System and method for multilayer fabrication of lithium polymer batteries and cells

A method of making lithium-intercalateable cells for a lithium-ion battery with polymeric separators comprising the steps of:

• (A) applying a first film-forming slurry with a polymeric separator backing onto a first face of an electrically conductive grid, said first film comprising a plurality of lithium-intercalateable particles dispersed throughout a mixture of a polymeric binder compatible with said battery and a plasticizer for said binder;
• (B) applying a second film-forming slurry to a second face of said polymeric separator backing opposite said first face, said second film comprising a plurality of said lithium-intercalateable particles dispersed throughout a mixture of said binder, said plasticizer and a solvent for said binder;
• (C) thereafter, drying said electrode by removing said solvent;
• (D) removing said plasticizer from said binder so as to leave a network of pores pervading said binder;
• and
• (E) backfilling said pores with a lithium-ion-conductive electrolyte.

A method of making lithium intercalcateable bicells for a lithium ion battery with polymeric separators comprising the steps of:

• (A) applying a film-forming slurry to a first face of an electrically-conductive grid, said slurry comprising a plurality of said lithium-intercalcateable particles dispersed throughout a mixture including polymeric binder;
• (B) thereafter, drying the slurry, thereby forming an electrode;
• (C) applying a film-forming slurry to a second face of said electrically-conductive grid, said slurry comprising a plurality of said lithium-intercalcateable particles dispersed throughout a mixture including polymeric binder;
• (D) thereafter, drying the slurry, thereby forming an electrode with film on either side of grid;
• (E) applying a film-forming slurry with a polymeric separator backing to an electrically-conductive grid, said slurry comprising a plurality of said lithium-intercalcateable particles dispersed throughout a mixture including polymeric binder;
• (F) thereafter, drying said slurry and polymeric backing, thereby forming an electrode laminated to said separator;
• (G) laminating on a first side of said electrode (D) to said electrode with separator (F);
• and
• (H) laminating on a second side of said electrode (D) opposing said first side to a second said electrode with separator (F).

A method of making lithium-intercalateable electrodes for a lithium-ion battery with polymeric separators comprising the steps of:

• (A) simultaneously applying (i) a first film-forming slurry with a first face of polymeric separator backing onto an electrically conductive grid comprising a plurality of lithium-intercalateable particles dispersed throughout a mixture of a polymeric binder compatible with said battery and a plasticizer for said binder;
• and (ii) a second film-forming slurry to a second face of said polymeric separator backing opposite said first face comprising a plurality of said lithium-intercalateable particles dispersed throughout a mixture of said binder, said plasticizer and a solvent for said binder;
• (B) thereafter, drying said electrode by removing said solvent to form respective first and second films;
• (C) removing said plasticizer from said binder so as to leave a network of pores pervading said binder;
• and
• (D) backfilling said pores with a lithium-ion-conductive electrolyte.