Lithium ion batteries are the power source of choice for portable electrical devices owing to performance in terms of high specific capacity and reliability. Liquid electrolyte in Li-ion batteries can cause significant fire hazards, and requires a rigid container making manufacture complex and expensive. Leeds has a continuous extrusion lamination process for manufacturing Polymer Gel Electrolytes based on the polymer poly(vinylidene fluoride) dissolved in organic liquids which provides advantages in safety while providing flexible batteries at low cost. Though successfully demonstrated the processing conditions are not optimised. To successfully develop this technology, it is necessary to determine both the structures formed in the gel system as a result of processing parameters (concentration, temperature and speed) and their relation to overall battery performance.