Process for making electrochemical cells using a polymer electrolyte

A process for making an electrochemical cell that contains a polymer electrolyte comprising:

• a) preparing a cathode by contacting a major amount of active cathode material with a binding amount of an ionically nonconductive prepolymeric composition to form an ionically nonconductive cathode mixture;
• b) polymerizing the prepolymeric composition to provide a polymer film having active cathode material dispersed through;
• c) placing an active anode material near to the cathode with an electrically insulating ion permeable material disposed between the cathode and the anode to form an electrode assembly;
• d) placing the electrode assembly inside a housing for the cell;
• and
• e) then adding an amount of an ionizable electrolyte salt solution to provide ionic conductivity to the polymer film between the cathode and anode to form an active electrochemical cell, said salt solution including solvent to cause said polymer film to swell.