Lithium batteries utilizing nanoporous separator layers

Abstract

Provided are methods of preparing lithium batteries comprising a separator/electrode assembly having one or more current collector layers interposed between first and second electrode layers of the same polarity, wherein the first electrode layer is coated or laminated overlying a separator layer and the separator/electrode assembly is interleaved with an electrode comprising a current collector layer interposed between two electrode layers of opposite polarity to said first and second electrodes.

1 - 23 . (canceled) 
     
     
         24 . A multilayer structure for use in a lithium battery comprising:
 (a) a first porous separator;   (b) a first electrode layer of a first polarity directly on a first portion of the first porous separator;   (c) a second electrode layer of the same polarity directly on a second portion of the first porous separator;   (d) one or more current collector layers directly on the first electrode layer to make a first separator/electrode stack; wherein   (e) the second electrode layer is also on the one or more current collector layers on a side opposite to the first electrode layer;   (f) a second porous separator that is the same or different than the first porous separator;   (g) a third electrode layer of the opposite polarity directly on a third portion of the second porous separator;   (h) a fourth electrode layer of the opposite polarity directly on a fourth portion of the second porous separator;   (i) one or more current collector layers directly on the third electrode layer to make a second separator/electrode stack, wherein   (j) the fourth electrode layer is also on the one or more current collector layers of (i) on a side opposite to the third electrode layer.   
     
     
         25 . The multilayer structure of  claim 24 , the one or more current collector layers of (d) comprising a metal layer. 
     
     
         26 . The multilayer structure of  claim 25 , wherein the thickness of the metal layer is less than 3 microns. 
     
     
         27 . The multilayer structure of  claim 24 , the one or more current collector layers of (i) comprising a metal layer. 
     
     
         28 . The multilayer structure of  claim 27 , wherein the thickness of the metal layer is less than 3 microns. 
     
     
         29 . The multilayer structure of  claim 24 , wherein the first and second electrode layers of the first polarity are anode layers and the third and fourth electrode layers of the opposite polarity are cathode layers. 
     
     
         30 . The multilayer structure of  claim 29 , wherein the one or more current collector layers of the anode layers comprises a metal selected from the group consisting of copper and nickel. 
     
     
         31 . The multilayer structure of  claim 29 , wherein the one or more current collector layers of the cathode layers comprises a metal selected from the group consisting of aluminum and nickel. 
     
     
         32 . The multilayer structure of  claim 24 , wherein the first and second electrode layers are coated directly on the first porous separator from a pigment dispersion comprising an organic solvent or water. 
     
     
         33 . The multilayer structure of  claim 24 , wherein the third and fourth electrode layers are coated directly on the second porous separator from a pigment dispersion comprising an organic solvent or water. 
     
     
         34 . The multilayer structure of  claim 24 , wherein the first porous separator comprises inorganic oxide particles in an amount greater than 30% by weight. 
     
     
         35 . The multilayer structure of  claim 24 , wherein the second porous separator comprises inorganic oxide particles in an amount greater than 30% by weight. 
     
     
         36 . The multilayer structure of  claim 24 , wherein the first porous separator has a thickness of less than 9 microns. 
     
     
         37 . The multilayer structure of  claim 24 , wherein the second porous separator has a thickness of less than 9 microns. 
     
     
         38 . The multilayer structure of  claim 24 , wherein the first porous separator comprises aluminum boehmite. 
     
     
         39 . The multilayer structure of  claim 24 , wherein the second porous separator comprises aluminum boehmite. 
     
     
         40 . The multilayer structure of  claim 24 , wherein the first porous separator is a heat resistant separator with dimensional stability at 200° C. 
     
     
         41 . The multilayer structure of  claim 24 , wherein the second porous separator is a heat resistant separator with dimensional stability at 200° C. 
     
     
         42 . A multilayer structure for use in a lithium battery comprising:
 (a) a first porous separator;   (b) a first electrode layer of a first polarity directly on a first portion of the first porous separator;   (c) a second electrode layer of the same polarity directly on a second portion of the first porous separator;   (d) one or more current collector layers directly on the first electrode layer to make a first separator/electrode stack; wherein   (e) the second electrode layer is also on the one or more current collector layers on a side opposite to the first electrode layer;   (f) a second porous separator that is the same or different than the first porous separator;   (g) a third electrode layer of the opposite polarity directly on a third portion of the second porous separator;   (h) a fourth electrode layer of the opposite polarity directly on a fourth portion of the second porous separator;   (i) one or more current collector layers directly on the third electrode layer to make a second separator/electrode stack, wherein   (j) the fourth electrode layer is also on the one or more current collector layers of (i) on a side opposite to the third electrode layer, and wherein
 the first and second electrode layers are coated directly on the first porous separator from a pigment dispersion comprising an organic solvent or water. 
   
     
     
         43 . A multilayer structure for use in a lithium battery comprising:
 (a) a first porous separator;   (b) a first electrode layer of a first polarity directly on a first portion of the first porous separator;   (c) a second electrode layer of the same polarity directly on a second portion of the first porous separator;   (d) one or more current collector layers directly on the first electrode layer to make a first separator/electrode stack; wherein   (e) the second electrode layer is also on the one or more current collector layers on a side opposite to the first electrode layer;   (f) a second porous separator that is the same or different than the first porous separator;   (g) a third electrode layer of the opposite polarity directly on a third portion of the second porous separator;   (h) a fourth electrode layer of the opposite polarity directly on a fourth portion of the second porous separator;   (i) one or more current collector layers directly on the third electrode layer to make a second separator/electrode stack, wherein   (j) the fourth electrode layer is also on the one or more current collector layers of (i) on a side opposite to the third electrode layer, and wherein
 the third and fourth electrode layers are coated directly on the second porous separator from a pigment dispersion comprising an organic solvent or water.