US Patent 9577267 Electrode structure and method for making same

Electrode structures and methods for making the same are generally described. In certain embodiments, the electrode structures can include a plurality of particles, wherein the particles comprise indentations relative to their convex hulls. As the particles are moved proximate to or in contact with one another, the indentations of the particles can define pores between the particles. In addition, when particles comprising indentations relative to their convex hulls are moved relative to each other, the presence of the indentations can ensure that complete contact does not result between the particles (i.e., that there remains some space between the particles) and that void volume is maintained within the bulk of the assembly. Accordingly, electrodes comprising particles with indentations relative to their convex hulls can be configured to withstand the application of a force to the electrode while substantially maintaining electrode void volume (and, therefore, performance). Particles having indentations relative to their convex hulls also occupy a relatively small volume, compared to spheres or other particles including boundaries that fill substantially all of their convex hulls, allowing one to introduce a desired amount of void volume while reducing the percentage of volume within the electrode occupied by particulate material.