Integrated electrode/separator structures

Claim 1

An electrochemical cell comprising: an anode electrode; an electrode/separator structure adjacent to the anode electrode; and an electrolytic solution in contact with the anode electrode and the electrode/separator structure; said electrode/separator structure comprising a metallic substrate having a plurality of interstice-defining members, an aggregate of discrete, semi-rigid, porous carbon conglomerates physically pressed into and supported by the interstice-defining members of the metallic substrate and defining a network of channels through the resultant structure by which said structure may be permeated by the electrolytic solution, said carbon conglomerates including carbon black and a binder, and an adherent porous layer of an electrically non-conductive material deposited on and physically integrated with the aggregration of carbon conglomerates of the electrode/separator structure, the material of said layer being chemically stable with the anode electrode, the metallic substrate, the carbon conglomerates and the electrolytic solution and being permeable by the electrolytic solution, said adherent porous layer consisting essentially of a material selected from the group consisting of aluminum oxide, magnesium silicate, zirconium oxide, talc, a molecular seive, and combinations thereof.