Abstract: Provided are lithium anodes for use in electrochemical cells, where the anode active layer has a first layer comprising lithium metal and a second layer of a temporary protective material, wherein the temporary protective material is a metal capable of forming an alloy with lithium metal or is capable of diffusing into lithium metal. The present invention also pertains to electrochemical cells comprising such anodes.

Abstract: Provided are anodes for use in electrochemical cells, wherein the anode comprises an anode active layer comprising lithium and a polymer anode substrate comprising a polymer film layer and a protective crosslinked polymer layer, in which the protective crosslinked polymer layer is in contact with the anode active layer on the side opposite to the surface in contact with the polymer film layer. The present invention also pertains to methods for forming such anodes and electrochemical cells comprising such anodes.

Abstract: Provided is an electroactive organic polymer, which polymer comprises conductive polymer segments and non-conductive polymer segments, having one or more of these polymer segments bonded to polysulfide chains, and wherein the polysulfide chains comprise one or more moieties selected from the group consisting of —(Sm)—, —(Sm)−, and (Sm)2−, where m is an integer from 3 to 200 and is the same or different at each occurrence. Also provided are composite cathodes comprising such polymers, electrochemical cells comprising such cathodes, and methods of making such polymers, composite cathodes, and cells.

Abstract: Provided is a lithium battery in which the cathode comprises an electroactive sulfur-containing material and the electrolyte comprises a lithium salt, a non-aqueous solvent, and one or more capacity-enhancing reactive components. Suitable reactive components include electron transfer mediators of the formula: wherein: R4 is the same or different at each occurrence and is selected from the group consisting of H, alkyl, alkenyl, aryl, or substituted derivatives thereof; E is the same or different at each occurrence and is selected from the group consisting of O, NR5, and S; where R5 is alkyl, aryl, or substituted derivatives thereof; a is an integer from 0 to 1; and r is an integer from 2 to 5. Also are provided methods for making the lithium battery.

Abstract: Provided is a composite cathode comprising (a) an electroactive sulfur-containing material; (b) a crosslinked polymer formed from a reaction of a polymeric material having carboxyl groups and a crosslinking agent; and (c) a conductive filler. The crosslinked polymer improves the flexibility, adhesion, and cycle life of the composite cathode in electrochemical cells comprising the cathode. Also provided are electrochemical cells comprising such cathodes and methods for preparing such cathodes and electrochemical cells.

Abstract: Provided are cathode current collectors for use in electrochemical cells, wherein the current collector comprises a conductive primer layer applied upon a conductive support, and the primer layer comprises from about 20 to 60% by weight of a crosslinked polymeric material formed from a reaction of a polymeric material having hydroxyl groups and a crosslinking agent, about 2 to 15% by weight of a cationic polymer comprising quaternary ammonium salt groups, and about 35 to 75% by weight of a conductive filler. The present invention also pertains to methods of forming such cathode current collectors for use in electrochemical cells comprising: (i) an anode comprising lithium, and (ii) a cathode comprising an electroactive sulfur-containing material, and electrochemical cells comprising such cathode current collectors.

Abstract: Provided are methods of preparing an article in which a microporous layer is coated on a temporary carrier substrate and a substrate is then laminated to the microporous layer, prior to removing the temporary carrier substrate from the microporous layer. The microporous layer may comprise one or more microporous xerogel layers. Optionally, the microporous layer assembly may comprise one or more non-microporous coating layers which are in contact with at least one of the microporous xerogel layers, and one of the non-microporous coating layers may be coated on the temporary carrier substrate prior to coating the microporous layer. Also provided are articles, such as electrochemical cells, capacitors, fuel cells, ink jet ink printing media, and filtration media, prepared by such methods.

Abstract: Provided are methods of preparing a cathode/separator assembly for use in electrochemical cells in which a microporous separator layer is coated on a temporary carrier substrate and a cathode active layer is then coated or laminated on the separator layer prior to removing the temporary carrier substrate from the separator layer. The microporous separator layer may comprise one or more microporous xerogel layers. Optionally, the cathode/separator assembly may comprise one or more protective coating layers which are in contact with at least one of the microporous xerogel layers, and one of the protective coating layers may be coated on the temporary carrier substrate prior to coating the separator layer. Also, provided are methods of preparing electrochemical cells utilizing cathode/separator assemblies prepared by such methods, and cathode/separator assemblies and electrochemical cells prepared by such methods.

Abstract: The present invention pertains to non-aqueous electrolytes which comprise (a) one or more solvents; (b) one or more ionic salts; and, (c) a multifunctional monomer comprising two or more unsaturated aliphatic reactive moieties per molecule, which multifuntional monomer is soluble in said one or more solvents, which multifuctional monomer rapidly polymerizes when said electrolyte is heated to an initiation temperature greater than 100° C., thereby increasing said viscosity and internal resistivity of said electrolyte. When incorporated into a nonaqueous electrolyte, the multifunctional reactive monomer improves the safety of electric current producing cells by rapidly polymerizing at elevated temperatures to increase the viscosity and internal resistivity of the electrolyte.

