Electrophoretic assembly of electrochemical devices

Abstract

Methods are provided for making bipolar electrochemical devices, such as batteries, using electrophoresis. A bipolar device is assembled by applying a field that creates a physical separation between two active electrode materials, without requiring insertion of a discrete separator film or electrolyte layer.

1 - 21 . (canceled) 
     
     
         22 . A bipolar device including a first terminal and a second terminal made by a method comprising
 providing the first terminal;   providing particles of a first electroactive material in a medium;   providing the second terminal electronically connected to a second electroactive material;   generating a field causing particles of the first electroactive material to form an electronically continuous electrode, and creating an electronically insulating separation between the first and second electroactive materials; and   preserving the electronically insulating separation between the first and second electroactive materials.   
     
     
         23 . The bipolar device of  claim 22 , wherein the method further comprises depositing particles of the first electroactive material on the first terminal thereby forming an electronically continuous first electrode; and
 generating a second field causing particles of the second electroactive material to deposit on the second terminal, thereby forming an electronically continuous second electrode.   
     
     
         24 . A method of making an electrode comprising:
 providing a first terminal;   providing conductive particles of an electroactive material in a medium;   providing a second terminal;   applying an electrical potential between the first and the second terminal to deposit conductive particles of the electroactive material at the first terminal thereby forming an electronically continuous electrode;   forming a continuous bridge of conductive particles of the electroactive material between the first and second terminals; and   removing the applied electrical potential.   
     
     
         25 . The method of  claim 24 , further comprising:
 providing a third terminal;   providing conductive particles of a second electroactive material in a medium;   providing a fourth terminal;   applying an electrical potential between the third and the fourth terminals to deposit conductive particles of the second electroactive material at the third terminal thereby forming a second electronically continuous electrode;   forming a second continuous bridge of conductive particles of the second electroactive material between the third and fourth terminals; and   removing the applied electrical potential.   
     
     
         26 . An electrode made by the method of  claim 24 . 
     
     
         27 . A battery comprising:
 a substrate;   a first terminal;   a second terminal; and   a localized conductive region comprising electroactive material formed on the substrate and surrounded by an insulating region,   wherein at least one of the first or second terminals is electronically connected to the conductive region.   
     
     
         28 . The battery of  claim 27 , wherein the localized conductive region has an area of less than 100 nanometers squared. 
     
     
         29 . The battery of  claim 27 , having a volume of less than 1 cubic millimeter.