US 7,066,971 B1 · Methods of preparing electrochemical cells

Abstract

Methods of preparing a cathode/separator assembly for use in electrochemical cells in which a protective coating layer, such as a single ion conducting layer, is coated on a temporary carrier substrate, a microporous separator layer is then coated on the protective coating layer, and a cathode active layer is then coated on the separator layer, prior to removing the temporary carrier substrate from the protective coating layer. Additional layers, including an edge insulating layer, a cathode current collector layer, an electrode insulating layer, an anode current collector layer, an anode layer such as a lithium metal layer, and an anode protective layer, such as a single ion conducting layer, may be applied subsequent to the coating step of the microporous separator layer. Also, methods of preparing electrochemical cells utilizing cathode/separator assemblies prepared by such methods, and cathode/separator assemblies and electrochemical cells prepared by such methods.

Claims19

Dependent claims

A method of preparing a cathode/separator assembly of an electrochemical cell, wherein said cathode/separator assembly comprises a cathode active layer and as microporous separator layer, said method comprising the steps of:

(a) coating a first protective coating layer on a temporary carrier substrate, wherein said first protective coating layer has a first surface in contact with said temporary carrier substrate and has a second surface on the side opposite from said temporary carrier substrate;
(b) coating a microporous separator layer on said second surface of said first protective coating layer, wherein said separator layer has a first surface in contact with said second surface of first protective coating layer and has a second surface on the side opposite from said first protective coating layer;
(c) coating a cathode active layer in a desired pattern on said second surface of said separator layer, wherein said cathode active layer has a first surface in contact with said second surface of said separator layer and has a second surface on the side opposite from said separator layer;
and
(d) removing said temporary carrier substrate from said first surface of said first protective coating layer to form said cathode/separator assembly.

2 more elements

A method of preparing an electrochemical cell, said method comprising the steps of:

(a) providing a cathode/separator assembly prepared by a method comprising the steps of:
(i) coating a first protective coating layer on a temporary carrier substrate, wherein said first protective coating layer has a first surface in contact with said temporary carrier substrate and has a second surface on the side opposite from said temporary carrier substrate;
(ii) coating a microporous separator layer on said second surface of said first protective coating layer, wherein said separator layer has a first surface in contact with said second surface of said first protective coating layer and has a second surface on the side opposite from said first protective coating layer;
(iii) coating a cathode active layer in a desired pattern on said second surface of said separator layer, wherein said cathode active layer has a first surface in contact with said second surface of said separator layer and has a second surface on the side opposite from said separator layer;
and
(iv) removing said temporary carrier substrate from said first surface of said first protective coating layer to form said cathode/separator assembly;
(b) providing an anode;
(c) providing a cathode current collector layer;
(d) providing an electrode insulating layer interposed between said anode and said cathode current collector layer;
and,
(e) providing an electrolyte, wherein said electrolyte is contained in the pores of said separator layer;
wherein said first surface of said first protective coating layer of said cathode/separator assembly and said anode are positioned in a face-to-face relationship and said second surface of said cathode active layer and said cathode current collector layer are positioned in a face-to-face relationship.

9 more elements

A method according to preparing an electrochemical cell, said method comprising the steps of:

(a) coating a first protective coating layer on a temporary carrier substrate, wherein said first protective coating layer has a first surface in contact with said temporary carrier substrate and has a second surface on the side opposite from said temporary carrier substrate;
(b) coating a microporous separator layer on said second surface of said is first protective coating layer, wherein said separator layer has a first surface in contact with said first protective coating layer and has a second surface on the side opposite from said first protective coating layer;
(c) coating a cathode active layer in a desired pattern on said second surface of said separator layer, wherein said cathode active layer has a first surface in contact with said second surface of said separator layer and has a second surface on the side opposite from said separator layer;
(d) depositing a cathode current collector layer in a desired pattern on said second surface of said cathode active layer, wherein said cathode current collector layer has a first surface in contact with said second surface of said cathode active layer and has a second surface on the side opposite from said cathode active layer;
(e) depositing an electrode insulating layer in a desired pattern on said second surface of said cathode current collector layer, wherein said electrode insulating layer has a first surface in contact with said second surface of said cathode current collector layer and has a second surface on the side opposite from said cathode current collector layer;
(f) depositing an anode current collector layer in a desired pattern on said second surface of said electrode insulating layer, wherein said anode current collector layer has a first surface in contact with said second surface of said electrode insulating layer and has a second surface on the side opposite from said electrode insulating layer;
(g) depositing an anode active material layer in a desired pattern on said second surface of said anode current collector layer, wherein said anode active material layer has a first surface in contact with said second surface of said anode current collector layer and has a second surface on the side opposite to said anode current collector layer;
(h) removing said temporary carrier substrate from said first surface of said first protective coating layer;
and
(i) providing an electrolyte, wherein said electrolyte is contained in the pores of said separator layer.

7 more elements

Dependencies are inferred from the claim text.

Methods of preparing electrochemical cells

Life of this patent

Methods of preparing electrochemical cells

Life of this patent

Abstract

Claims19