Patent ID: 6488721
Filing Date: 2002-12-03
Classification: H01M,Y02E,Y02P,Y10T

Abstract:
A method of preparing a cathode/separator assembly for use in an electrochemical cell, wherein said cathode/separator assembly comprises a cathode active layer, a microporous separator layer and one or more protective coating layers comprising a polymer; wherein said separator layer comprises one or more microporous xerogel layers, and wherein said one or more protective coating layers are in contact with at least one of said one or more microporous xerogel layers of said separator layer; said method comprising the steps of:(a) coating one of the one or more protective coating layers on a temporary carrier substrate, wherein said one of the one or more protective coating layers 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 said microporous separator layer on said second surface of said one of the one or more protective coating layers, wherein said separator layer has a first surface in contact with said second surface of said one of the one or more protective coating layers and has a second surface on the side opposite from said one of the one or more protective coating layers; (c) coating said cathode active layer in a 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 one of the one or more protective coating layers to form said cathode/separator assembly.