Lithium battery with retained gel-electrolyte

A process for preparing a microcomposite structure composed of a continuous solid phase reticulated membrane loaded with a formed in situ continuous gel phase, and including a solid phase anionic surfactant at an interface between said solid and gel phases, said process comprising:

• selecting a polymer blend consisting essentially of polyvinyl chloride and polystyrene, said polyvinyl chloride and polystyrene being present in said polymer blend in a ratio of from about 1:0.05 to 1:0.6;
• selecting an amount of an aprotic solvent system that is sufficient to dissolve said polymer blend;
• selecting an amount of said anionic surfactant that is sufficient to stabilize said gel phase;
• selecting an amount of a surfactant solvent system that is sufficient to dissolve said anionic surfactant;
• selecting a phase separation liquid that is miscible with said aprotic solvent system, and in which said polymer blend is substantially insoluble, said selecting including selecting an amount of said phase separation liquid to promote the formation of said microcomposite structure;
• mixing said polymer blend, said surfactant, said solvent systems and said phase separation liquid together to form a liquid phase mixture;
• casting said solution into a desired configuration;
• and
• allowing said solvent systems to evaporate to form said microcomposite structure.

A microcomposite structure including a continuous reticulated solid phase and an interdispersed formed in situ continuous gel phase, said microcomposite structure comprising:

• a polymer blend consisting essentially of polyvinyl chloride and polystyrene forming said reticulated solid phase;
• a mixture comprising a polymer blend of polyvinyl chloride and polystyrene, and a gel forming amount of an aprotic solvent system for said polymer blend forming said gel phase;
• and
• a gel phase stabilizing amount of a solid phase anionic surfactant at an interface between said solid and gel phases.

A battery including an anode, a cathode and a separator therebetween, said battery comprising a substantially continuous microcomposite structure, said microcomposite structure comprising:

• a continuous reticulated solid phase and a formed in situ continuous gel phase interdispersed with said reticulated solid phase;
• said reticulated solid phase being formed of a polymer blend consisting essentially of polyvinyl chloride and polystyrene forming;
• said gel phase being formed of a mixture comprising a polymer blend of polyvinyl chloride and polystyrene, a gel forming amount of an aprotic solvent system for said polymer blend;
• and
• a gel phase stabilizing amount of anionic surfactant at an interface between said solid and gel phases.

A process for forming a battery including an anode, a cathode and a separator therebetween, said battery comprising a plurality of microcomposite structures, each of said microcomposite structures including a continuous reticulated solid phase and a formed in situ continuous gel phase interdispersed with said reticulated solid phase, said reticulated solid phase being formed of a polymer blend consisting essentially of polyvinyl chloride and polystyrene forming, said gel phase being formed of a mixture comprising a polymer blend of polyvinyl chloride and polystyrene, a gel forming amount of an aprotic solvent system for said polymer blend, and a gel phase stabilizing amount of solid phase anionic surfactant present at an interface between said solid and gel phases, said process comprising:

• preparing a said microcomposite structure as an anode;
• preparing a said microcomposite structure as a separator;
• preparing a said microcomposite structure as a cathode;
• adhering said anode and cathode on opposed faces of said separator when said opposed faces are sufficiently moist with said aproitic solvent system to enable said anode and cathode to bond to said separator.

A liquid phase mixture for use in preparing a microcomposite structure composed of a continuous solid phase reticulated membrane loaded with a formed in situ continuous gel phase, said solution comprising:

• a polymer blend consisting essentially of polyvinyl chloride and polystyrene;
• a sufficient amount of an aprotic solvent system to dissolve the polymer blend;
• a sufficient amount of an anionic surfactant to stabilize the gel phase;
• a sufficient amount of a surfactant solvent system to dissolve the anionic surfactant;
• and
• a phase separation liquid that is miscible with said aprotic solvent system, and in which the polymer blend is substantially insoluble, to promote the formation of the solid and gel phases and the precipitation of the anionic surfactant at an interface between said solid and gel phases.