/g. In another
embodiment of the present disclosure, the first conducting carbon has a surface area
in a range of 1300 to 1390 m2/g; and the second conducting carbon has a surface
30 area in a range of 18 to 20 m2/g. In yet another embodiment of the present
disclosure, the first conducting carbon has a surface area in a range of 1300 to 1370
15
m2/g; and the second conducting carbon has a surface area in a range of 19 to 20
m2/g.
[0065] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite, the process comprising: i) mixing an active
5 material with a first part of a first conducting carbon, and a second conducting
carbon, to obtain a first mixture; ii) blending a cohesive binder with the first mixture
to obtain a second mixture; followed by addition of a third part of the first
conducting carbon with the second mixture to obtain a third mixture; iii) blending
a fibrillating binder with the third mixture to obtain a fourth mixture, followed by
10 addition of a second part of the first conducting carbon with the fourth mixture to
obtain a fifth mixture; and iv) subjecting the fifth mixture to high shear mixing at a
tip speed in a range of 25 to 35 m/s, at temperature in a range of 65 to 75°C, and
subsequently cooling to a temperature in a range of 0 to 19℃ to obtain the
composite, wherein the first conducting carbon has a surface area in a range of 1300
15 to 1400 m2/g; and the second conducting carbon has a surface area in a range of 17
to 20 m2/g.
[0066] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite as disclosed herein, wherein the first conducting
carbon and the second conducting carbon is coated on the active material in a range
20 of 70 to 95% coating of the total surface of the active material.
[0067] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite as disclosed herein, wherein the specific surface
area of active material coated with first conducting carbon and the second
conducting carbon is in a range of 5 to 15 m2/g. In another embodiment of the
25 present disclosure, the specific surface area of active material coated with first
conducting carbon and the second conducting carbon is 6 to 13 m2/g. In yet another
embodiment of the present disclosure, the specific surface area of active material
coated with first conducting carbon and the second conducting carbon is 6 to 10
m2/g.
30 [0068] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite as disclosed herein, wherein the electrode
16
composite exhibits a specific surface area in a range of 10 to 13 m2/g. In another
embodiment of the present disclosure, the electrode composite exhibits a specific
surface area in a range of 10.2 to 12.8 m2/g. In yet another embodiment, the
electrode composite exhibits a specific surface area in a range of 10.5 to 12.5 m2/g.
5 [0069] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite as disclosed herein, wherein mixing in step (i) is
carried out at a tip speed in a range of a 15 to 35 m/s, and at a temperature in a range
of 0 to 25℃, for a duration of 50 to 100 minutes. In another embodiment of the
present disclosure, mixing in step (i) is carried out at a tip speed in a range of a 16
10 to 34 m/s, and at a temperature in a range of 5 to 25℃, for a duration of 60 to 90
minutes. In yet another embodiment of the present disclosure, mixing in step (i) is
carried out at a tip speed in a range of a 17 to 32 m/s, and at a temperature in a range
of 10 to 24℃, for a duration of 70 to 80 minutes.
[0070] In an embodiment of the present disclosure, there is provided a process for
15 preparing an electrode composite as disclosed herein, wherein blending in step (ii)
and step (iii) are independently carried out at a tip speed in a range of 10 to 25 m/s,
and at a temperature in a range of 0 to 19℃ for a duration of 10 to 60 minutes. In
another embodiment of the present disclosure, blending in step (ii) and step (iii) are
independently carried out at a tip speed in a range of 11 to 24 m/s, and at a
20 temperature in a range of 5 to 18℃ for a duration of 12 to 50 minutes. In yet another
embodiment of the present disclosure, blending in step (ii) and step (iii) are
independently carried out at a tip speed in a range of 12 to 22 m/s, and at a
temperature in a range of 8 to 17℃ for a duration of 13 to 45 minutes.
[0071] In an embodiment of the present disclosure, there is provided a process for
25 preparing an electrode composite as disclosed herein, wherein cooling is carried out
at a tip speed in a range of 4 to 10 m/s. In another embodiment of the present
disclosure, cooling is carried out at a tip speed in a range of 5 to 9 m/s. In yet another
embodiment of the present disclosure, cooling is carried out at a tip speed in a range
of 5 to 8 m/s. In still another embodiment of the present disclosure, cooling is
30 carried out at temperature in a range of 5 to 20℃ a tip speed in a range of 5 to 8
17
m/s. In one another embodiment of the present disclosure, cooling is carried out at
temperature in a range of 10 to 18℃ a tip speed in a range of 5 to 7 m/s.
[0072] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite as disclosed herein, wherein the active material is
5 nickel manganese cobalt oxide (NMC), and the active material is in a weight range
of 95 to 97% (w/w), with respect to the total weight of the electrode composite. In
another embodiment of the present disclosure, the active material is in a weight
range of 95.5 to 97% (w/w), with respect to the total weight of the electrode
composite. In yet another embodiment of the present disclosure, the active material
10 is in a weight range of 95.5 to 96.5% (w/w), with respect to the total weight of the
electrode composite.
[0073] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite as disclosed herein, wherein the nickel
manganese cobalt has a bimodal distribution with a single crystal size in a range 2
15 to 3.5 µm and a polycrystal size in a range 5 to 15 µm. In another embodiment of
the present disclosure, the nickel manganese cobalt has a bimodal distribution with
a single crystal size in a range 2.2 to 3.5 µm and a polycrystal size in a range 7 to
15 µm. In yet another embodiment of the present disclosure, the nickel manganese
cobalt has a bimodal distribution with a single crystal size in a range 2.5 to 3.4 µm
20 and a polycrystal size in a range 7 to 13 µm.
[0074] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite as disclosed herein, wherein the nickel
manganese cobalt (NMC) exhibits a specific surface area of in arrange of 0.5 to 1.3
m2/g. In another embodiment of the present disclosure, the nickel manganese cobalt
25 (NMC) exhibits a specific surface area in a range of 0.5 to 1.2 m2/g. In yet another
embodiment of the present disclosure, the nickel manganese cobalt (NMC) exhibits
a specific surface area of 0.7 m2/g.
