Patent ID: 6302928
Filing Date: 2001-10-16
Classification: H01M,Y02E,Y02P,Y10T

Abstract:
A method of forming a solid composite cathode for use in an electric current producing cell, wherein said method comprises the steps of:(a) dispersing or suspending solid materials comprising:(i) elemental sulfur; and(ii) an electrically conductive material; in a liquid medium to form a liquid mixture;(b) casting said liquid mixture formed in step (a) onto a substrate to form a cast layer;(c) removing some or all of said liquid medium from said cast layer formed in step (b) to form a dried layer on said substrate;(d) melting said elemental sulfur in said dried layer by heating to a temperature above the melting point of said elemental sulfur to form a melt layer; and(e) resolidifying said melted elemental sulfur formed in step (d) to form a cathode active layer, wherein the thickness of said cathode active layer of step (e) is at least 8% less than the thickness of said dried layer of step (c) and said elemental sulfur is present in said cathode active layer at a volumetric density of greater than 500 mg/cm.sup.3.