A thin-film battery (10) is disclosed which includes a cathode current
collector (11), a cathode (12), an electrolyte (13), an anode (14), and
an anode current collector (15). The cathode is produced by grinding
lithium cobalt oxide or other suitable cathode material to a powder
having a mean particle size of between 5 and 12 microns, forming a liquid
slurry with the cathode material, casting the liquid slurry upon a
substrate, drying the liquid slurry to form a layer of cathode material,
and compressing the cathode layer to a generally uniform and smooth
thickness of between 5 and 12 microns. The compressed layer is then
heated to a temperature which sinters or melts the peripheral edges of
the cathode particles together.