[0075] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite as disclosed herein, wherein the first conducting
30 carbon is selected from amorphous carbon, carbon black, Ketjen Black, super P, or
combinations thereof, and the first conducting carbon is in a weight range of 0.8 to
18
2% (w/w), with respect to total weight of the electrode composite. In another
embodiment of the present disclosure, the first conducting carbon is selected from
amorphous carbon, carbon black, Ketjen Black, or combinations thereof, and the
first conducting carbon is in a weight range of 0.9 to 2% (w/w), with respect to total
5 weight of the electrode composite. In yet another embodiment of the present
disclosure, the first conducting carbon is selected from amorphous carbon, Ketjen
Black, or combinations thereof, and the first conducting carbon is in a weight range
of 1 to 2% (w/w), with respect to total weight of the electrode composite.
[0076] In an embodiment of the present disclosure, there is provided a process for
10 preparing an electrode composite as disclosed herein, wherein the second
conducting carbon is selected from graphene, KS6L, single walled carbon nanotube
(SWCNT), or combinations thereof, and the second conducting carbon is in a
weight range of 0.2 to 0.8% (w/w), with respect to total weight of the electrode
composite. In another embodiment of the present disclosure, the second conducting
15 carbon is selected from KS6L, single walled carbon nanotube (SWCNT), or
combinations thereof, and the second conducting carbon is in a weight range of 0.2
to 0.7% (w/w), with respect to total weight of the electrode composite. In yet
another embodiment of the present disclosure, the second conducting carbon is
KS6L, and the second conducting carbon is in a weight range of 0.2 to 0.6% (w/w),
20 with respect to total weight of the electrode composite.
[0077] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite as disclosed herein, wherein the cohesive binder
is selected from polyvinylidene fluoride (PVDF), polyvinylidene fluoride
hexafluoropropylene copolymer (PVDF-HFP), polyvinylidene fluoride-vinylidene
25 fluoride copolymers (PVDF-VF2), polyvinylidene fluoride copolymers (PVDF-
copolymers), or combinations thereof, and the cohesive binder is in a weight range
of 0.7 to 1.2% (w/w), with respect to total weight of the electrode composite. In
another embodiment of the present disclosure, the cohesive binder is selected from
polyvinylidene fluoride (PVDF), polyvinylidene fluoride hexafluoropropylene
30 copolymer (PVDF-HFP), polyvinylidene fluoride-vinylidene fluoride copolymers
(PVDF-VF2), or combinations thereof, and the cohesive binder is in a weight range
19
of 0.8 to 1.2% (w/w), with respect to total weight of the electrode composite. In yet
another embodiment of the present disclosure, the cohesive binder is selected from
polyvinylidene fluoride (PVDF), polyvinylidene fluoride-vinylidene fluoride
copolymers (PVDF-VF2), or combinations thereof, and the cohesive binder is in a
5 weight range of 0.8 to 1.1% (w/w), with respect to total weight of the electrode
composite.
[0078] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite as disclosed herein, wherein the fibrillating binder
is selected from polytetrafluoroethylene (PTFE), polytetrafluoroethylene
10 copolymers (PTFE-copolymer), or combinations thereof, and the fibrillating binder
is in a weight range of 0.7 to 1.2% (w/w), with respect to total weight of the
electrode composite. In another embodiment of the present disclosure, the
fibrillating binder is selected from polytetrafluoroethylene (PTFE), or combinations
thereof, and the fibrillating binder is in a weight range of 0.7 to 1.1% (w/w), with
15 respect to total weight of the electrode composite. In yet another embodiment of the
present disclosure, the fibrillating binder is polytetrafluoroethylene (PTFE), and the
fibrillating binder is in a weight range of 0.8 to 1.1% (w/w), with respect to total
weight of the electrode composite.
[0079] In an embodiment of the present disclosure, there is provided a process for
20 preparing an electrode composite as disclosed herein, wherein the fibrillating binder
has a primary particle size in a range of 180 to 280 nm, and a secondary particle
size in a range of 400 to 700 µm. In another embodiment of the present disclosure,
the fibrillating binder has a primary particle size in a range of 190 to 260 nm, and a
secondary particle size in a range of 450 to 650 µm. In yet another embodiment of
25 the present disclosure, the fibrillating binder has a primary particle size 230 nm,
and a secondary particle size in a range of 550 µm.
[0080] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite as disclosed herein, wherein the cohesive binder
has melting point between 138 to 152°C, secondary particle size of 3 to 10 µm, and
30 melt viscosity between 12 to 39 Kp.
20
[0081] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite as disclosed herein, wherein the cohesive binder
is high melting polyvinylidene fluoride-vinylidene fluoride copolymer (PVDF-
VF2) having melting point in a range of 148 to 152°C, a primary particle size in a
5 range of 150 to 200 nm, a secondary particle size in a range of 3 to 9 µm, and melt
viscosity in a range of 33 to 39 kP.
[0082] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite as disclosed herein, wherein the cohesive binder
is low melting polyvinylidene fluoride-vinylidene fluoride copolymers (PVDF-
10 VF2) having melting point in a range of 138 to 146°C, a primary particle size in a
range of 150 to 200 nm, a secondary particle size in a range of 5 to 10 µm, and melt
viscosity in a range of 12 to 20 kP.
[0083] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite as disclosed herein, further comprising
15 calendaring the electrode composite to obtain an electrode film, followed by
lamination onto a current collector.
[0084] In an embodiment of the present disclosure, there is provided a process for
preparing an electrode composite as disclosed herein, wherein the current collector
is selected from primer coated aluminum foil, or bare aluminum foil. In another
20 embodiment of the present disclosure, the current collector is primer coated
aluminum foil.
[0085] In an embodiment of the present disclosure, there is provided an electrode
comprising the electrode composite prepared by the process as disclosed herein,
wherein the electrode is a cathode.
25 [0086] In an embodiment of the present disclosure, there is provided an electrode
as disclosed herein, wherein the electrode composite has resistance in a range of 0.2
to 0.7 Ω. In another embodiment of the present disclosure, the electrode composite
has resistance in a range of 0.3 to 0.7 Ω. In yet another embodiment of the present
disclosure, the electrode composite has resistance in a range of 0.4 to 0.65 Ω.
