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| Method of etching polyimide |
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Continuous process to produce lithium-polymer batteries
| Details |
Inventors: Chern, Terry Song-Hsing; Keller, David Gerard; MacFadden, Kenneth Orville;
Assignee: W. R. Grace & Co. -Conn. (New York, NY)
Primary Examiner: Maples; John S.
Assistant Examiner:
Attorney, Agent or Firm: Troffkin; Howard J.
Solid polymer electrolytes are extruded with active electrode material in a continuous, one-step process to form composite electrolyte-electrodes ready for assembly into battery cells. The composite electrolyte-electrode sheets are extruded onto current collectors to form electrodes. The composite electrodes, as extruded, are electronically and ionically conductive. The composite electrodes can be overcoated with a solid polymer electrolyte, which acts as a separator upon battery assembly. The interface between the solid polymer electrolyte composite electrodes and the solid polymer electrolyte separator has low resistance. |
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention is directed to a single step extrusion process to form a novel solid polymer electrolyte-electrode composite.
The instant process formed the desired electrode without the need for providing for porosity within the electrode product's structure.
The electrode-solid polymer electrolyte composite is formed by initially forming a substantially uniform mixture of electrochemically active and/or electrically conductive solid particulate material suitable for forming the desired electrode.
For cathodes, suitable solid particulate materials are for example, metal chalcogenides having a metal selected from Ti, Zr, Hf, Nb, Cu, Fe, Ta, V, Mn, Cr, Co, Ni and mixtures of these metals alone or together with intercalated metals, such as lithium or sodium and up to 30 wt.
% conductive carbon of particle size 1-100 nm.
When the electrode being formed is an anode, the active material may be one wherein lithium can intercalate within the materials structure.
Such materials include graphite, coke and the like.
In addition to the electrochemically-electrically conductive material, the feed composition is composed of solid polymer electrolyte components of a polymer binder, liquid and salt.
The polymer binder can be any solid polymer electrolyte binder component capable of withstanding (being stable with respect to) the extrusion processing conditions, in particular the temperature shear and pressure conditions.
The polymer binder must be electrochemically stable (inert) at normal battery operating conditions.
These polymers are, for example, polyacrylonitrile (PAN), polyvinylidene difluoride (PVDF), polyvinylpyrrolidone (PVP) and the like and copolymers thereof.
The preferred polymers are PAN and PVDF, with the most preferred material being PAN having a weight average molecular weight of at least about 150,000 for cathodes and PVDF is most preferred for anodes.
The liquid component of the feed can be any organic liquid capable of solvating the salt component and plasticize the polymer
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Nonmetallic Processes 
