Method of fabrication of composite electrodes in lithium ion battery and cells

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

• (A) applying a first film-forming slurry 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 grid 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-intercalateable electrodes for a lithium-ion battery with polymeric separators comprising the steps of:

• (A) forming a first film comprising of plurality of said lithium-intercalateable particles dispersed throughout a mixture of a polymeric binder compatible with said battery, a plasticizer for said binder, and a solvent for said binder;
• (B) drying said first film by removing said solvent;
• (C) embedding a first face of an electrically conductive grid into said first film;
• (D) applying a film-forming slurry to a second face of said grid opposite said first to form a second film overlying said first film, said slurry comprising a plurality of said lithium-intercalateable particles dispersed throughout a mixture of said binder, said plasticizer and said solvent whereby said solvent from said slurry dissolves at least some of said binder in said first film, and promotes solvent bonding of said first and second films to each other and to said grid;
• (E) thereafter drying said electrode by removing said solvent;
• (F) removing said plasticizer from said mixture so as to leave a network of pores pervading said binder;
• and
• (G) backfilling said pores with a lithium-ion-conductive electrolyte.

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 a plasticizer for said binder;
• 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, 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.