30 [0087] In an embodiment of the present disclosure, there is provided an electrode
as disclosed herein, wherein the electrode is in the form of a free-standing film, or
21
a film coated on a current collector. In another embodiment of the present
disclosure, the electrode is in the form of a film coated on a current collector. In
one another embodiment of the present disclosure, the electrode is in the form of a
free-standing film.
5 [0088] In an embodiment of the present disclosure, there is provided an electrode
as disclosed herein, wherein the active material is in a weight range of 95 to 97%
(w/w), the first conducting carbon is in a weight range of 0.8 to 2% (w/w), the
second conducting carbon is in a weight range of 0.2 to 0.8% (w/w), the fibrillated
binder is in a weight range of 0.7 to 1.2% (w/w), and the cohesive binder is in a
10 weight range of 0.7 to 1.2% (w/w), with respect to the total weight of the electrode.
In another embodiment of the present disclosure, the active material is in a weight
range of 95.5 to 97% (w/w), the first conducting carbon is in a weight range of 0.9
to 2% (w/w), the second conducting carbon is in a weight range of 0.2 to 0.7%
(w/w), the fibrillated binder is in a weight range of 0.7 to 1.1% (w/w), and the
15 cohesive binder is in a weight range of 0.8 to 1.2% (w/w), with respect to the total
weight of the electrode. In yet another embodiment of the present disclosure, the
active material is in a weight range of 95.5 to 96.5% (w/w), the first conducting
carbon is in a weight range of 1 to 2% (w/w), the second conducting carbon is in a
weight range of 0.2 to 0.6% (w/w), the fibrillated binder is in a weight range of 0.8
20 to 1.1% (w/w), and the cohesive binder is in a weight range of 0.8 to 1.1% (w/w),
with respect to the total weight of the electrode.
[0089] In an embodiment of the present disclosure, there is provided an electrode
as disclosed herein, wherein the electrode composite has a true density in a range
of 4.0 to 5.0 g/cc, a tap density in a range of 1.0 to 3.0 g/cc, and a bulk density in a
25 range of 1.2 to 1.6 g/cc. In another embodiment of the present disclosure, the
electrode composite has a true density in a range of 4.1 to 4.9 g/cc, a tap density in
a range of 1.1 to 2.8 g/cc, and a bulk density in a range of 1.2 to 1.5 g/cc. In yet
another embodiment of the present disclosure, the electrode composite has a true
density in a range of 4.2 to 4.8 g/cc, a tap density in a range of 1.5 to 2.5 g/cc, and
30 a bulk density in a range of 1.3 to 1.5 g/cc.
22
[0090] In an embodiment of the present disclosure, there is provided an electrode
as disclosed herein, wherein the void ratio of the electrode is in a range of 10 to
25%, based on the electrode density to the true density of electrode composite. In
another embodiment of the present disclosure, the void ratio of the electrode is in a
5 range of 17 to 21%, based on the electrode density to the true density of electrode
composite.
[0091] In an embodiment of the present disclosure, there is provided an electrode
as disclosed herein, wherein the void ratio of the electrode composite is 45 to 70%,
based on the true density to the bulk density of the electrode composite.
10 [0092] In an embodiment of the present disclosure, there is provided an electrode
as disclosed herein, wherein the void ratio of the electrode composite is 20 to 45%,
based on the true density to the tap density of the electrode composite.
[0093] In an embodiment of the present disclosure, there is provided an electrode
as disclosed herein, wherein the aspect ratio of the fibrillated binder to the active
15 material is in a range of 0.5 to 5.
[0094] In an embodiment of the present disclosure, there is provided an electrode
as disclosed herein, wherein the average length of the fibrillated binder is in a range
of 5 to 40 µm.
[0095] In an embodiment of the present disclosure, there is provided an electrode
20 as disclosed herein, wherein the electrode has a peel strength in a range of 1.1 to
2.0 N/25mm, and an electrical resistance in a range of 0.15 to 0.25 Ω. In another
embodiment of the present disclosure, the electrode has a peel strength in a range
of 1.1 to 1.9 N/25mm, and an electrical resistance in a range of 0.16 to 0.24 Ω. In
yet another embodiment of the present disclosure, the electrode has a peel strength
25 in a range of 1.1 to 1.8 N/25mm, and an electrical resistance in a range of 0.16 to
0.22 Ω. In still another embodiment of the present disclosure, the electrode is a
single coated electrode.
[0096] In an embodiment of the present disclosure, there is provided an electrode
as disclosed herein, wherein the electrode is double-sided and exhibits an electrical
30 resistance in a range of 0.3 to 0.5 Ω.
23
[0097] In an embodiment of the present disclosure, there is provided an electrode
as disclosed herein, wherein the electrode has a charge capacity in a range of 230
to 233 mAh/g, and a discharge capacity in a range of 211 to 215 mAh/g. In another
embodiment of the present disclosure, the electrode has a charge capacity in a range
5 of 230 to 232.5 mAh/g, and a discharge capacity in a range of 211 to 214 mAh/g.
In yet another embodiment of the present disclosure, the electrode has a charge
capacity in a range of 230 to 232 mAh/g, and a discharge capacity in a range of 212
to 214 mAh/g.
[0098] In an embodiment of the present disclosure, there is provided an electrode
10 comprising the electrode composite prepared by the process as disclosed herein,
wherein the electrode exhibits at least 98% capacity retention up to 50 cycles, a
specific capacity of at least 163 mAh/g at a 2C rate and has an initial coulombic
efficiency in a range of 92 to 94%. In another embodiment of the present disclosure,
the electrode exhibits 98 to 99.9% capacity retention up to 50 cycles, a specific
15 capacity of 163 to 170 mAh/g at a 2C rate and has an initial coulombic efficiency
in a range of 92 to 94%. In yet another embodiment of the present disclosure, the
electrode exhibits 98.5% capacity retention up to 50 cycles, a specific capacity of
164.15 mAh/g at a 2C rate and has an initial coulombic efficiency in a range of 92
to 93.5%. In still yet another embodiment of the present disclosure, the electrode
20 exhibits 99% capacity retention up to 50 cycles, a specific capacity of 167.19
mAh/g at a 2C rate and has an initial coulombic efficiency in a range of 92 to 93%.
