# US 5,700,300 A · Electrolyte coating system for porous electrodes

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- Number: US 5,700,300 A
- Document ID: US5700300A
- Status: Granted
- Kind: A
- Application number: 08/689,586
- Filed: 1996-08-12
- Granted: 1997-12-23
- Earliest claimed: 1996-08-12
- Assignees: Valence Technology, Inc.
- Inventors: Gert Jensen; Dale Shackle
- Web page: https://patentgrep.com/patent/US5700300A

## CPC

- H01M 10/052: Li-accumulators
- H01M 6/40: Printed batteries {, e.g. thin film batteries}
- H01M 10/0565: Polymeric materials, e.g. gel-type or solid-type
- H01M 50/46: Separators, membranes or diaphragms characterised by their combination with electrodes
- H01M 2300/0085: Immobilising or gelification of electrolyte
- Y02E 60/10: Energy storage using batteries
- Y10T 29/49108: Electric battery cell making
- Y10T 29/49115: including coating or impregnating
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The subject invention provides a three-step process for electrolyte deposition. A surplus of electrolyte pre-wet material, having a relatively low viscosity, is layered onto a dry, porous electrode. Surplus pre-wet material is mechanically removed from the surface of the electrode. This also removes bubbles or foaminess which has developed in the pre-wet material. The pre-wet solution is allowed to absorb into the porous electrode, and the surface is then coated with the high-viscosity electrolyte precursor. Curing or further processing of the electrode/electrolyte then continues with standard processes.

## Claims

### Claim 1

A method of preparing a porous electrode structure having an electrolyte layer thereupon, said method comprising:
(a) preparing a porous electrode structure;
(b) layering excess low-viscosity electrolyte pre-wet material upon an electrode surface of the porous electrode;
(c) removing excess low-viscosity electrolyte pre-wet material to remove bubbles and form a scraped pre-wet material;
(d) allowing the scraped pre-wet material to absorb into the porous electrode structure; and
(e) applying a viscous electrolyte precursor material to the surface of the porous electrode structure with absorbed pre-wet material.

### Claim 2 (depends on 1)

A method of claim 1 wherein said low-viscosity electrolyte pre-wet material has a viscosity of about 20 to 40 centipoise.

### Claim 3 (depends on 1)

A method of claim 1 wherein said low-viscosity electrolyte pre-wet material comprises a matrix forming polymer and a plasticizing solvent.

### Claim 4 (depends on 1)

A method of claim 1 wherein said viscous electrolyte precursor has a viscosity of greater than 300 centipoise.

### Claim 5 (depends on 1)

A method of claim 1 wherein said step of preparing a porous electrode structure further comprises the step of preparing a porous electrode structure upon a current collector.

### Claim 6 (depends on 1)

A method of claim 1 wherein said scraped pre-wet material is present at approximately 3 to 5 mg/cm.sup.2.

### Claim 7

A method of preparing a porous electrode structure having an electrolyte layer thereupon, said method comprising the steps of:
(a) layering a low-viscosity electrolyte pre-wet material upon a porous electrode surface;
(b) scraping the surface of the low-viscosity electrolyte pre-wet material to remove bubbles formed therein;
(c) allowing the scraped low-viscosity electrolyte pre-wet material to permeate the porous electrode; and
(c) applying a viscous electrolyte precursor material to the surface of the porous electrode permeated with low-viscosity pre-wet material.

### Claim 8 (depends on 7)

A method of claim 7 wherein said low-viscosity electrolyte pre-wet material has a viscosity of about 20 to 40 centipoise.

### Claim 9 (depends on 7)

A method of claim 7 wherein said low-viscosity electrolyte pre-wet material comprises a matrix forming polymer and a plasticizing solvent.

### Claim 10 (depends on 7)

A method of claim 7 wherein said step of preparing a porous electrode structure further comprises the step of preparing a porous electrode structure upon a current collector.

### Claim 11

A method of preparing a battery having a solid electrolyte, said method comprising the steps of:
(a) preparing a porous cathode structure;
(b) layering a low-viscosity electrolyte pre-wet material upon a cathodic surface of the porous cathode;
(c) shaving the surface of the low-viscosity electrolyte pre-wet material upon the surface of the porous cathode to remove any bubbles formed thereupon;
(d) applying a viscous electrolyte precursor material to the surface of the shaved cathode/pre-wet surface to produce a cathode/electrolyte structure;
(e) preparing a porous anode structure;
(f) layering a low-viscosity electrolyte pre-wet material upon an anodic surface of the porous anode;
(g) shaving the surface of the low-viscosity electrolyte pre-wet material upon the surface of the porous anode to remove any bubbles formed thereupon;
(h) applying a viscous electrolyte precursor material to the surface of the shaved anode/pre-wet surface to produce an anode/electrolyte structure;
(i) laminating together the electrolyte surfaces of the cathode/electrolyte structure and the anode/electrolyte structure to form an anode/electrolyte/cathode structure; and
(j) curing the electrolyte.

### Claim 12 (depends on 11)

A method of claim 11 wherein said low-viscosity electrolyte pre-wet material has a viscosity of about 20 to 40 centipoise.

### Claim 13 (depends on 11)

A method of claim 11 wherein said low-viscosity electrolyte pre-wet material comprises a matrix forming polymer and a plasticizing solvent.

### Claim 14 (depends on 11)

A method of claim 11 wherein said step of preparing a porous cathode structure comprises the step of preparing a porous cathode structure layered upon a cathodic current collector.