LITHIUM BATTERIES UTILIZING NANOPOROUS SEPARATOR LAYERS
Provided are methods of preparing lithium batteries comprising a separator/electrode assembly having one or more current collector layers interposed between first and second electrode layers of the same polarity, wherein the first electrode layer is coated or laminated overlying a separator layer and the separator/electrode assembly is interleaved with an electrode comprising a current collector layer interposed between two electrode layers of opposite polarity to said first and second electrodes.
1 - 23 . (canceled)
24 . A multilayer structure for use in a lithium battery comprising:
(a) a first porous separator;
(b) a first electrode layer of a first polarity directly on a first portion of the first porous separator;
(c) a second electrode layer of the same polarity directly on a second portion of the first porous separator;
(d) one or more current collector layers directly on the first electrode layer to make a first separator/electrode stack; wherein
(e) the second electrode layer is also on the one or more current collector layers on a side opposite to the first electrode layer;
(f) a second porous separator that is the same or different than the first porous separator;
(g) a third electrode layer of the opposite polarity directly on a third portion of the second porous separator;
(h) a fourth electrode layer of the opposite polarity directly on a fourth portion of the second porous separator;
(i) one or more current collector layers directly on the third electrode layer to make a second separator/electrode stack, wherein
(j) the fourth electrode layer is also on the one or more current collector layers of (i) on a side opposite to the third electrode layer.
25 . The multilayer structure of claim 24 , the one or more current collector layers of (d) comprising a metal layer.
26 . The multilayer structure of claim 25 , wherein the thickness of the metal layer is less than 3 microns.
27 . The multilayer structure of claim 24 , the one or more current collector layers of (i) comprising a metal layer.
28 . The multilayer structure of claim 27 , wherein the thickness of the metal layer is less than 3 microns.
29 . The multilayer structure of claim 24 , wherein the first and second electrode layers of the first polarity are anode layers and the third and fourth electrode layers of the opposite polarity are cathode layers.
30 . The multilayer structure of claim 29 , wherein the one or more current collector layers of the anode layers comprises a metal selected from the group consisting of copper and nickel.
31 . The multilayer structure of claim 29 , wherein the one or more current collector layers of the cathode layers comprises a metal selected from the group consisting of aluminum and nickel.
32 . The multilayer structure of claim 24 , wherein the first and second electrode layers are coated directly on the first porous separator from a pigment dispersion comprising an organic solvent or water.
33 . The multilayer structure of claim 24 , wherein the third and fourth electrode layers are coated directly on the second porous separator from a pigment dispersion comprising an organic solvent or water.
34 . The multilayer structure of claim 24 , wherein the first porous separator comprises inorganic oxide particles in an amount greater than 30% by weight.
35 . The multilayer structure of claim 24 , wherein the second porous separator comprises inorganic oxide particles in an amount greater than 30% by weight.
36 . The multilayer structure of claim 24 , wherein the first porous separator has a thickness of less than 9 microns.
37 . The multilayer structure of claim 24 , wherein the second porous separator has a thickness of less than 9 microns.
38 . The multilayer structure of claim 24 , wherein the first porous separator comprises aluminum boehmite.
39 . The multilayer structure of claim 24 , wherein the second porous separator comprises aluminum boehmite.
40 . The multilayer structure of claim 24 , wherein the first porous separator is a heat resistant separator with dimensional stability at 200° C.
41 . The multilayer structure of claim 24 , wherein the second porous separator is a heat resistant separator with dimensional stability at 200° C.
42 . A multilayer structure for use in a lithium battery comprising:
(a) a first porous separator;
(b) a first electrode layer of a first polarity directly on a first portion of the first porous separator;
(c) a second electrode layer of the same polarity directly on a second portion of the first porous separator;
(d) one or more current collector layers directly on the first electrode layer to make a first separator/electrode stack; wherein
(e) the second electrode layer is also on the one or more current collector layers on a side opposite to the first electrode layer;
(f) a second porous separator that is the same or different than the first porous separator;
(g) a third electrode layer of the opposite polarity directly on a third portion of the second porous separator;
(h) a fourth electrode layer of the opposite polarity directly on a fourth portion of the second porous separator;
(i) one or more current collector layers directly on the third electrode layer to make a second separator/electrode stack, wherein
(j) the fourth electrode layer is also on the one or more current collector layers of (i) on a side opposite to the third electrode layer, and wherein
the first and second electrode layers are coated directly on the first porous separator from a pigment dispersion comprising an organic solvent or water.
43 . A multilayer structure for use in a lithium battery comprising:
(a) a first porous separator;
(b) a first electrode layer of a first polarity directly on a first portion of the first porous separator;
(c) a second electrode layer of the same polarity directly on a second portion of the first porous separator;
(d) one or more current collector layers directly on the first electrode layer to make a first separator/electrode stack; wherein
(e) the second electrode layer is also on the one or more current collector layers on a side opposite to the first electrode layer;
(f) a second porous separator that is the same or different than the first porous separator;
(g) a third electrode layer of the opposite polarity directly on a third portion of the second porous separator;
(h) a fourth electrode layer of the opposite polarity directly on a fourth portion of the second porous separator;
(i) one or more current collector layers directly on the third electrode layer to make a second separator/electrode stack, wherein
(j) the fourth electrode layer is also on the one or more current collector layers of (i) on a side opposite to the third electrode layer, and wherein
the third and fourth electrode layers are coated directly on the second porous separator from a pigment dispersion comprising an organic solvent or water.