Abstract: An anode material made from nanoparticles, said anode material including a homogeneous mixture of lithium-alloying nanoparticles with active support matrix nanoparticles, is provided. The active support matrix nanoparticle is a compound that participates in the conversion reaction of the lithium battery. The compound is preferably a transition metal compound, with said compound including a nitride, carbide, oxide or combination thereof. An electrode manufactured from the anode material preferably has a porosity of between 5 and 80% and more preferably has a porosity between 10 and 50%. The anode material nanoparticles preferably have a mean linear dimension of between 2 and 500 nanometers, and more preferably have a mean linear dimension of between 2 and 50 nanometers.

Abstract: High-purity crystalline ferric phosphate material with desirable characteristics for use in synthesis of nano-sized LFP cathode material are described. The ferric phosphate dihydrate material has as disclosed herein has a molar ratio of phosphorous to iron is from about 1.001 to about 1.05, a surface area of from about 25 m2/g to about 65 m2/g, and is substantially free of metallic or magnetic impurities. Methods of synthesizing high-purity crystalline ferric phosphate material with desirable characteristics for use in synthesis of nano-sized LFP cathode material are also described. In some embodiments, one or more magnetic traps are used during the reaction process and/or after the formation of the final product to remove magnetic impurities. In some embodiments, a synthetic method of ferric phosphate using multiple steps is described, wherein the intermediate of the synthesis is isolated and purified to improve the purity of the ferric phosphate material.

Abstract: A composite material having utility for removing sulfur from a feedstock comprises a ceramic matrix having a relatively low melting point metal such as tin, zinc, lead or bismuth nanodispersed therein. The material may be prepared from a mixture of particles of a precursor of the ceramic matrix and precursor of the metal. The precursors are selected such that the melting point of the precursor of the ceramic is less than the melting point of the precursor of the metal. The mixture of precursor materials is heated to a temperature sufficient to melt the precursor of the ceramic material so as to coat it onto the precursor of the metal. The ceramic precursor is then reacted so as to convert it to a ceramic. Thereafter, the precursor of the metal is converted to a free metal which is retained within the ceramic matrix so as to prevent agglomeration.

Abstract: An anode material with lithium-alloying particles contained within a porous support matrix is provided. The porous support matrix preferably has a porosity of between 5 and 80% afforded by porosity channels and expansion accommodation pores, and is electrically conductive. More preferably the support matrix has a porosity of between 10 and 50%. The support matrix is made from an organic polymer, an inorganic ceramic or a hybrid mixture of organic polymer and inorganic ceramic. The organic polymer support matrix and can be made from a rod-coil polymer, a hyperbranched polymer, UV cross-linked polymer, heat cross-linked polymer or combination thereof. An inorganic ceramic support matrix can be made from at least one group IV-VI transition metal compound, with the compound being a nitride, carbide, oxide or combination thereof.

Abstract: A positive electrode material is provided including an electroactive material having one or more phases comprising lithium (Li), an electroactive metal (M), and phosphate (PO4), wherein in the fully lithiated state, the overall composition has a ratio of Li:M ranging from greater than about 1.0 to about 1.3, a ratio of (PO4):M ranging from about 1.0 to about 1.132, M is one or more metals selected from the group consisting of Cr, Mn, Fe, Co, and Ni, and at least one phase includes an olivine lithium electroactive metal phosphate. In some instances, a composite cathode material including an electroactive olivine transition metal phosphate and a lithium and phosphate rich secondary phase is disclosed for use in a lithium ion battery.

Abstract: A composite material having utility as an anode for lithium ion batteries comprises silicon, a transition metal, a ceramic and an electrically conductive diluent such as carbon. In particular instances, the ceramic is electrically conductive, and may comprise vanadium carbide or tungsten carbide. The transition metal may, in some instances, comprise iron. The material may be fabricated by grinding together a starting mixture of the components, and grinding may be accomplished in a high impact ball milling process, and the grinding step may cause partial alloying of the silicon with the metal and/or carbon. Further disclosed is a method for making the material as well as electrodes which incorporate the material.

Abstract: An anode material made from nanoparticles, said anode material including a homogeneous mixture of lithium-alloying nanoparticles with active support matrix nanoparticles, is provided. The active support matrix nanoparticle is a compound that participates in the conversion reaction of the lithium battery. The compound is preferably a transition metal compound, with said compound including a nitride, carbide, oxide or combination thereof. An electrode manufactured from the anode material preferably has a porosity of between 5 and 80% and more preferably has a porosity between 10 and 50%. The anode material nanoparticles preferably have a mean linear dimension of between 2 and 500 nanometers, and more preferably have a mean linear dimension of between 2 and 50 nanometers.

