PLASMA DEPOSITION TO FABRICATE LITHIUM BATTERIES

Multi-layer lithium-ion cell units for lithium batteries are made using multiple stages of atmospheric plasma spray depositing devices. A suitable substrate layer is conveyed past the respective plasma spray devices to form, in a predetermined sequence, a current collector layer, a particulate electrode material layer, a porous separator layer for a liquid lithium-ion conducting electrolyte, a layer of particulate material for an opposing electrode, and a current collector film for the electrode material. The plasma deposition process allows flexibility and economy in making layered lithium-ion cell units. For example, the multistage process may be conducted in a continuous processing, multi-stage plasma deposition line in which one or more multi-layer cell units may be formed in the line.