Patent ID: 7008722

Claim:
A method of making a rechargeable polymer lithium ion battery comprising the steps of: (a) forming a battery cell using a negative electrode, positive electrode and separator element and placing the battery cell into a soft package film element, wherein said electrodes each have a plurality of surfaces and the separator element is a microporous membrane, having a plurality of sides; (b) depositing adherent particles from a P-fluid element on to the surfaces of the electrodes and sides of the separator element and having electrolyte from an E-solution element absorbed in to micropores of the electrodes and separator element during battery assembly process; wherein said P-fluid element is a polymer fluid to deposit adherent particles onto separators, which will bond both anode and cathode onto the separators; and wherein said E-solution element is a liquid electrolyte solution, comprising lithium salts and solvents to form polymer gelling electrolyte; (c) performing a chemical liquid deposition (CLD) wherein the step of depositing adherent particles comprises the steps of: i) introducing the polymer fluid (P-fluid) into the packaged battery cell; ii) extracting solvent from the P-fluid under a vacuum at a temperature of about 25–80° C. for a time period of about 5–500 seconds to recrystallize polymer from the P-fluid into particles, wherein said particles are characterized by: a. a particle size in the range of about 0.01–5 μm; b. a surface density in the range of about 0.01–0.4 mg/cm 2 ; wherein the CLD process self-strengthens and self-supports the battery cell; and (d) curing the battery in the soft package film element resulting in a packaged battery cell.