Patent ID: 6727017
Filing Date: 2004-04-27
Classification: H01M,Y02E,Y02P,Y10T

Abstract:
A method of fabricating a rechargeable battery having at least one anode, at least one cathode in opposing spaced relationship with each anode, two layers of a porous separator/binder intermediate each opposed anode and cathode to maintain said spacing and to bind each anode to each cathode, and an non-aqueous electrolyte filing pores of each separator/binder, said method comprisingcoating at least one surface of each said anode and/or cathode with a layer of a first separator/binder containing polymer P1 with polymer P1 dissolved in solvent S1, in a manner such that a single layer of said first separator/binder is present between each anode and cathode in the battery when fabrication is complete; then drying each said layer of said first separator/binder; then providing a layer of a second separator/binder containing polymer P2, with polymer P2 at least partially dissolved in a solvent S2, to at least one coated or non-coated surface of each anode and/or cathode in a manner such that a single layer of said second separator/binder is present between each anode and cathode in the battery when fabrication is complete; placing each anode in opposing spaced relationship to each cathode; then drying each layer of said second separator/binder so as to bind each said anode to each said cathode; said first separator/binder comprising the polymer P1 and a particulate material M1, said second separator/binder comprising the polymer P2 and a particulate material M2, wherein: polymer P1 is soluble in solvent S1, polymer P2 is soluble in solvent S2, polymer P1 is non-soluble in solvent S2, polymer P2 is non-soluble in solvent S1, particulate material M1 is non-soluble in solvent P1, and particulate material M2 is non-soluble in solvent S2.