Description:AS ATTACHED , Claims:AS ATTACHED

I/We Claim:
1. A dry cathode composite comprising:
a. 95.6 to 97% by weight of an active material;
b. 1.2 to 1.5% by weight of a first conductive carbon having a surface
area in a range of 250 m2
/g to 1800 m2
5 /g;
c. 0.35 to 0.5% by weight of a second conductive carbon having a
surface area in a range of 10 m2
/g to 50 m2
/g;
d. 0.8 to 1.2% by weight of a fibrillating binder; and
e. 0.7 to 1.2% by weight of an adhesive binder selected from
10 polyvinylidene fluoride (PVDF), polyvinylidene fluoride-cohexafluoropropylene (PVDF-HFP), polyethylene oxide, vinylidene
fluoride, polyacrylic acid (PAA), high molecular weight polyethylene
(HMWPE), polyvinylidene fluoride-vinylidene difluoride copolymers
(PVDF-VF2), or combinations thereof.
15 2. The dry cathode composite as claimed in claim 1, wherein the first conductive
carbon and the second conductive carbon are in a combined weight in a range of
1.6 to 2% (w/w), with respect to total weight of the composite.
3. The dry cathode composite as claimed in claim 1, wherein the active
material is selected from layered lithium nickel manganese cobalt oxide
20 (LiaNixMnyCozMbO2), spinel lithium nickel manganese oxide (LiNiMnMbO4),
olivine lithium iron phosphate (LiFeMbPO4) or combinations thereof, wherein M is
selected from Fe, Mn, Ni, Co, Cr, Al, Ti, Zr, W, Mo, Ru, V, Y, or Nb, a=0.9 to 1.3,
b=0.01 to 0.5, x=0.1 to 0.9, y=0.01 to 0.7, and z= 0.01 to 0.5; and the active material
has a particle size in a range of 2 to 20 micron.
25 4. The dry cathode composite as claimed in claim 1, wherein first conductive
carbon is selected from carbon black (CB), acetylene black, or combinations
thereof.
5. The dry cathode composite as claimed in claim 1, wherein the second
conductive carbon is selected from graphite, graphene, carbon nanotubes, or
30 combinations thereof

6. The dry cathode as claimed in claim 1, wherein the fibrillating binder is
selected from polytetrafluoroethylene (PTFE), ethylene vinyl acetate (EVA),
fluoroethylene vinyl ether (FEVE), or combinations thereof.
7. The dry cathode composite as claimed in claim 1, wherein the first
5 conductive carbon and the second conductive carbon are in a weight ratio in a range
of 10:1 to 2:1.
8. The dry cathode composite as claimed in claim 1, wherein the first
conductive carbon and second conductive carbon are in a surface area ratio in a
range of 20: 1 to 180: 1.
10 9. The dry cathode composite as claimed in claim 1, wherein the first
conductive carbon has a particle size in a range of 0.1 to 2.5 µm; and the second
conductive carbon has a particle size in a range of 3 to 5 µm.
10. A process for preparation of the dry cathode composite as claimed in claim
1, said process comprising:
15 i) mixing an active material, a first conductive carbon, and a second
conductive carbon to obtain a first mixture;
ii) blending the first mixture with a fibrillating binder and an adhesive binder
followed by high shear mixing at a tip speed in a range of 20 to 40 m/s, at
a temperature in a range of 60 to 80 °C to obtain a second mixture; and
20 iii) cooling the second mixture to a temperature in a range of 10 to 19 °C to
obtain the dry cathode composite.