Multilayer structure including an active electrochemical material and ionic polymer in a electrochemical cell

An electrochemical cell comprising at least one composite structure made by a process for forming a multilayer composite structure, said process comprising:

• combining at least one first heat-stable dry component and at least one first heat-stable liquid component to form a macroscopically homogeneous first mass;
• fusing the first mass to form a first plastically formable mass;
• combining at least one second dry component and at least one second liquid component to form a macroscopically homogeneous second mass;
• fusing the second mass to form a second plastically formable mass;
• providing a first die having at least one slot;
• simultaneously forcing the first plastically formable mass and the second plastically formable mass through at least one slot onto a first support to form a first multilayer composite structure;
• wherein the at least one first heat-stable dry components comprises an active electrochemical material, particulate material and an ionomeric polymer, and
• wherein the polymer comprises monomer units of vinylidene fluoride and 2–50 mol-% of a perfluoroalkenyl monomer unit having a pendant group comprising the radical represented by formula (I):
• —(OCF2CFR)aOCF2(CFR′)bSO2X−(M+)[YZc]d (I)
• wherein R and R′ are independently selected from F, Cl or a perfluoroalkyl group having 1 to 10 carbon atoms, optionally substituted by one or more ether oxygens;
• a=0, 1 or 2;
• b=0 to 6;
• M+ is H+ or a univalent metal cation;
• X is O, C or N with the proviso that
• d=0 when X is O and d=1 otherwise, and
• c=1 when X is C and c=0 when X is N;
• when c=1, Y and Z are electron-withdrawing groups selected from the group consisting of CN, SO2Rf, SO2R3, P(O)(OR3)2, CO2R3, P(O)R32, C(O)Rf, C(O)R3, and cycloalkenyl groups formed therewith wherein Rf is a perfluoroalkyl group of 1–10 carbon atoms optionally substituted with one or more ether oxygens;
• R3 is an alkyl group of 1–6 carbon atoms optionally substituted with one or more ether oxygens, or an aryl group optionally further substituted;
• or
• when c=0, Y may be an electron-withdrawing group represented by the formula —SO2Rf′ where Rf′ is the radical represented by formula (II):
• —(Rf″SO2N—(M+)SO2)mRf″ (II)
• where m=0 or 1, and Rf″ is —CnF2n— and Rf′″ is —CnF2n+1 where n=1–10, optionally substituted with one or more ether oxygens.