Abstract: An anode material with lithium-alloying particles contained within a porous support matrix is provided. The porous support matrix preferably has a porosity of between 5 and 80% afforded by porosity channels and expansion accommodation pores, and is electrically conductive. More preferably the support matrix has a porosity of between 10 and 50%. The support matrix is made from an organic polymer, an inorganic ceramic or a hybrid mixture of organic polymer and inorganic ceramic The organic polymer support matrix and can be made from a rod-coil polymer, a hyperbranched polymer, UV cross-linked polymer, heat cross-linked polymer or combination thereof. An inorganic ceramic support matrix can be made from at least one group IV-VI transition metal compound, with the compound being a nitride, carbide, oxide or combination thereof.

Abstract: A composite material having utility as a cathode material for a lithium ion battery includes a first component which is a metal phosphate and a second component which is a metal nitride, a metal oxynitride, or a mixture of the two. The second component is coated on, or dispersed through the bulk of, the first component. The metal phosphate may be a lithiated metal phosphate and may be based upon one or more transition metals. Also disclosed is a method for preparing the material as well as electrodes fabricated from the material and lithium ion cells which include such electrodes.

Abstract: A multiphase composite material having utility as an electrochemical electrode or catalyst includes a first active phase which is an amorphous, electrochemically active material; and a second, stabilizer phase which includes one or more of: metals, carbon, ceramics, and intermetallic compounds. The stabilizer phase is configured as a plurality of spaced apart regions having the active phase disposed therebetween. The active phase may comprise one or more of: Sn, Sb, Bi, Pb, Ag, In, Si, Ge, and Al. The stabilizer phase may include one or more of: Fe, Zr, Ti, and C. Also disclosed are electrodes and batteries which include the material as well as methods for manufacturing the material by using a mechanical alloying process.

Abstract: A composite material which may be used as an electrode for a battery or other electrochemical device, or as a catalyst, has a matrix which is one or more metal carbide, metal nitride, metal boride, metal silicide or intermetallic compound. A metallic component is dispersed in the matrix. The metallic component comprises a metal and an agent which increases the melting point of the metal. The metallic component may be nanodispersed in the matrix. A specific material comprises a nanodispersion of tin, alloyed with an element which increases its melting point to at least 600° C., disposed in a matrix of a transition metal carbide or nitride. This material has very good utility as an anode material for lithium batteries. Also disclosed are other compositions as well as methods for manufacturing the compositions.

Abstract: A composite material having utility as a cathode material for a lithium ion battery includes a first component which is a metal phosphate and a second component which is a metal nitride, a metal oxynitride, or a mixture of the two. The second component is coated on, or dispersed through the bulk of, the first component. The metal phosphate may be a lithiated metal phosphate and may be based upon one or more transition metals. Also disclosed is a method for preparing the material as well as electrodes fabricated from the material and lithium ion cells which include such electrodes.

Abstract: A multiphase composite material having utility as an electrochemical electrode or catalyst includes a first active phase which is an amorphous, electrochemically active material; and a second, stabilizer phase which includes one or more of: metals, carbon, ceramics, and intermetallic compounds. The stabilizer phase is configured as a plurality of spaced apart regions having the active phase disposed therebetween. The active phase may comprise one or more of: Sn, Sb, Bi, Pb, Ag, In, Si, Ge, and Al. The stabilizer phase may include one or more of: Fe, Zr, Ti, and C. Also disclosed are electrodes and batteries which include the material as well as methods for manufacturing the material by using a mechanical alloying process.

Abstract: Provided are methods of forming an electrode suitable for use in an electrochemical cell, and novel electrodes which can be formed therefrom. The methods involve the steps of: (a) forming an electrode slurry from components comprising a solvent, a polymeric binder material and a solid electrode material, wherein the polymeric binder material is formed by modifying a polyolefin with at least one unsaturated polycarboxylic acid or an anhydride of the acid, chlorinating the modified polyolefin and partially crosslinking carboxyl groups or acid anhydride groups on the chlorinated, modified polyolefin with an epoxy group of a compound which has at least two epoxy groups per molecule; (b) coating the electrode slurry on a substrate; and (c) evaporating the solvent. Also provided are electrochemical cells which include the inventive electrodes. The invention has particular applicability to the manufacture of nonaqueous electrochemical power supplies.