Patent ID: 6503432
Filing Date: 2003-01-07
Classification: B29C,B29L,H01M,Y02E,Y02P,Y10T

Abstract:
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): â€”(OCF2CFR)aOCF2(CFRâ€²)bSO2Xâˆ’(M+)[YZc]dâ€ƒâ€ƒ(I) â€ƒwherein R and Râ€² 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 â€”SO2Rfâ€² where Rfâ€² is the radical represented by formula (II): â€”Rfâ€³SO2Nâ€”(M+)SO2)mRfâ€³â€ƒâ€ƒ(II) where m=0 or 1, and Rfâ€² is â€”CnF2nâ€” and Rfâ€²â€³ is â€”CnF2n+1 where n=1-10, optionally substituted with one or more ether oxygens.