John Manufacturing Limited

Johnson Research Development Company, Inc.

Other

Timothy J Stachoviak

Daniel A Schneider

Shirley A Craanen

Joseph P Nestler

Lonnie G Johnson

El-Sayed A Megahed

Jackson C Ma

Amy K Lawrence

John M Baxley

A secondary battery separator comprises a fibrous core coated with a polymer having improved electrode adhesion properties in unitary laminated construction. Vacuum removal of plasticizer without solvent extraction prevents brittleness and results in microporosity in a thin layer of enhanced ion conductivity.

Lithium battery with secondary battery separator

An electrode and separator composite comprises a separator and an electrode embedded in a polymer matrix. Application of an electrode slurry to a polymer coated separator and subsequent drying in a solvent enriched atmosphere forms a secondary battery structure characterized by a seamless composite structure.

Composite separator and electrode

Arc spray deposition of molten metal droplets on plastic electrodes creates a tight bonded adhesion and increases the surface area contact between collector and electrode. This is especially efficacious for lithium secondary batteries which are known to flex during charge and discharge cycles leading to battery failure. The strength of the bonding interaction, and a resistance to stress cracking are observed when a perforated or expanded metal strip is utilized to reinforce the arc spray deposited metal collector.

Current collector manufacture by arc spray deposition

An apparatus and method for extracting plasticizer from polymer structures includes, in one embodiment, a vacuum chamber, a heating member and a condenser, the plasticizer being vaporized from the polymer structure by a combination of low temperature and heat, and in another embodiment, an evaporation chamber, a conveyer belt, and a plasticizer removal system, the plasticizer removal system including a duct having mounted therein a heating member, a fan and a condenser so that plasticizer may be extracted by forced air convection.

Apparatus and method for extracting plasticizer

A secondary battery separator comprises a fibrous core embedded in a polymeric sheet having improved electrode fusion thereto in unitary construction. In the process of manufacturing the separator, a fibrous, polymeric, substantially two-sided core matrix is coated with a polymer mixture containing a plasticizer and a solvent vehicle, and a vacuum is applied to the reverse side from the coated side to cause the polymer mixture to penetrate and infuse the capillary voids of the core matrix from the opposite coated side. The vacuum is continued until the solvent vehicle is fully volatilized. After the solvent vehicle has dissipated, the fiber matrix is turned over, and the process is repeated by applying a coating of polymer mixture to the second side and pulling a vacuum on the opposite side to cause penetration of the matrix.

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Waunakee, WI, United States of America

Timothy J Stachoviak