System and method for multilayer fabrication of lithium polymer batteries and cells using surface treated separators

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

• (A) subjecting a polymeric separator backing to a surface treatment;
• (B) applying a first film-forming slurry with said 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;
• (C) 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;
• and
• (D) drying the slurry, thereby forming an electrode with film on either side of the grid.

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 surface-treated 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 electrode laminated to said surface-treated separator;
• (G) laminating on a first side of said electrode (D) to said electrode with surface-treated separator (F);
• and
• (H) laminating on a second side of said electrode (D) opposing said first side to a second said electrode with surface-treated separator (F).

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

• (A) simultaneously applying (i) a first film-forming slurry with a first face of a surface treated 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 (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;
• and
• (B) thereafter, drying said electrode to form respective first and second films.

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

• (A) subjecting a polymeric separator backing to a surface treatment;
• (B) applying a first film-forming slurry with said 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;
• (C) 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, and a solvent for said binder;
• (D) thereafter, drying said electrode by removing said solvent;
• (E) placing said electrode in a non-solvent thereby creating a microporous matrix resulting from precipitation of polymeric separator backing particles;
• and
• (F) backfilling said microporous matrix with a lithium-ion-conductive electrolyte.

A method of making lithium-intercalateable electrodes for batteries comprising the step of:

• (A) applying a film-forming slurry to an electrically-conductive grid, said slurry comprising a plurality of said lithium-intercalateable particles dispersed throughout a mixture including polymeric binder;
• (B) thereafter, drying the slurry, thereby forming an electrode;
• and
• (C) treating said electrode with a surface treatment wherein said surface treatment is one selected from the group comprising a plasma treatment and a corona treatment.

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 onto a first face of an electrically conductive grid comprising a plurality of lithium-intercalateable particles dispersed throughout a mixture of a polymeric binder compatible with said battery;
• and (ii) a second film-forming slurry to a second face of said grid opposite said first face comprising a plurality of said lithium-intercalateable particles dispersed throughout a mixture of said binder;
• and
• (B) thereafter, drying said electrode to form respective first and second films.