Abstract: Battery packaging is described which permits gas generated inside of a battery package to safely escape through a vent. A sealant in communication with the vent substantially and selectively seals the vent. As the battery temperature rises to or above a minimum temperature, gas is generated. The heat causes the sealant to become substantially softened, such that the sealant unseals the vent, and the gas passes through the vent into the ambient atmosphere.

Abstract: The invention provides an electrochemically active material comprising particles of spinel lithium manganese oxide having on the surface of each particle cationic metal species bound to the spinel at anionic sites of the particle surface; where the cationic metal species includes a metal selected from the group consisting of transition metals, non-transition metals having a +3 valence state, and mixtures thereof. The active material is characterized by a reduced surface area and increased capacity expressed in milliamp hour per gram as compared to the spinel alone.

Abstract: A method for activating electrochemical cells including the steps of sealing the electrochemical cells in a container with an activating electrolyte solvent and salt, treatment steps, such as the application of compression and decompression cycles to the container, for providing good distribution of the electrolyte within the electrochemical cells.

Abstract: The invention provides an electrochemically active material comprising particles of spinel lithium manganese oxide having on the surface of each particle cationic metal species bound to the spinel at anionic sites of the particle surface; where the cationic metal species includes a metal selected from the group consisting of transition metals, non-transition metals having a +3 valence state, and mixtures thereof. The active material is characterized by a reduced surface area and increased capacity expressed in milliamp hour per gram as compared to the spinel alone.

Abstract: The invention provides an electrochemically active material comprising particles of spinel lithium manganese oxide having on the surface of each particle cationic metal species bound to the spinel at anionic sites of the particle surface; where the cationic metal species includes a metal selected from the group consisting of transition metals, non-transition metals having a +3 valence state, and mixtures thereof. The active material is characterized by a reduced surface area and increased capacity expressed in milliamp hour per gram as compared to the spinel alone.

Abstract: The methods and compositions of the invention provide two solutions to reduce the reactivity of VDF-based copolymers to lithiated graphite. The two approaches can be used separately or combined. In one embodiment, the relative proportion of the VdF and the other fluorinated monomer (OFM, i.e. HFP) in the copolymer is significantly reduced below conventional formulations in order to reduce the reactivity of the copolymer. In a second approach, the reactivity of the copolymer, over a broad range of monomer VdF:OFM molar ratios, is reduced by deactivating the reactive sites on the copolymer, thereby blocking the ability to undergo undesired reaction during cell operation. These methods and compositions have heretofore not been proposed and are of primary importance in preventing large exothermic reaction which can lead to thermal runaway when conventional polymer formulations are utilized in batteries in the presence of reactive components such as lithiated graphite.

Abstract: A plasma polymerization method of preparing an electrochemical cell wherein the composite electrode material adheres to the current collector to create good electrical contact is provided. The electrode/current collector comprises a current collector having a layer of electrically conductive polymeric adhesive material on at least one surface of the current collector and either a composite cathode and composite anode, wherein the layer of polymeric adhesive material is positioned between the current collector and composite electrode. The composite electrode remains substantially and permanently attached to the electrically conductive polymeric adhesive material layer on the surface(s) of the current collector during the life of the electrochemical cell or battery.

Abstract: The subject invention discloses a novel method of providing a binary electrolyte-solvent solution in a solid battery system. A first component of this binary electrolyte solvent system is provided by a material which acts as a plasticizer in the formation of a solid polymeric matrix (separator), composite cathode and/or composite anode, and which also acts as an electrolyte solvent in the completed electrochemical cell. The second component of the binary electrolyte solvent system is an electrolyte solvent, which generally carries the electrolyte salt into the electrolytic cell precursor. The first and second components of the binary electrolyte solvent system mix within the electrolytic cell, dispersing the electrolyte salt throughout the binary electrolyte solvent system. The addition of the electrolyte salt to the electrolytic cell precursor acts to activate the cell precursor, and to form a functional electrolytic cell or battery system.

Abstract: A method of fabricating electrochemical cells employing novel plasticizers that can be removed by evaporation under vacuum is provided thereby obviating the need for solvent extraction. The plasticizers comprise 2-(2-ethoxyethoxy) ethyl acetate, dimethyl adipate, dibutyl phthalate, propylene carbonate, and mixtures thereof.

Abstract: A method of preparing an electrochemical cell wherein the electrode material adheres to the current collector to create good electrical contact is provided. A critical aspect in the process of preparing the polymer mixture for both the anode and cathode slurries is that the polymer (or copolymer) not be subject to high shear so as to be degraded. Polymer degradation contributes to the creation of the polymer concentration gradient in the electrode film.