[0099] In an embodiment of the present disclosure, there is provided an
electrochemical cell comprising: a. the electrode as disclosed herein; b. an anode,
and c. an electrolyte. In another embodiment of the present disclosure, the anode
25 comprises lithium metal.
[0100] In an embodiment of the present disclosure, there is provided the use of the
electrode as disclosed herein, or the electrochemical cell as disclosed herein, for the
manufacture of a battery.
[0101] Although the subject matter has been described in considerable detail with
30 reference to certain examples and implementations thereof, other implementations
are possible.
24
EXAMPLES
[0102] The disclosure will now be illustrated with the following examples, which
are intended to illustrate the working of disclosure and not intended to restrictively
5 imply any limitations on the scope of the present disclosure. Unless defined
otherwise, all technical and scientific terms used herein have the same meaning as
commonly understood to one of ordinary skill in the art to which this disclosure
belongs. Although methods and materials similar or equivalent to those described
herein can be used in the practice of the disclosed methods and compositions, the
10 exemplary methods, devices, and materials are described herein. It is to be
understood that this disclosure is not limited to particular composition, methods,
and experimental conditions described, as such methods and conditions may apply.
The present invention will be described in a more detailed manner by way of
examples. However, these examples should not be construed as limiting the scope
15 of the present invention.
EXAMPLE 1
Preparation of electrode composite
[0103] The objective of this example is to elaborate on the process of preparing the
20 electrode composite.
[0104] The electrode composite EC1 was prepared by mixing 96.00% by weight of
nickel manganese cobalt oxide (NMC) (active material) with 1.00% by weight of
Ketjen Black 600JD (first part-first conducting carbon), and 0.30% by weight of
KS6L (second conducting carbon) at a tip speed of 30.6 m/s, and at 20℃, for a
25 duration of 75 minutes to obtain a first mixture. This first mixture was then blended
with 0.90% by weight of polyvinylidene fluoride-vinylidene fluoride copolymers
(PVDF-VF2) (high melting point-cohesive binder) at a tip speed of 15.3 m/s, and
at temperature in a range of 12 to 15℃ for 15 minutes to obtain a second mixture.
Subsequently, 0.40% by weight of Ketjen Black 600JD (second part-first
30 conducting carbon) was added to the second mixture, which was further mixed at a
tip speed of 15.3 m/s, and at temperature in a range of 12 to 15℃ for 30 minutes
25
obtain a third mixture. Followed by this, 1.00% by weight of
polytetrafluoroethylene (PTFE) (fibrillating binder) was blended with the third
mixture at a tip speed of 15.3 m/s, and at temperature in a range of 12 to 15℃ for
15 minutes to obtain a fourth mixture. This was followed by the addition of 0.40%
5 by weight of Ketjen Black 600JD (third part-first conducting carbon) at a tip speed
of 15.3 m/s, and at temperature in a range of 12 to 15℃ for 30 minutes to obtain a
fifth mixture. Finally, the fifth mixture was subjected to high shear mixing at a tip
speed in a range of 30.6 m/s, at temperature 70°C. It was then cooled to a
temperature of 15℃, while mixing at a tip speed of 6.13 m/s, to obtain the electrode
10 composite EC1. The first part, second part, and third part of the Ketjen Black 600JD
(first conducting carbon) was maintained in a weight ratio of 1:0.4:0.4.
[0105] Similar to, electrode composite EC1, electrode composites EC2, and EC3,
were also prepared. The first part, second part, and third part of the Ketjen Black
600JD (first conducting carbon) were maintained in a weight ratio of 1:0.45:0.45
15 and 1:0.35:0.35, respectively (Table-1).
[0106] For comparative purposes, similar to electrode composite EC1, comparative
electrode composite ECP1 was also prepared, as mentioned in Table-1.
[0107] Additionally, for comparative purposes, comparative electrode
composite, ECP2, was prepared using a conventional, less controlled process,
20 unlike EC1, which employed a staged mixing approach with timed additions of
binder and conducting carbons to optimize their distribution.
[0108] The preparation of ECP2 involved mixing 96.20% by weight of nickel
manganese cobalt oxide (NMC), 1% by weight of Ketjen Black 600JD, and 0.30%
by weight of KS6L at a tip speed of 30.6 m/s, and at a temperature below 25℃, for
25 75 minutes to form a homogenous mixture. To this, 1.00% by weight of
polyvinylidene fluoride-vinylidene fluoride copolymers (PVDF-VF2), 0.19% by
weight of Ketjen Black 600JD, and 0.06% by weight of KS6L were added and
mixed at a tip speed of 15.3 m/s and a temperature below 19 ℃ for 30 minutes.
This was followed by a single-stage addition of 1% by weight of
30 polytetrafluoroethylene (PTFE), 0.19% by weight of Ketjen Black 600JD, and
0.06% by weight of KS6L, mixed again under the same conditions (tip speed of
26
15.3 m/s and temperature below 19 °C) for 30 minutes. The resulting mixture was
then subjected to high shear mixing at a tip speed of 30.6 m/s, and a temperature of
70°C. Finally, it was cooled to below 19℃ while mixing at a tip speed of 6.13 m/s
to obtain the comparative electrode composite ECP2.
5 [0109] Similar to the preparation process of the comparative electrode composite
ECP2, the comparative electrode composite ECP3 was also prepared.
Table-1
S.No.
Component
(wt%)
EC1 EC2 EC3 ECP1 ECP2 ECP3
1
NMC
(Active
material)
96.00 96.00 96.20 96.20 96.20 96.20
2
Ketjen
Black 600JD
(First
conducting
carbon)
1.80 1.90 1.70 1.50 1.38 1.50
3
KS6L
(Second
conducting
carbon)
0.30 0.3 0.30 0.30 0.42 0.30
4
PTFE
(Fibrillating
binder)
1.00 0.90 0.90 1.00 1.00 1.00
5
PVDF-VF2
(Cohesive
binder)
0.90
(high
melting)
0.90
(low
melting)
0.90
(low
melting)
1.00
(high
melting)
1.00
(high
melting)
1.00
(high
melting)
6
First part:
Second part
Third part
(First
conducting
carbon)
1:0.4:0.4
1:0.45:0.
45
1:0.35:0.
35
1:0.25:0.
