Abstract: 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.

Abstract: 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.