Abstract: A secondary battery separator comprises a fibrous core coated with a polymer having improved electrode adhesion properties in unitary laminated construction. Vacuum removal of plasticizer without solvent extraction prevents brittleness and results in microporosity in a thin layer of enhanced ion conductivity.

Abstract: An electrode and separator composite comprises a separator and an electrode embedded in a polymer matrix. Application of an electrode slurry to a polymer coated separator and subsequent drying in a solvent enriched atmosphere forms a secondary battery structure characterized by a seamless composite structure.

Abstract: Arc spray deposition of molten metal droplets on plastic electrodes creates a tight bonded adhesion and increases the surface area contact between collector and electrode. This is especially efficacious for lithium secondary batteries which are known to flex during charge and discharge cycles leading to battery failure. The strength of the bonding interaction, and a resistance to stress cracking are observed when a perforated or expanded metal strip is utilized to reinforce the arc spray deposited metal collector.

Abstract: A secondary battery separator comprises a fibrous core embedded in a polymeric sheet having improved electrode fusion thereto in unitary construction. In the process of manufacturing the separator, a fibrous, polymeric, substantially two-sided core matrix is coated with a polymer mixture containing a plasticizer and a solvent vehicle, and a vacuum is applied to the reverse side from the coated side to cause the polymer mixture to penetrate and infuse the capillary voids of the core matrix from the opposite coated side. The vacuum is continued until the solvent vehicle is fully volatilized. After the solvent vehicle has dissipated, the fiber matrix is turned over, and the process is repeated by applying a coating of polymer mixture to the second side and pulling a vacuum on the opposite side to cause penetration of the matrix.