25
- -
EXAMPLE 2
10 Characterization studies of the prepared electrode composite
Structural studies
[0110] The prepared electrode composites EC1, EC2, and EC3, and the
comparative electrode composites ECP1, ECP2, and ECP3 (prepared in Example
1) were analysed for their structural studies.
27
[0111] The Brunauer–Emmett–Teller (BET) plot was studied to analyse the
specific surface area of the prepared electrode composites. The electrode composite
EC1, exhibited specific surface area of 11.5 m2/g.
[0112] The nickel manganese cobalt (NMC) (active material) used for the
5 preparation of the electrode composite EC1 exhibited a specific surface area of 0.7
m2/g. The bimodal particle size distribution of nickel manganese cobalt (NMC)
(active material) showed a single crystal peak at 3 µm and a polycrystalline peak at
10 µm.
[0113] The first conducting carbon used for the preparation of the electrode
10 composite EC1 had surface area in a range of 1369 m2/g.
[0114] The second conducting carbon used for the preparation of the electrode
composite EC1, had a surface area of 20 m2/g.
[0115] The first conducting carbon) and second conducting carbon) was coated on
the active material in a range of 70 to 95% coating of the total surface of the active
15 material.
Resistance
[0116] The resistance of the prepared electrode composite EC1 was analyzed by
pressing the composite powder into 10 mm diameter pellets with a thickness
ranging from 160 to 200 µm. The resistance of the electrode composite was found
20 to be 0.6 Ω.
EXAMPLE 3
Preparation of cathode
[0117] For analysis purposes, cathodes C1, C2, and C3, and comparative cathodes
25 CP1, CP2, and CP3, were prepared using electrode composites EC1, EC2, and EC3,
and comparative electrode composites ECP1, ECP2, and ECP3, respectively, as
described in Example 1.
[0118] These cathodes were fabricated by calendaring to form an electrode film,
followed by lamination onto primer coated aluminum foil, serving as the current
30 collector. Subsequently, the cathodes were analysed for their mechanical and
electrochemical performance characteristics.
28
EXAMPLE 4
Determination of morphological, mechanical and electrical properties of the
cathodes
5 [0119] The morphological, mechanical and electrical properties of the prepared
cathodes C1, C2, and C3, and the comparative cathodes CP1, CP2, and CP3, were
measured and analysed as described below.
Morphological studies
Scanning electron microscopic studies (SEM)
10 [0120] The morphological characteristics of the cathodes were analysed using
scanning electron microscopy (SEM). The surface microstructures (2048 x 1526
resolution bits’) of the prepared cathodes (C1 to C3, and CP1 to CP3) shown in
Figures 1(a)-(f). The morphological analysis (Figures 2 (a)(i), b(i), and c(i) at 2048
x 1526 resolution bits’, and Figures 2 (a)(ii), b(ii), and c(ii) at 2048 x 1536
15 resolution bits’) of the comparative cathode CP2 (Figure 2(c)) revealed poor
particle distribution, characterized by ribbon-like structures and noticeable particle
segregation. This was attributed to the agglomeration of the fibrillating binder,
cohesive binder, both types of conducting carbon, and the active material. In
contrast, Figures 2(a) and 2(b) show that the electrode composites of cathodes C1,
20 and C2 exhibited improved distribution of the fibrillating binder, cohesive binder,
and both conducting carbons, resulting in a more uniform particle morphology.
[0121] Hence, it was revealed that the controlled sequential addition of conducting
carbons creates uniform conductive pathways throughout the electrode composite
(EC1, and EC2) structure in cathodes C1, and C2, eliminating carbon
25 agglomerations and insulating regions that are characteristic of conventional
mixing processes. Subsequently, the present process facilitated a more uniform,
steady, and homogeneous dispersion of all components within the composite
powder.
[0122] To understand the compactness, packing efficiency, of the electrode
30 composite EC1, in fabricated cathode C1. The true density, tap density, and bulk
density of the fabricated cathode C1, were measured.
29
[0123] Bulk density was calculated by dividing the mass of the electrode composite
EC1 by the volume it occupied in a container, without applying any external
pressure or tapping. This method reflected how the material behaved in its loose,
uncompacted form. The desired powder was transferred to the measuring cylinder
5 and fitted into the tapping machine. The bulk density was calculated by measuring
the volume after first 10 taps.
[0124] Tap density was determined using the ASTM B527-22 standard. The
desired powder was transferred to the measuring cylinder and fitted into the tapping
machine. The tap density was calculated by measuring the volume after 5000 taps
10 with 250 taps/ minute.
[0125] True density was measured using a helium pycnometer. A known mass of
the sample was sealed into the sample chamber and helium gas was purged inside
the chamber. The change in pressure of the helium gas in the chamber was measured
to calculate the true density.
15 [0126] The cathode C1, fabricated using the electrode composite EC1, exhibited a
true density of 4.5 g/cc. Additionally, the tap density and bulk density of the
composite were measured to be 2.0 g/cc and 1.42 g/cc, respectively.
Mechanical Studies
Peel strength
20 [0127] Peel strength analysis is a conventional method in battery industry to rank
the adhesion strength of samples. The peel strength of the cathodes (prepared in
Example 3) was measured using the Scotch tape method with ASTM D3330D
standards. A piece of Pinball aluminium tape measuring 25 mm in width and 150
mm in length was applied to the surface of the prepared cathode. The cathode was
25 secured with fixtures at top and bottom, followed by the application of a load at the
front and back twice using a rubber roller. The lower side of the cathode was placed
in the lower fixed grips, and the upper movable grip was brought down and
tightened firmly to adjust the cathode’s position. Care was taken to ensure that the
cathode was placed in the grips, the grip movement speed was set to 3 rpm and the
30 average force required to peel off the unit width in the peel strength of the sample
was applied. The rotary switch was then turned upward, causing the upper grip to
30
move upward. At this point, the rotary switch was turned off, and the peeled sample
was collected. The peel strength data for the cathodes (prepared in Example 3) are
provided in Table-2.
Electrical studies
5 Electrical resistance
[0128] Electrical resistance studies were conducted for the cathodes (prepared in
Example 3) were carried out and obtained results are provided in Table-2.
