Methods of preparing electrochemical cells

1. A method of preparing a cathode/separator assembly of an electrochemical cell, wherein said cathode/separator assembly comprises a cathode comprising a cathode active layer and a microporous separator layer, said method comprising the steps of:

(a) coating a first protective coating layer on a temporary carrier substrate, wherein said first protective coating layer has a first surface in contact with said temporary carrier substrate and has a second surface on the side opposite from said temporary carrier substrate;

(b) coating a microporous separator layer on said second surface of said first protective coating layer, wherein said separator layer has a first surface in contact with said second surface of said first protective coating layer and has a second surface on the side opposite from said first protective coating layer;

(c) laminating a first surface of said cathode in a desired adhesion pattern on said second surface of said separator layer; and

(d) removing said temporary carrier substrate from said first surface of said first protective coating layer to form said cathode/separator assembly.

2. The method of claim 1 , wherein said first protective coating layer is a single ion conducting layer.

3. The method of claim 2 , wherein the single ion conducting layer comprises a glassy material selected from the group consisting of lithium silicates, lithium borates, lithium aluminates, lithium phosphates, lithium phosphorus oxynitrides, lithium silicosulfides, lithium germanosulfides, lithium lanthanum oxides, lithium titanium oxides, lithium borosulfides, lithium aluminosulfides, and lithium phosphosulfides, and combinations thereof.

4. The method of claim 3 , wherein the single ion-conducting layer further comprises a polymer.

5. The method of claim 1 , wherein said first protective coating layer is an ionically conductive layer which is impervious to dimethoxyethane and 1,3-dioxolane, and combinations thereof.

6. The method of claim 1 , wherein said first protective coating layer comprises a polymer selected from the group consisting of electrically conductive polymers, ionically conductive polymers, sulfonated polymers, and hydrocarbon polymers.

7. The method of claim 1 , wherein said first protective coating layer comprises an ionically conductive polymer.

8. The method of claim 7 , wherein said ionically conductive polymer is a polydivrnyl poly(ethylene glycol).

9. The method of claim 1 , wherein said first protective coating layer comprises a sulfonated polymer.

10. The method of claim 9 , wherein said sulfonated polymer is a sulfonated polystyrene.

11. The method of claim 1 , wherein said first protective coating layer comprises a microporous xerogel layer.

12. The method of claim 11 , wherein said microporous xerogel layer comprises an organic polymer.

13. A method of preparing an electrochemical cell, said method comprising the steps of:

(a) providing a cathode/separator assembly prepared by a method comprising the steps of:

(i) coating a first protective coating layer on a temporary carrier substrate, wherein said first protective coating layer has a first surface in contact with said temporary carrier substrate and has a second surface on the side opposite from said temporary carrier substrate;

(ii) coating a microporous separator layer on said second surface of said first protective coating layer, wherein said separator layer has a first surface in contact with said second surface of said first protective coating layer and has a second surface on the side opposite from said first protective coating layer;

(iii) laminating a first surface of a cathode in a desired adhesion pattern on said second surface of said separator layer, wherein said cathode comprises a cathode active layer; and

(iv) removing said temporary carrier substrate from said first surface of said first protective coating layer to form said cathode/separator assembly;

(b) providing an anode; and

(c) providing an electrolyte, wherein said electrolyte is contained in the pores of said separator layer, wherein said first surface of said first protective coating layer of said cathode/separator assembly and said anode are positioned in a face-to-face relationship.

14. The method of claim 13 , wherein said first protective coating is a single ion conducting layer.

15. The method of claim 14 , wherein the single ion conducting layer comprises a glassy material selected from the group consisting of lithium silicates, lithium borates, lithium aluminates, lithium phosphates, lithium phosphorus oxynitrides, lithium silicosulfides, lithium germanosulfides, lithium lanthanum oxides, lithium titanium oxides, lithium borosulfides, lithium aluminosulfides, and lithium phosphosulfides, and combinations thereof.

16. The method of claim 14 , wherein the single ion-conducting layer further comprises a polymer.

17. The method of claim 13 , wherein said first protective coating layer is an ionically conductive layer which is impervious to dimethoxyethane and 1,3-dioxolane, and combinations thereof.

18. The method of claim 13 , wherein said first protective coating layer comprises a polymer selected from the group consisting of electrically conductive polymers, ionically conductive polymers, sulfonated polymers, and hydrocarbon polymers.

19. The method of claim 13 , wherein said first protective coating layer comprises an ionically conductive polymer.

20. The method of claim 19 , wherein said ionically conductive polymer is a polydivinyl-poly(ethylene glycol).

21. The method of claim 13 , wherein said first protective coating layer comprises a sulfonated polymer.

22. The method of claim 21 , wherein said sulfonated polymer is a sulfonated polystyrene.

23. The method of claim 13 , wherein said first protective coating layer comprises a microporous xerogel layer.

24. The method of claim 23 , wherein said microporous xerogel layer comprises an organic polymer.