Valence Technology, Inc.

Gert L Jensen

Benjamin M Chaloner-Gill

Ib I Olsen

Mark Joseph Isaacson

In a new process for making an electrode current collector assembly, an electrode composition is mixed with a volatile casting solvent and is coated onto a substrate. Then, the coated substrate is heated to drive off a major portion of the volatile casting solvent. Next, force is applied on an external surface of the coating and directed toward the substrate so as to compact the coating and reduce the volume of pore spaces in the coating. An electrolyte composition may be applied to the compacted electrode composition either before or after curing. The electrode and electrolyte compositions are each cured. In a final step, a counter-electrode layer is applied onto the electrolyte composition to form a cell assembly.

Method for producing low porosity electrode

In making a laminar assembly for use in the battery, a layer of battery electrode material is deposited onto a substrate surface and the battery electrode material is caused to have an uneven surface. Then an electrolyte layer is deposited onto the uneven surface of the battery electrode material. Where the method calls for first depositing the electrolyte material, then electrolyte material is deposited onto the substrate layer where the electrolyte layer is caused to have an uneven surface. Thereafter, the battery electrode material is deposited onto the uneven surface of the electrolyte material. In both cases, slippage between the battery electrode material and electrolyte material is reduced during cutting, folding and other handling process in making a laminar battery, thereby reducing the probability of shorts in the battery. In order to form the cathode or electrolyte layer, a pump is used to squeeze a viscous cathode or electrolyte material through a nozzle onto a substrate surface and the viscous material and substrate layer are passed between two pressing surfaces moving in the same direction pressing the viscous material onto the substrate layer. The two pressing surfaces are spaced apart by a predetermined distance so that the viscous material is pressed into a layer with a predetermined thickness with no pin holes therein so that the material adheres to the substrate layer.

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San Jose, CA, United States of America

Gert L Jensen