Patent ID: 7717968

Claim:
A method of forming a cell having a first electrode and a second electrode to collect electric current and an electrolyte disposed therebetween, said method comprising the steps of: moving a metal tape of at least one of the first and second electrodes; orienting an injecting mechanism generally perpendicular to the metal tape of the least one of the first and second electrode to inject a plurality of heated first particles of active material onto the metal tape of at least one of the first and second electrodes; forming an active layer of the metal tape of at least one of the first and second electrodes by impacting the first particles against the metal tape to increase surface temperature of the metal tape thereby resulting in a multitude of aerosol drops melted of the metal tape in response to the increased temperature resulting from the impact; and solidifying the aerosol drops into second particles to form a porous structure of the said active layer with the first particles connecting to and disposed within the second particles.