Patent ID: 6986967

Claim:
An electrochemical cell comprising at least one composite structure made by 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): —(OCF 2 CFR) a OCF 2 (CFR′) b SO 2 X − (M + )[YZ c ] d (I) wherein R and R′ 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, SO 2 R f , SO 2 R 3 , P(O)(OR 3 ) 2 , CO 2 R 3 , P(O)R 3 2 , C(O)R f , C(O)R 3 , and cycloalkenyl groups formed therewith wherein R f is a perfluoroalkyl group of 1–10 carbon atoms optionally substituted with one or more ether oxygens; R 3 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 —SO 2 R f′ where R f′ is the radical represented by formula (II): —(R f″ SO 2 N—(M + )SO 2 ) m R f″ (II) where m=0 or 1, and R f″ is —C n F 2n — and R f′″ is —C n F 2n+1 where n=1–10, optionally substituted with one or more ether oxygens.