Abstract: Provided are methods for preparing non-corrosive, electroactive, conductive organic polymers, such as for use in electrochemical cells, wherein the non-corrosive polymers are formed by treatment of electroactive, conductive organic polymer compositions, comprising corrosive anions, with sulfide anions. Also provided are non-corrosive conductive organic polymers prepared by such methods, composite cathodes comprising such polymers, electrochemical cells comprising such cathodes, and methods of preparing such composite cathodes and cells.

Abstract: Provided is an electrochemical cell in which the cathode comprises an electroactive sulfur-containing material, the anode comprises lithium, and the electrolyte comprises a lithium salt, a non-aqueous solvent, and a self-discharge inhibiting amount of one or more organic sulfites. Suitable organic sulfites include alkyl sulfite esters. Also are provided methods for increasing the storage life of electrochemical cells.

Abstract: This invention pertains to separators for electrochemical cells which comprise (i) two microporous pseudo-boehmite layers and (ii) a protective coating layer comprising a polymer interposed between the microporous pseudo-boehmite layers; electrolyte elements comprising such separators; electrical current producing cells comprising such separators; and methods of making such separators, electrolyte elements and cells.

Abstract: This invention pertains to separators for electrochemical cells which comprise (i) a microporous pseudo-boehmite layer and (ii) a protective coating layer comprising a polymer; electrolyte elements comprising such separators; electrical current producing cells comprising such separators; and methods of making such separators, electrolyte elements and cells.

Abstract: The present invention pertains to solid composite cathodes which comprise (a) an electroactive sulfur-containing cathode material which, in its oxidized state, comprises a polysulfide moiety of the formula, —Sm—, wherein m is an integer from 3 to 10; and (b) a non-electroactive particulate material having a strong adsorption of soluble polysulfides. The present invention also pertains to electric current producing cells comprising such solid composite cathodes, and methods of making such solid composite cathodes and electric current producing cells.

Abstract: Provided are cathode current collectors for use in electrochemical cells, wherein the current collector comprises a conductive primer layer applied upon a conductive support, and the primer layer comprises from about 25 to 70% by weight of a crosslinked polymeric material formed from a reaction of a polyvinyl acetal and a crosslinking agent, and about 30 to 75% by weight of a conductive filler. The present invention also pertains to methods of forming such cathode current collectors for use in electrochemical cells comprising (i) an anode comprising lithium, and (ii) a cathode comprising an electroactive sulfur-containing material.

Abstract: A secondary lithium-sulfur electrochemical cell is provided comprising: (a) an anode comprising lithium; (b) a cathode comprising an electroactive sulfur-containing material; and (c) a non-aqueous electrolyte interposed between the anode and the cathode, wherein the electrolyte comprises: (i) one or more lithium salts; (ii) one or more non-aqueous solvents; and (iii) a cycle life enhancing amount of water; wherein the cycle life enhancing amount of water is greater than 3000 ppm by weight of the electrolyte. Such cells have a long cycle life.

Abstract: The present invention pertains to solid composite cathodes which comprise (a) an electroactive sulfur-containing cathode material which, in its oxidized state, comprises a polysulfide moiety of the formula, —Sm—, wherein m is an integer from 3 to 10; and (b) a cationic polymer comprising quaternary ammonium salt groups. The present invention also pertains to electric current producing cells comprising such solid composite cathodes, and methods of making such solid composite cathodes and electric current producing cells.

Abstract: This invention pertains to separators for electrochemical cells which comprise a microporous pseudo-boehmite layer; electrolyte elements comprising such separators; electrical current producing cells comprising such separators; and methods of making such separators, electrolyte elements and cells.

Abstract: An electrode having a notch along one edge is provided. The notch prevents unintentional internal shorting between the electrode and internal cell structures having an opposing polarity. In a preferred embodiment, the electrode is used in jellyroll electrochemical cells to avoid contact between the most exterior electrode wrap of the jellyroll and the can. A method of making such an electrode from a continuous strip of electrode material is also provided.

Abstract: A seal and method of sealing for use in electrochemical cells and similar devices. A preformed seal assembly is produced by insert-molding a seal element about a cell cover plate. By preforming the seal element, a more effective seal geometry is produced. In particular, the seal element is formed with a low profile seal flange on the outer face of the cover plate. One benefit of this lower profile is to assist in increasing the effective capacity of the associated cell. Another benefit of the preformed seal element is that it is not necessary to grossly deform the seal element during cell assembly in order to capture the cover plate. This enables use of more desired seal materials such as amorphous polymers, particularly polysulfone. To improve the effectiveness of the seal, a seal flange and shoulder portions, between which the cover plate is captured, are each axially compressed to increase the leakage path and reduce cold flow of the seal element.