Patent ID: 7615508

Claim:
A method of making a cathode for a rechargeable air assisted battery, the cathode comprising (1) a catalyst comprising manganese dioxide, (2) carbon particles, and (3) a hydrophobic polymer, the method comprising (a) combining the catalyst comprising manganese dioxide, the carbon particles, and a solvent to form a mixture that does not include the hydrophobic polymer; (b) combining the mixture with the hydrophobic polymer and stirring the combination at a temperature below about 10°C. to provide a slurry without fibrillation of the hydrophobic polymer; (c) warming the slurry to at least about 20°C. and mixing the slurry at this temperature to fibrillate the hydrophobic polymer; (d) loading the slurry onto a cathode current collector; and (e) drying the slurry by removing the solvent to provide the cathode, wherein the cathode comprises at least 70% of manganese dioxide by weight.