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Methods of making coated battery components

  • US 7,544,384 B2
  • Filed: 11/24/2003
  • Issued: 06/09/2009
  • Est. Priority Date: 11/24/2003
  • Status: Active Grant
First Claim
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1. A method of making a cathode for a primary lithium battery comprising:

  • step A;

    pulling an expanded metal grid including aluminum and having an initial tensile strength and an array of diamond-shaped openings, each opening having a long dimension and a short dimension, and each opening defined by four elongated boundary elements, each boundary element having a length and the pulling being along a direction other than along the length of any of the elements, the pulling providing a pulled expanded metal grid having an increase in the short dimension of the openings and an increase in the tensile strength to greater than 5 lb/in;

    step B;

    leveling the pulled expanded metal grid by passing the pulled expanded metal grid between rollers, andstep C;

    coating the pulled expanded metal grid with a composition including a cathode active material to provide a coated and pulled expanded metal grid,wherein leveling is conducted before coating and in a separate step before step C.

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