Table-2
C1 C2 CP1 CP2 CP3
Peel
strength
(N/25mm)
1.26 1.18 1.29 1.56 0.87
Electrical
resistance
(Ω)
0.19 0.17 0.28 0.30 0.26
10 [0129] The results demonstrated that cathodes C1 and C2 provided a superior
balance of peel strength and electrical resistance compared to the comparative
cathodes CP1, CP2, and CP3. Although CP1 and CP2 exhibited relatively higher
peel strength, they also showed significantly higher electrical resistance.
Conversely, C1 and C2, developed through the inventive process, achieved both
15 improved peel strength (1.26 N/25mm, and 1.18 N/25mm) and reduced resistance
(0.19 Ω and 0.17Ω). This indicated enhanced mechanical adhesion as well as better
electrical conductivity. These findings underscored the importance of
simultaneously optimizing peel strength and electrical resistance, as both
parameters critically influenced the electrode’s structural integrity and
20 electrochemical performance. Furthermore, the results highlighted that the
electrode’s resistance was strongly dependent on the type of conducting carbon,
binder, and processing method employed. This notable improvement was expected
to contribute to enhanced power output and minimized energy losses during battery
operation.
25
EXAMPLE 5
31
Preparation of electrochemical cell
[0130] For the analysis purposes, cathode (prepared in Example 3) was used as dry
electrode half-cell. The electrochemical studies of the prepared half-cell were
studied and analysed.
5
Electrochemical properties of cathodes
[0131] The charge capacity, discharge capacity, and initial coulombic efficiency
(ICE) at 25oC of C1, C2 and CP2 cathodes were calculated and depicted in Table-
3).
10 Table-3
Cathode
Charge capacity
(mAh/g)
Discharge
capacity
(mAh/g)
ICE
Capacity at 2C
(mAh/g)
C1 231.66
213.58
92.20 167.19
C2 230.57 212.84 92.31 164.15
CP2 228.96 210.32 91.86 151.40
[0132] Cathodes C1 and C2 were found to exhibit higher charge capacity,
discharge capacity and initial coulombic efficiency (ICE) compared to CP2 (Table-
3). These observations indicated that the charge stored was effectively recovered
15 during discharge at high rate, reflected a longer lifespan and better overall
efficiency of the electrochemical cell. A more uniform dispersion of active material
and more effective charge transport contributed to the enhanced electrochemical
performance of C1 and C2.
[0133] The discharge capacities of the cathodes C1, C2, and CP2 were evaluated at
20 various C-rates, ranging from 0.1C to 3C, as shown in Figure 3(a). Figure 3(b)
illustrated the charge-discharge plots of the cathodes C1, C2, and CP2 at a 3C rate.
It was revealed that cathodes C1 and C2 demonstrated improved capacity retention
at higher discharge rates compared to CP2. As shown in Table-3, C1, and C2
retained more capacity than CP2 at 2C rate. This enhanced rate performance was
32
attributed to reduced electrical resistance and improved carbon distribution in the
cathode formulations.
Cycle life
[0134] The cycle life of an electrochemical cell was characterized by an initial
5 period of stable performance, followed by gradual degradation, and eventually,
accelerated capacity loss leading to the end of life. The cycle life of electrochemical
cells comprising cathodes C1, C2, and CP2 was independently analysed within a
capacity retention range of 80 to 105% and a cycle range of 0 to 50. As shown in
Figure 4, the cells with cathodes C1 and C2 exhibited stable behaviour up to 50
10 charge-discharge cycles and maintained consistent charge retention. Additionally,
cathodes C1 and C2 demonstrated improved capacity retention compared to CP2,
as depicted in the capacity retention curves over 50 cycles. Specifically, C1 and C2
showed 98.5% and 99% capacity retention, respectively indicated enhanced
electrochemical stability during extended cycling. These results highlighted the
15 superior electrochemical efficiency of electrode composites EC1 and EC2
compared to ECP2.
ADVANTAGES OF THE PRESENT INVENTION
[0135] The present disclosure provides a process for an electrode composite, the
20 process comprising: i) mixing an active material with a first part of a first
conducting carbon, and a second conducting carbon, to obtain a first mixture; ii)
blending a cohesive binder with the first mixture to obtain a second mixture;
followed by addition of a second part of the first conducting carbon with the second
mixture to obtain a third mixture; iii) blending a fibrillating binder with the third
25 mixture to obtain a fourth mixture, followed by addition of a third part of the first
conducting carbon with the fourth mixture to obtain a fifth mixture; and iv)
subjecting the fifth mixture to high shear mixing at a tip speed in a range of 25 to
35 m/s, at temperature in a range of 65 to 75°C, and subsequently cooling to a
temperature in a range of 0 to 19℃ to obtain the composite. The specific pattern of
30 addition of both type of conducting carbon ensures efficient and homogenous
33
mixing of active material and cohesive binder and fibrillating binder resulting in a
highly uniformly packed and consistent electrode composite. The cathode
developed through present electrode composite has low electrical resistance
indicating enhanced conductivity. This lower electrical resistance significantly
5 reduces resistive heating during high-rate discharge operations, effectively
addressing the critical issue of temperature spikes at C-rates above 2C.
Consequently, the sequential mixing process in dry electrode manufacturing
delivers a transformative leap in battery performance by improving electrical
conductivity, rate capability, thermal stability, and mechanical integrity. It enables
10 solvent-free, scalable production with consistent quality, high active material
utilization, and minimal energy losses, making it ideal for electric vehicles, energy
storage systems, and portable electronics, while also lowering manufacturing costs
and environmental impact.
34
I/We Claim:
1. A process for preparing an electrode composite, the process comprising:
i) mixing an active material with a first part of a first conducting carbon, and
5 a second conducting carbon, to obtain a first mixture;
ii) blending a cohesive binder with the first mixture to obtain a second
mixture; followed by addition of a second part of the first conducting
carbon with the second mixture to obtain a third mixture;
iii) blending a fibrillating binder with the third mixture to obtain a fourth
10 mixture, followed by addition of a third part of the first conducting carbon
with the fourth mixture to obtain a fifth mixture; and
iv) subjecting the fifth mixture to high shear mixing at a tip speed in a range
of 25 to 35 m/s, at temperature in a range of 65 to 75°C, and subsequently
cooling to a temperature in a range of 0 to 19℃ to obtain the composite.
