Method of making chalcogenide cathodes

Claim 3

A method according to claim 1 which comprises: (a) forming a mixture containing from about 45% to about 90% by weight of at least one intercalatable layered transition metal chalcogenide cathode active material, from about 1% to about 46% by weight of a conductivity enhancing agent and from about 1% to about 10% by weight of a binding agent; (b) forming a slurry containing from about 20% to about 80% by weight of the mixture and from about 80% to about 20% by weight of a vehicle therefor; (c) treating a high porosity current collector substrate having about 10-1000 pores per square inch by applying an adhesion promoting agent thereon in an amount of from about 5% to about 35% by weight and drying the treated substrate; (d) applying the slurry to the treated and dried substrate for a weight pickup of from about 10 mg/cm 2 to about 300 mg/cm 2 ; and (e) heating the substrate in an inert atmosphere at a temperature of from about 10° C. to about 350° C. to drive off the vehicle and coalesce the binding agent.

Claim 4

A method according to claim 1 which comprises: (a) forming a mixture containing about 75% by weight of mixed titanium disulfide--titanium trisulfide, about 20% by weight of carbon black and about 5% by weight of polyethylene; (b) forming a slurry containing about 33% by weight of the mixture and about 67% by weight of diethylene (c) treating nickel foam having about 35-100 pores per square inch by vacuum impregnating vinyltriethoxy silane thereon in an amount of about 10% by weight and drying the treated nickel foam; (d) applying the slurry to the treated and dried nickel foam by vacuum impregnation for a weight pickup of about 125 mg/cm 2 ; and (e) heating the nickel foam in an argon atmosphere at a temperature of about 150° C. to drive off the diethylene glycol butyl ether and coalesce the polyethylene.

Claim 5

A method according to claim 1 which comprises: (a) forming a mixture containing about 75% by weight of titanium disulfide, about 20% by weight of titanium carbide and about 5% by weight of polytetrafluoroethylene; (b) forming a slurry containing about 50% by weight of the mixture and about 50% by weight of acetone; (c) treating nickel foam having about 35-100 pores per square inch by vacuum impregnating vinyl tris-(beta-methoxyethoxy) silane thereon in an amount of about 10% by weight and drying the treated nickel foam; (d) applying the slurry to the treated and dried nickel foam by vacuum impregnation for a weight pickup of about 50 mg/cm 2 ; and (e) heating the nickel foam in an argon atmosphere at a temperature of about 90° C. to drive off the acetone and then at a temperature of about 350° C. to coalesce the polytetrafluoroethylene.