Abstract: A method for removing plasticizers such dibutyl phthalate from the anode, cathode, and polymeric matrix components of electrochemical cell precursors using carbon dioxide in the supercritical state is provided. The method forms porous polymeric structures that enhances the mass transport of ions in the cell which results in improved electrochemical performance.

Abstract: A method of fabricating polymeric matrices suitable for use in non-aqueous electrochemical cells is provided. The method includes forming an organic emulsion comprising an organic solvent and having a polar phase comprising polar polymer precursors and a non-polar phase comprising non-polar polymer precursors wherein the polar phase is substantially immiscible in the non-polar phase, said emulsion further including an effective amount of surfactant to maintain said emulsion; and initiating polymerization of said polar polymer precursors to form first polymers and of said non-polar polymer precursors to form second polymers wherein said first polymers are crosslinked by said second polymers to form a polymeric matrix. The polymeric matrix will have superior physical strength and puncture resistance.

Abstract: A method of preparing an electrochemical cell wherein the composite electrode material adheres to the metal current collector to create good electrical contact is provided. The electrode/current collector comprises a current collector, a layer of an electrically conductive adhesion promoter formed on at least one surface of the current collector which comprises an electrically conductive material and an adhesive polymer; and a composite electrode selected from the group consisting of composite cathode and composite anode, wherein the thickness of said electrically conductive adhesive promoter is sufficient to bind the composite electrode to said current collector.

Abstract: A method of improving the structural integrity of the binder and polymeric matrix components of electrochemical cell precursors by employing polymer blends comprising fluoropolymers is provided. The method forms porous polymeric structures that enhances the mass transport of ions in the cell which results in improved electrochemical performance. Films or webs of electrochemical cell precursors comprising the fluoropolymer blends are flexible which enhances processability.

Abstract: A method of improving the structural integrity of polymer electrolytes of electrochemical cell by employing lithiated zeolites, and optionally, inorganic fillers selected from SiO.sub.2, Al.sub.2 O.sub.3, TiO.sub.2 and ZrO is provided.

Abstract: A method for removing plasticizers such dibutyl phthalate from the anode, cathode, and polymeric matrix components of electrochemical cell precursors using carbon dioxide in the supercritical state is provided. The method forms porous polymeric structures that enhances the mass transport of ions in the cell which results in improved electrochemical performance.

Abstract: A method of preparing an electrochemical cell wherein the electrode material adheres to the current collector to create good electrical contact is provided. A critical aspect in the process of preparing the polymer mixture for both the anode and cathode slurries is that the polymer (or copolymer) not be subject to high shear so as to be degraded. Polymer degradation contributes to the creation of the polymer concentration gradient in the electrode film.

Abstract: Apparatus and method for supporting at least a portion of an article while the article is being formed. A source of self-adhering particles is directed by a particle jetting device, or the like, to a predetermined position in a controlled environment to form the article. A support structure is carried in the controlled environment for substantially rigidly supporting at least a portion of the article during the formation of the article (by build-up of the self-adhering particles). The support structure is a fluid which changes state to a solid responsive to an electrical charge and reverts back to a fluid responsive to removal of the electrical charge.

Abstract: The mixing of high solids loaded propellants is accomplished under reduced viscosity conditions by employing near critical liquid (NCL) carbon dioxide as the processing fluid in a volume amount from about 10 to about 20 percent of the volume of the propellant ingredients.A typical propellant composition contains about 88 percent solids portion by weight comprised of ammonium perchlorate, aluminum powder, ballistic modifiers, and bonding agent and about 12 percent liquid portion by weight comprised of liquid polymers, plasticizers, and curatives.NCL carbon dioxide facilitates low viscosity mixing of propellant ingredients in a completely inert processing fluid. The method allows the entire mixing procedure to be conducted under reduced temperature conditions (e.g., 90.degree. F. vs 140.degree. F.), and thereby, provides for extended propellant pot life. Pressure mixing in a range of 760 psig to 1000 psig enables carbon dioxide to be maintained as a NCL to assist propellant mixing.

Abstract: An effective method to recover the catalyst material, ferrocene or its deatives, from high burn rate propellants comprises the method which uses compressed gas in the form of a near critical liquid to extract, remove, and recover the specific catalyst material directly from rocket motors or from chunks of cut propellant.The method comprises introducing compressed carbon dioxide into a pressure vessel containing the propellant from which the catalyst material is to be recovered. The carbon dioxide as a near critical liquid (NCL) is circulated within the pressure vessel where extraction of ferrocene or its derivatives directly from the propellant takes place. The NCL with extractibles is transported to a warming and recovery zone where the extractibles are recovered after the carbon dioxide is volatilized and returned for recycling, compressing, and further extracting after being adjusted to a near critical liquid.Analytical data indicates that from 99.