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Method of making Li-intercalateable electrodes for a lithium-ion battery by applying a first film onto a first face of an electrically conductive grid, which film comprises a plurality of Li-intercalateable particles dispersed throughout a mixture of a polymeric binder and a plasticizer for the bind

Method of making Li-intercalateable electrodes for a lithium-ion battery by applying a first film onto a first face of an electrically conductive grid, which film comprises a plurality of Li-intercalateable particles dispersed throughout a mixture of a polymeric binder and a plasticizer for the binder. Thereafter, a film-forming slurry having the same composition as the first film, plus a solvent therefor, is applied to a second face of the grid opposing the first face so as to provide a second film and such that the solvent in the slurry dissolves at least a portion of the first film and promotes solvent bonding of the films with the grid embedded therein. A polymeric backing film defining a separator is used as a manufacturing process aid, thereby eliminating the step of using a carrier film onto which the electrodes are fabricated and stripping off the carrier and discarding the same.

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1. A method of making lithium-intercalateable cells for a lithium-ion battery with polymeric separators comprising the steps of: (A) providing a polymeric backing defining a separator; (B) applying a film-forming slurry and an electrically-conductive grid onto said separator such that said grid

1. A method of making lithium-intercalateable cells for a lithium-ion battery with polymeric separators comprising the steps of: (A) providing a polymeric backing defining a separator; (B) applying a film-forming slurry and an electrically-conductive grid onto said separator such that said grid is imbedded in said slurry, wherein said slurry comprises a plurality of lithium-intercalateable particles dispersed throughout a mixture that includes a polymeric binder compatible with said battery and a plasticizer for said binder; and (C) thereafter, drying said slurry, thereby forming a first electrode having said separator; (D) thereafter, drying said first electrode by removing said solvent; (E) removing said plasticizer from said binder so as to leave a network of pores pervading said binder; (F) backfilling said pores with a lithium-ion-conductive electrolyte; (G) applying a first film-forming slurry to a first face of an electrically-conductive grid, said slurry comprising a plurality of said lithium-intercalateable particles dispersed throughout a mixture including polymeric binder; (H) thereafter, drying the first film-forming slurry; (I) applying a second film-forming slurry to a second face of said electrically-conductive grid of (G), said slurry comprising a plurality of said lithium-intercalateable particles dispersed throughout a mixture including polymeric binder; (J) thereafter, drying said second-film forming slurry, thereby forming a second electrode with film on either side of said grid of (G); and (K) laminating said first electrode with separator to said second electrode of (J). 2. The method according to claim 1 including heating said electrode to effect said drying.3. The method according to claim 2 including the step of pressing said first and second films together while said films are still warm from said heating.4. A method of making lithium intercalateable bicells for a lithium ion battery with polymeric separators comprising the steps of: (A) applying a first film-forming slurry to a first face of an electrically-conductive grid, said slurry comprising a plurality of said lithium-intercalateable particles dispersed throughout a mixture including polymeric binder; (B) thereafter, drying the first film-forming slurry; (C) applying a second film-forming slurry to a second face of said electrically-conductive grid, said slurry comprising a plurality of said lithium-intercalateable particles dispersed throughout a mixture including polymeric binder; (D) thereafter, drying the second film-forming slurry, thereby forming an electrode with film on either side of grid; (E) providing a polymeric backing defining a separator; (F) applying a film-forming slurry and an electrically-conductive grid onto said separator of (E) such that said grid is imbedded in said slurry, wherein said slurry comprises a plurality of lithium-intercalateable particles dispersed throughout a mixture that includes a polymeric binder; (G) thereafter, drying said slurry of (F), thereby forming an electrode having said separator; (H) laminating a first side of the electrode of (D) to said electrode with separator of (G); and (I) laminating a second side of the electrode of (D) opposing said first side to a second said electrode with separator of (G). 5. The method of claim 4 further including the step of: forming the film-forming slurry to further include a plasticizer for the binder and a solvent, wherein the drying step comprising the substep of removing the solvent. 6. The method of claim 5 further comprising the step of removing said plasticizer so as to leave a network of pores pervading said binder.7. The method of claim 6 further comprising the step of backfilling said pores with a lithium-ion-conductive electrolyte.8. A method of making lithium-intercalateable electrodes for a lithium-ion battery with polymeric separators comprising the steps of: (A) providing a polymeric backing defining a separator; (B) simultaneously applying (i) a first film-forming slurry and an electrically-conductive grid onto a first face of said separator such that said grid is imbedded in said slurry, wherein said slurry comprises a plurality of lithium-intercalateable particles dispersed throughout a mixture that includes a polymeric binder compatible with said battery and a plasticizer for said binder; and (ii) a second film-forming slurry onto a second face of said separator opposite said first face, wherein said slurry comprises a plurality of said lithium-intercalateable particles dispersed throughout a mixture of said binder, said plasticizer and a solvent for said binder; (C) thereafter, drying said electrode by removing said solvent to form respective first and second films; (D) removing said plasticizer from said binder so as to leave a network of pores pervading said binder; and (E) backfilling said pores with a lithium-ion-conductive electrolyte. 9. The method according to claim 8 including heating said electrode to effect said drying.10. The method according to claim 9 including the step of pressing said first and second films together while said films are still warm from said heating.