Abstract: In a new process for making an electrode current collector assembly, an electrode composition is mixed with a volatile casting solvent and is coated onto a substrate. Then, the coated substrate is heated to drive off a major portion of the volatile casting solvent. Next, force is applied on an external surface of the coating and directed toward the substrate so as to compact the coating and reduce the volume of pore spaces in the coating. An electrolyte composition may be applied to the compacted electrode composition either before or after curing. The electrode and electrolyte compositions are each cured. In a final step, a counter-electrode layer is applied onto the electrolyte composition to form a cell assembly.

Abstract: In making a laminar assembly for use in the battery, a layer of battery electrode material is deposited onto a substrate surface and the battery electrode material is caused to have an uneven surface. Then an electrolyte layer is deposited onto the uneven surface of the battery electrode material. Where the method calls for first depositing the electrolyte material, then electrolyte material is deposited onto the substrate layer where the electrolyte layer is caused to have an uneven surface. Thereafter, the battery electrode material is deposited onto the uneven surface of the electrolyte material. In both cases, slippage between the battery electrode material and electrolyte material is reduced during cutting, folding and other handling process in making a laminar battery, thereby reducing the probability of shorts in the battery.

Abstract: A process for forming a layer of metal on a substrate which comprises the steps of: (a) forming a bath of a molten metal in a vessel; (b) circulating said molten metal in said bath such that said molten metal is projected above the upper surface of said vessel (c) transporting a substrate along a path which traverses the upper surface of said vessel; and (d) transferring said molten metal to one surface of said substrate by directly or indirectly contracting said molten metal with said surface of said substrate, and an apparatus for performing the method is disclosed.

Abstract: A process for forming a layer of metal on a substrate which comprises the steps of: (a) forming a bath of a molten metal in a vessel; (b) circulating said molten metal in said bath such that said molten metal is projected above the upper surface of said vessel; (c) transporting a substrate along a path which traverses the upper surface of said vessel; and (d) transferring said molten metal to one surface of said substrate by directly or indirectly contacting said molten metal with said surface of said substrate, and an apparatus for performing the method is disclosed.