Method for producing electrochemical cell
First Claim
1. A process for making an electrochemical cell comprising the steps of:
- a. applying a cathode composition onto a current collector providing an external surface of such composition which is not in contact with the current collector;
b. applying a releasable layer onto the external surface of the cathode composition;
c. applying pressure to the external surface of the cathode composition sufficient to reduce discontinuities and irregularities on the external surface;
d. cooling the cathode composition of step (c) for a time and at a temperature each sufficient to reduce the temperature of the cathode composition to -20°
C. or less to reduce the tackiness thereof;
e. removing the releasable layer while maintaining such cathode composition in a condition of reduced tackiness;
f. applying an ionically conductive electrolyte composition onto the cathode composition of step (e);
g. at least partially curing the cathode and the electrolyte compositions; and
h. applying an anode layer onto the electrolyte composition of step (g) to form a cell assembly.
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Accused Products
Abstract
In a new process for making a cathode current collector assembly, a cathode composition is positioned on a substrate between the substrate and a releasable layer. Next, force is applied on the releasable layer and directed toward the substrate so as to provide a smooth cathode surface in contact with the releasable layer. The cathode composition having the releasable layer maintained thereon is cooled to reduce the tackiness of the cathode composition and then the releasable layer is removed while the cathode composition remains in its condition of reduced tackiness. In an alternative process, the cathode composition is applied and then force is applied immediatly before or simultaneously with cooling the composition to a state of reduced tackiness. An electrolyte composition is applied to the smooth surface cathode and the cathode and electrolyte compositions are cured together. In a final step, an anode layer is applied onto the electrolyte composition to form a cell assembly and further curing may occur.
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Citations
33 Claims
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1. A process for making an electrochemical cell comprising the steps of:
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a. applying a cathode composition onto a current collector providing an external surface of such composition which is not in contact with the current collector; b. applying a releasable layer onto the external surface of the cathode composition; c. applying pressure to the external surface of the cathode composition sufficient to reduce discontinuities and irregularities on the external surface; d. cooling the cathode composition of step (c) for a time and at a temperature each sufficient to reduce the temperature of the cathode composition to -20°
C. or less to reduce the tackiness thereof;e. removing the releasable layer while maintaining such cathode composition in a condition of reduced tackiness; f. applying an ionically conductive electrolyte composition onto the cathode composition of step (e); g. at least partially curing the cathode and the electrolyte compositions; and h. applying an anode layer onto the electrolyte composition of step (g) to form a cell assembly. - View Dependent Claims (2, 3, 4, 5)
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6. A process for making an electrochemical cell comprising the steps of:
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a. applying a cathode composition onto a current collector providing an external surface of such composition which is not in contact with the current collector; b. applying a releasable layer onto the external surface of the cathode composition; c. applying pressure to the external surface of the cathode composition sufficient to reduce discontinuities and irregularities on the external surface; d. cooling the cathode composition of step (c) for a time and at a temperature sufficient to substantially solidify the cathode composition to reduce the tackiness thereof; e. removing the releasable layer while maintaining such cathode composition in a condition of reduced tackiness; f. applying an ionically conductive electrolyte composition onto the cathode composition of step (e); g. at least partially curing the cathode and the electrolyte compositions; and h. applying an anode layer onto the electrolyte composition of step (g) to form a cell assembly. - View Dependent Claims (7, 8, 9, 10, 11)
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12. A process for making a cathode/current collector comprising the steps of:
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a. positioning a cathode composition on a substrate between the substrate and a releasable layer; b. directing pressure on the releasable layer and toward the substrate; c. cooling the cathode composition for a time and at a temperature each sufficient to reduce the temperature of the cathode composition to -20°
C. or less to reduce the tackiness thereof; andd. removing the releasable layer while maintaining the cathode composition in a condition of reduced tackiness. - View Dependent Claims (13, 14, 15)
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16. A process for making a cathode/current collector comprising the steps of:
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a. positioning a cathode composition on a substrate between the substrate and a releasable layer; b. directing pressure on the releasable layer and toward the substrate; c. cooling the cathode composition to substantially solidify the cathode composition to reduce the tackiness thereof; and removing the releasable layer while maintaining the cathode composition in a condition of reduced tackiness. - View Dependent Claims (17, 18, 19)
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20. A process for making an electrochemical cell comprising the steps of:
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a. applying a cathode composition onto a current collector providing an external surface of such composition which is not in contact with the current collector; applying pressure to the external surface of the cathode composition sufficient to reduce discontinuities on the external surface and essentially simultaneously cooling the cathode composition for a time and at a temperature sufficient to reduce the tackiness thereof by rolling the external surface with a chill roller; applying an ionically conductive electrolyte composition onto the pressed and chilled cathode composition; d. at least partially curing one or both of the cathode and the electrolyte compositions; and e. applying an anode layer onto the electrolyte composition to form a cell assembly. - View Dependent Claims (21)
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22. A process for making an electrochemical cell comprising the steps of:
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a. applying a cathode composition onto a current collector providing an external surface of such composition which is not in contact with the current collector; b. applying pressure to the external surface of the cathode composition sufficient to reduce discontinuities on the external surface; c. cooling the cathode composition for a time and at a temperature sufficient to reduce the temperature of the cathode composition to a substantially solidified condition or to about -20°
C. or less thereby reducing the tackiness thereof;d. applying an ionically conductive electrolyte composition onto the pressed and chilled cathode composition; e. at least partially curing one or both of the cathode and the electrolyte compositions; and f. applying an anode layer onto the electrolyte composition to form a cell assembly. - View Dependent Claims (23, 24, 25)
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26. A process for making a cathode/current collector comprising the steps of:
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a. applying a cathode composition onto a substrate providing an external surface of such composition which is not in contact with the substrate; b. directing pressure on the external surface and toward the substrate; and c. immediately after step (b) and/or during step (b), cooling the cathode composition to reduce the temperature of the cathode composition to a substantially solidified condition or to about -20°
C. or less thereby reducing the tackiness thereof. - View Dependent Claims (27, 28)
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29. A process for making a cathode/current collector comprising the steps of:
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a. applying a cathode composition onto a substrate providing an external surface of such composition which is not in contact with the substrate; and b. directing pressure on the external surface and toward the substrate, and cooling the cathode composition to reduce the tackiness thereof by rolling the external surface with a chill roller. - View Dependent Claims (30, 31)
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32. A process for making a cathode/current collector comprising the steps of:
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a. applying a cathode composition onto a substrate providing an external surface of such composition which is not in contact with the substrate; b. directing pressure on the external surface and toward the substrate; c. immediately after step (b) and/or during step (b), cooling the cathode composition to reduce the tackiness thereof; and d. after step (c), at least partially curing the cathode composition.
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33. A process for making a cathode/current collector comprising the steps of:
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a. applying a cathode composition onto a substrate providing an external surface of such composition which is not in contact with the substrate; b. directing pressure on the external surface and toward the substrate; c. immediately after step (b) and/or during step (b), cooling the cathode composition to reduce the tackiness thereof; d. after step (c), the additional steps of; i. applying an electrolyte composition onto the cathode composition; ii. at least partially curing the cathode and the electrolyte compositions; and iii. applying an anode layer onto the electrolyte composition to form a cell assembly.
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Specification