All-solid-state electrochemical cells and batteries employing very thin
film, highly conductive polymeric electrolyte and very thin electrode
structures are disclosed, along with economical and high-speed methods of
manufacturing. A preferred embodiment is a rechargeable lithium polymer
electrolyte battery. New polymeric electrolytes employed in the devices
are strong yet flexible, dry and non-tacky. The new, thinner electrode
structures have strength and flexibility characteristics very much like
thin film capacitor dielectric material that can be tightly wound in the
making of a capacitor. A wide range of polymers, or polymer blends,
characterized by high ionic conductivity at room temperature, and below,
are used as the polymer base material for making the solid polymer
electrolytes. The preferred polymeric electrolyte is a cationic conductor.
In addition to the polymer base material, the polymer electrolyte
compositions exhibit a conductivity greater than 1.times.10.sup.-4 S/cm at
25.degree. C. or below and contain an electrically conductive polymer, a
metal salt, a finely divided ionic conductor, and a finely divided
inorganic filler material. Certain rechargeable batteries of the invention
provide high specific energy (250 to 350 Wh/kg) (gravimetric) and energy
density (450 to 550 Wh/l) (volumetric), high cycle life (1000 cycles), low
self-discharge and improved safety.