15 2. The process as claimed in claim 1, wherein the first part of the first conducting
carbon, the second part of the first conducting carbon, and the third part of the
first conducting carbon are in a weight ratio range of 1:0.3:0.3 to 1:1:1.
3. The process as claimed in claim 1, wherein the first conducting carbon has a
surface area in a range of 1300 to 1400 m2/g; and the second conducting carbon
20 has a surface area in a range of 17 to 20 m2/g.
4. The process as claimed in claim 1, wherein the first conducting carbon and the
second conducting carbon is coated on the active material in a range of 70 to
95% coating of the total surface of the active material.
5. The process as claimed in claim 1, wherein the electrode composite exhibits a
25 specific surface area in a range of 10 to 13 m2/g.
6. The process as claimed in claim 1, wherein mixing in step (i) is carried out at
a tip speed in a range of a 15 to 35 m/s, and at a temperature in a range of 0 to
25℃, for a duration of 50 to 100 minutes.
7. The process as claimed in claim 1, wherein blending in step (ii) and step (iii)
30 are independently carried out at a tip speed in a range of 10 to 25 m/s, and at a
temperature in a range of 0 to 19℃ for a duration of 10 to 60 minutes.
35
8. The process as claimed in claim 1, wherein cooling is carried out at a tip speed
in a range of 4 to 10 m/s.
9. The process as claimed in claim 1, wherein the active material is nickel
manganese cobalt oxide (NMC), and the active material is in a weight range of
5 95 to 97% (w/w), with respect to the total weight of the electrode composite.
10. The process as claimed in claim 9, wherein the nickel manganese cobalt has a
bimodal distribution with a single crystal size in a range 2 to 3.5 µm and a
polycrystal size in a range 5 to 15 µm.
11. The process as claimed in claim 1, wherein the first conducting carbon is
10 selected from amorphous carbon, carbon black, Ketjen Black, super P, or
combinations thereof, and the first conducting carbon is in a weight range of
0.8 to 2% (w/w), with respect to total weight of the electrode composite.
12. The process as claimed in claim 1, wherein the second conducting carbon is
selected from graphene, KS6L, single walled carbon nanotube (SWCNT), or
15 combinations thereof, and the second conducting carbon is in a weight range
of 0.2 to 0.8% (w/w), with respect to total weight of the electrode composite.
13. The process as claimed in claim 1, wherein the cohesive binder is selected from
polyvinylidene fluoride (PVDF), polyvinylidene fluoride hexafluoropropylene
copolymer (PVDF-HFP), polyvinylidene fluoride-vinylidene fluoride
20 copolymers (PVDF-VF2), polyvinylidene fluoride copolymers (PVDF-
copolymers), or combinations thereof, and the cohesive binder is in a weight
range of 0.7 to 1.2% (w/w), with respect to total weight of the electrode
composite.
14. The process as claimed in claim 1, wherein the fibrillating binder is selected
25 from polytetrafluoroethylene (PTFE), polytetrafluoroethylene copolymers
(PTFE-copolymer), or combinations thereof, and the fibrillating binder is in a
weight range of 0.7 to 1.2% (w/w), with respect to total weight of the electrode
composite.
15. The process as claimed in claim 1, further comprising calendaring the electrode
30 composite to obtain an electrode film, followed by lamination onto a current
collector.
36
16. The process as claimed in claim 15, wherein the current collector is selected
from primer coated aluminum foil, or bare aluminum foil.
17. An electrode comprising the electrode composite prepared by the process as
claimed in claim 1, wherein the electrode is a cathode.
5 18. The electrode as claimed in claim 17, wherein the electrode composite has
resistance in a range of 0.2 to 0.7 Ω.
19. The electrode as claimed in claim 17, wherein the active material is in a weight
range of 95 to 97% (w/w), the first conducting carbon is in a weight range of
0.8 to 2% (w/w), the second conducting carbon is in a weight range of 0.2 to
10 0.8% (w/w), the cohesive binder is in a weight range of 0.7 to 1.2% (w/w), and
the fibrillated binder is in a weight range of 0.7 to 1.2% (w/w), with respect to
the total weight of the electrode.
20. The electrode as claimed in claim 17, wherein the electrode composite has a
true density in a range of 4.0 to 5.0 g/cc, a tap density in a range of 1.0 to 3.0
15 g/cc, and a bulk density in a range of 1.2 to 1.6 g/cc.
21. The electrode as claimed in claim 17, wherein the electrode has a peel strength
in a range of 1.1 to 2.0 N/25mm, and an electrical resistance in a range of 0.15
to 0.25 Ω.
22. The electrode as claimed in claim 17, wherein the electrode has a charge
20 capacity in a range of 230 to 233 mAh/g, and a discharge capacity in a range
of 211 to 215 mAh/g.
23. The electrode as claimed in claim 17, wherein the electrode exhibits at least
98% capacity retention up to 50 cycles, a specific capacity of at least 163
mAh/g at a 2C rate and has an initial coulombic efficiency in a range of 92 to
25 94%.
24. An electrochemical cell comprising:
a. the electrode as claimed in claim 17;
b. an anode, and
c. an electrolyte.
30
37
25. Use of the electrode as claimed in claim 17, or the electrochemical cell as
claimed in claim 24, for the manufacture of a battery.
38
Date 03 October 2025
MALATHI LAKSHMIKUMARAN
IN/PA-1433
Agent for the Applicant
To,
The Controller of Patents
The Patent Office at Chennai
ABSTRACT
A PROCESS FOR PREPARING A CATHODE ELECTRODE
COMPOSITE, CATHODE ELECTRODE AND ITS IMPLEMENTATIONS
THEREOF
5 The present disclosure provides a process for preparing an electrode composite, the
process comprising: i) mixing an active material with a first part of a first
conducting carbon, and a second conducting carbon, to obtain a first mixture; ii)
blending a cohesive binder with the first mixture to obtain a second mixture;
followed by addition of a second part of the first conducting carbon with the second
10 mixture to obtain a third mixture; iii) blending a fibrillating binder with the third
mixture to obtain a fourth mixture, followed by addition of a third part of the first
conducting carbon with the fourth mixture to obtain a fifth mixture; and iv)
subjecting the fifth mixture to high shear mixing and subsequently cooling to obtain
the composite. The present disclosure further provides an electrode obtained by the
15 process, an electrochemical cell comprising the electrode, and use thereof.
