Claims
- 1. A multi-layer electrode assembly, comprising:
a separator layer positioned between an anode layer and a cathode layer; the separator layer formed as a polymer web having first and second major surfaces, portions of which interface with an organic layer that includes a gel-forming polymer material and an adhesive resin material that promotes adhesion of the separator layer to the anode and cathode layers; and each of the anode layer and cathode layer including a material composition having electrical conductivity properties.
- 2. The electrode assembly of claim 1, in which the separator layer is formed as an extruded web from an ultrahigh molecular weight polyolefin.
- 3. The electrode assembly of claim 2, in which the ultrahigh molecular weight polyolefin is ultrahigh molecular weight polyethylene.
- 4. The electrode assembly of claim 1, in which the separator layer comprises a gel-forming polymer-coated web, portions of which are coated with the adhesive resin material.
- 5. The electrode assembly of claim 1, in which the adhesive resin material is selected from the group consisting essentially of polymethyl methacrylate, ethylene-acrylic acid copolymers, styrene-butadiene copolymers, styrene-isoprene copolymers, polyvinyl acetate, polybutadiene, polyurethane, polyisoprene, butadiene-acrylonitrile copolymers, isobutylene-isoprene copolymers, ethylene-propylene-diene monomer terpolymers, ethylene-propylene copolymers, acrylic copolymers, and combinations thereof.
- 6. The electrode assembly of claim 1, in which the anode layer includes an electrically conductive carbon-based material and a polymer binder adhered to a current collector.
- 7. The electrode assembly of claim 6, in which the electrically conductive carbon-based material is selected from a group consisting essentially of crystalline or amorphous carbonaceous materials in the form of fiber, powder, or microbeads including natural or synthetic graphite, carbon black, coke, mesocarbon microbeads, or activated carbon.
- 8. The electrode assembly of claim 1, in which the cathode layer includes a metal oxide component, an electrically conductive carbon-based material, and a polymer binder attached to a current collector.
- 9. The electrode assembly of claim 8, in which the metal oxide component is selected from a group consisting essentially of lithium cobalt oxide (LiCoO2), lithium nickel oxide (LiNiO2), lithium manganese oxide (LiMn2O4), and lithium nickel cobalt oxide (LiNixCol−xO2).
- 10. The electrode assembly of claim 1, further comprising a container into which an electrolyte that acts as an ion transport medium is placed to form an energy storage device.
- 11. A method of forming a multi-layer electrode assembly, comprising:
applying a gel-forming polymer material and an adhesive resin material to a separator layer to form a coated separator layer; positioning the coated separator layer between an anode layer and a cathode layer to form a multi-layer assembly, each of the anode and cathode layer formed as a polymer web including a material composition having electrical conductivity properties; and heating the multi-layer assembly at a temperature and for an amount of time sufficient to promote adhesion of the coated separator layer to the anode and cathode layers.
- 12. The method of claim 11, further comprising:
adding to the multi-layer assembly an electrolyte that acts as an ion transport medium and whose addition forms a battery power source.
- 13. The method of claim 11, in which the separator layer is formed as an extruded web from an ultrahigh molecular weight polyolefin.
- 14. The method of claim 13, in which the ultrahigh molecular weight polyolefin is ultrahigh molecular weight polyethylene.
- 15. The method of claim 11, in which the coated separator layer comprises a gel-forming polymer-coated web that has an outer surface coated with an adhesive resin material that at least partly penetrates the gel-forming polymer-coated web.
- 16. The method of claim 11, in which the adhesive resin material is selected from the group consisting essentially of polymethyl methacrylate, ethylene-acrylic acid copolymers, styrene-butadiene copolymers, styrene-isoprene copolymers, polyvinyl acetate, polybutadiene, polyurethane, polyisoprene, butadiene-acrylonitrile copolymers, isobutylene-isoprene copolymers, ethylene-propylene-diene monomer terpolymers, ethylene-propylene copolymers, acrylic copolymers, and combinations thereof.
- 17. The method of claim 11, in which the anode layer includes an electrically conductive carbon-based material and a polymer binder adhered to a current collector.
- 18. The method of claim 17, in which the conductive carbon-based material is selected from a group consisting essentially of crystalline or amorphous carbonaceous materials in the form of fiber, powder, or microbeads including natural or synthetic graphite, carbon black, coke, mesocarbon microbeads, or activated carbon.
- 19. The method of claim 11, in which the cathode layer includes a metal oxide component, an electrically conductive carbon-based material, and a polymer binder attached to a current collector.
- 20. The method of claim 19, in which the metal oxide component is selected from a group consisting essentially of lithium cobalt oxide (LiCoO2), lithium nickel oxide (LiNiO2), lithium manganese oxide (LiMn2O4), and lithium nickel cobalt oxide (LiNixCo1−xO2).
RELATED APPLICATIONS
[0001] This application derives priority from U.S. patent application Ser. No. 09/777,367, filed Feb. 5, 2001, which derives priority from provisional patent application Nos. 60/232,184, 60/186,732, and 60/180,419, filed Sep. 12, Mar. 3, and Feb. 4, 2000, respectively, and from provisional patent application No. 60/275,963, filed Mar. 14, 2001.
Provisional Applications (4)
|
Number |
Date |
Country |
|
60232184 |
Sep 2000 |
US |
|
60186732 |
Mar 2000 |
US |
|
60180419 |
Feb 2000 |
US |
|
60275963 |
Mar 2001 |
US |
Continuation in Parts (1)
|
Number |
Date |
Country |
Parent |
09777367 |
Feb 2001 |
US |
Child |
10098967 |
Mar 2002 |
US |