39
, Claims:I/We Claim:
1. A process for preparing an electrode composite, the process comprising:
i) mixing an active material with a first part of a first conducting carbon, and
5 a second conducting carbon, to obtain a first mixture;
ii) blending a cohesive binder with the first mixture to obtain a second
mixture; followed by addition of a second part of the first conducting
carbon with the second mixture to obtain a third mixture;
iii) blending a fibrillating binder with the third mixture to obtain a fourth
10 mixture, followed by addition of a third part of the first conducting carbon
with the fourth mixture to obtain a fifth mixture; and
iv) subjecting the fifth mixture to high shear mixing at a tip speed in a range
of 25 to 35 m/s, at temperature in a range of 65 to 75°C, and subsequently
cooling to a temperature in a range of 0 to 19℃ to obtain the composite.
15 2. The process as claimed in claim 1, wherein the first part of the first conducting
carbon, the second part of the first conducting carbon, and the third part of the
first conducting carbon are in a weight ratio range of 1:0.3:0.3 to 1:1:1.
3. The process as claimed in claim 1, wherein the first conducting carbon has a
surface area in a range of 1300 to 1400 m2/g; and the second conducting carbon
20 has a surface area in a range of 17 to 20 m2/g.
4. The process as claimed in claim 1, wherein the first conducting carbon and the
second conducting carbon is coated on the active material in a range of 70 to
95% coating of the total surface of the active material.
5. The process as claimed in claim 1, wherein the electrode composite exhibits a
25 specific surface area in a range of 10 to 13 m2/g.
6. The process as claimed in claim 1, wherein mixing in step (i) is carried out at
a tip speed in a range of a 15 to 35 m/s, and at a temperature in a range of 0 to
25℃, for a duration of 50 to 100 minutes.
7. The process as claimed in claim 1, wherein blending in step (ii) and step (iii)
30 are independently carried out at a tip speed in a range of 10 to 25 m/s, and at a
temperature in a range of 0 to 19℃ for a duration of 10 to 60 minutes.
8. The process as claimed in claim 1, wherein cooling is carried out at a tip speed
in a range of 4 to 10 m/s.
9. The process as claimed in claim 1, wherein the active material is nickel
manganese cobalt oxide (NMC), and the active material is in a weight range of
5 95 to 97% (w/w), with respect to the total weight of the electrode composite.
10. The process as claimed in claim 9, wherein the nickel manganese cobalt has a
bimodal distribution with a single crystal size in a range 2 to 3.5 µm and a
polycrystal size in a range 5 to 15 µm.
11. The process as claimed in claim 1, wherein the first conducting carbon is
10 selected from amorphous carbon, carbon black, Ketjen Black, super P, or
combinations thereof, and the first conducting carbon is in a weight range of
0.8 to 2% (w/w), with respect to total weight of the electrode composite.
12. The process as claimed in claim 1, wherein the second conducting carbon is
selected from graphene, KS6L, single walled carbon nanotube (SWCNT), or
15 combinations thereof, and the second conducting carbon is in a weight range
of 0.2 to 0.8% (w/w), with respect to total weight of the electrode composite.
13. The process as claimed in claim 1, wherein the cohesive binder is selected from
polyvinylidene fluoride (PVDF), polyvinylidene fluoride hexafluoropropylene
copolymer (PVDF-HFP), polyvinylidene fluoride-vinylidene fluoride
20 copolymers (PVDF-VF2), polyvinylidene fluoride copolymers (PVDF-
copolymers), or combinations thereof, and the cohesive binder is in a weight
range of 0.7 to 1.2% (w/w), with respect to total weight of the electrode
composite.
14. The process as claimed in claim 1, wherein the fibrillating binder is selected
25 from polytetrafluoroethylene (PTFE), polytetrafluoroethylene copolymers
(PTFE-copolymer), or combinations thereof, and the fibrillating binder is in a
weight range of 0.7 to 1.2% (w/w), with respect to total weight of the electrode
composite.
15. The process as claimed in claim 1, further comprising calendaring the electrode
30 composite to obtain an electrode film, followed by lamination onto a current
collector.
16. The process as claimed in claim 15, wherein the current collector is selected
from primer coated aluminum foil, or bare aluminum foil.
17. An electrode comprising the electrode composite prepared by the process as
claimed in claim 1, wherein the electrode is a cathode.
5 18. The electrode as claimed in claim 17, wherein the electrode composite has
resistance in a range of 0.2 to 0.7 Ω.
19. The electrode as claimed in claim 17, wherein the active material is in a weight
range of 95 to 97% (w/w), the first conducting carbon is in a weight range of
0.8 to 2% (w/w), the second conducting carbon is in a weight range of 0.2 to
10 0.8% (w/w), the cohesive binder is in a weight range of 0.7 to 1.2% (w/w), and
the fibrillated binder is in a weight range of 0.7 to 1.2% (w/w), with respect to
the total weight of the electrode.
20. The electrode as claimed in claim 17, wherein the electrode composite has a
true density in a range of 4.0 to 5.0 g/cc, a tap density in a range of 1.0 to 3.0
15 g/cc, and a bulk density in a range of 1.2 to 1.6 g/cc.
21. The electrode as claimed in claim 17, wherein the electrode has a peel strength
in a range of 1.1 to 2.0 N/25mm, and an electrical resistance in a range of 0.15
to 0.25 Ω.
22. The electrode as claimed in claim 17, wherein the electrode has a charge
20 capacity in a range of 230 to 233 mAh/g, and a discharge capacity in a range
of 211 to 215 mAh/g.
23. The electrode as claimed in claim 17, wherein the electrode exhibits at least
98% capacity retention up to 50 cycles, a specific capacity of at least 163
mAh/g at a 2C rate and has an initial coulombic efficiency in a range of 92 to
25 94%.
24. An electrochemical cell comprising:
a. the electrode as claimed in claim 17;
b. an anode, and
c. an electrolyte.
30
25. Use of the electrode as claimed in claim 17, or the electrochemical cell as
claimed in claim 24, for he manufacture of a battery.