Abstract: A method for fabricating an active metal electrode involves depositing lithium or other active metal electrode on a protective layer. The protective layer is a glassy or amorphous material that conducts ions of the active metal. It may be deposited on a releasable web carrier or other substrate such as polymer electrolyte layer. Lithium is then deposited on the protective layer. Finally, a current collector is attached to the lithium.

Abstract: Disclosed is a redox electrode for a battery cell that has a coating to mitigate plugging by precipitated discharge products. The coating comprises a mixed ionic electronic conductor (MIEC) which is applied to the surface of a redox electrode. The presence of the MIEC coating allows for rapid removal of discharge product precipitates from redox electrodes since it is capable of conducting both electrons and ions. As a result, the chemical action necessary to remove such precipitates may take place on both the electrolyte side of the precipitate and at the precipitate/electrode interface. MIEC coatings in accordance with the present invention may be composed of any suitable material having ionic conductivity for a metal ion in a negative electrode with which the redox electrode is to be paired in a battery cell, and reversible redox capacity. Examples include titanium sulfide (TiS2), iron sulfide (FeS2), and cobalt oxides.

Abstract: Disclosed is a positive electrode that has a low equivalent weight and high cell voltage and consequently a high specific energy, and a high discharge rate pulse capability. Also disclosed are methods for fabricating active-sulfur-based composite electrodes, and battery cells incorporating such electrodes. The batteries of this invention are preferably rechargeable and operate at high sulfur utilization over many cycles. Positive electrodes according to the present invention are composed of at least two electrochemically active materials: an “active-sulfur” material, and a second electrochemically active material having a higher discharge rate than the active-sulfur component. The active-sulfur component is also oxidizing with respect to the higher discharge rate material. In operation, the active-sulfur component of the positive electrode discharges to satisfy power demands below its maximum discharge rate.

Abstract: An electrochemical timer is described that is compact, lightweight, inexpensive to manufacture, and simple to use in which the consumption of reactive materials in an electrochemical reaction provides a visual indication of the passage of time. In one embodiment, the electrochemical timer includes a first electrode, an electrolyte, and a second electrode. The electrodes and electrolyte are chosen such that the first electrode is consumed at a predetermined rate upon electrochemical contact of the electrodes and electrolyte. The electrodes and electrolyte are further configured such that the consumption of the first electrode can be monitored to provide an indication of the passage of time. In one embodiment, the electrochemical timers provided herein are used to monitor the shelf-life of perishables.

Abstract: Batteries including a lithium electrode and a sulfur counter electrode that demonstrate improved cycling efficiencies are described. In one embodiment, an electrochemical cell having a lithium electrode and a sulfur electrode including at least one of elemental sulfur, lithium sulfide, and a lithium polysulfide is provided. The lithium electrode includes a surface coating that is effective to increase the cycling efficiency of said electrochemical cell. In a more particular embodiment, the lithium electrode is in an electrolyte solution, and, more particularly, an electrolyte solution including either elemental sulfur, a sulfide, or a polysulfide. In another embodiment, the coating is formed after the lithium electrode is contacted with the electrolyte. In a more particular embodiment, the coating is formed by a reaction between the lithium metal of the lithium electrode and a chemical species present in the electrolyte.

Abstract: A process for forming an electrode involves mixing or homogenizing one or more electrode components in a "fugitive carrier". This mixture is then frozen by dropping the temperature to a level below which the fugitive carrier freezes. This locks the well-mixed electrode components in place in a solid matrix to form an electrode precursor. Thereafter, the fugitive carrier is sublimated from the electrode precursor to form an electrode in which the components are substantially unsegregated.

Abstract: Disclosed is an alkali metal negative electrode having a protective layer. Specifically, the disclosed negative electrode includes a glassy or amorphous surface protective layer which conducts alkali metal ions but effectively blocks the alkali metal in the electrode from direct contact with the ambient. The protective layer has improved smoothness and reduced internal stress in comparison to prior protective layers such as those formed by sputtering. In a specific embodiment, the protective layer is formed on the lithium metal electrode surface by a plasma assisted deposition technique.

Abstract: Batteries including a lithium electrode and a sulfur counter electrode that demonstrate improved cycling efficiencies are described. In one embodiment, an electrochemical cell having a lithium electrode and a sulfur electrode including at least one of elemental sulfur, lithium sulfide, and a lithium polysulfide is provided. The lithium electrode includes a surface coating that is effective to increase the cycling efficiency of said electrochemical cell. In a more particular embodiment, the lithium electrode is in an electrolyte solution, and, more particularly, an electrolyte solution including either elemental sulfur, a sulfide, or a polysulfide. In another embodiment, the coating is formed after the lithium electrode is contacted with the electrolyte. In a more particular embodiment, the coating is formed by a reaction between the lithium metal of the lithium electrode and a chemical species present in the electrolyte.

Abstract: Disclosed is an electrochemical device having a shuttle-type redox mechanism for overcharge protection in which the redox reaction is "tuned" with a tuning agent to adjust the potential at which the redox reaction occurs. Such device may be characterized as including the following elements: (1) a negative electrode (e.g., lithium); (2) a positive electrode containing one or more intermediate species (e.g., polysulfides) which are oxidized to one more oxidized species during overcharge; and (3) a tuning species (e.g., an organosulfur compound) which adjusts the rate at which the oxidized species are reduced and thereby adjusts the voltage at which overcharge protection is provided. The oxidized species produced during overcharge move to the negative electrode where they are reduced back to said intermediate species as in a normal redox shuttle. However, the oxidized species react more rapidly than the intermediate species at the negative electrode.

Abstract: Disclosed are positive electrodes containing active-sulfur-based composite electrodes. The cells include active-sulfur, an electronic conductor, and an ionic conductor. These materials are provided in a manner allowing at least about 10% of the active-sulfur to be available for electrochemical reaction. Also disclosed are methods for fabricating active-sulfur-based composite electrodes. The method begins with a step of combining the electrode components in a slurry. Next, the slurry is homogenized such that the electrode components are well mixed and free of agglomerates. Thereafter, before the electrode components have settled or separated to any significant degree, the slurry is coated on a substrate to form a thin film. Finally, the coated film is dried to form the electrode in such a manner that the electrode components do not significantly redistribute.

Abstract: Disclosed are positive electrodes containing active-sulfur-based composite electrodes. The cells include active-sulfur, an electronic conductor, and an ionic conductor. These materials are provided in a manner allowing at least about 10% of the active-sulfur to be available for electrochemical reaction. Also disclosed are methods for fabricating active-sulfur-based composite electrodes. The method begins with a step of combining the electrode components in a slurry. Next, the slurry is homogenized such that the electrode components are well mixed and free of agglomerates. Thereafter, before the electrode components have settled or separated to any significant degree, the slurry is coated on a substrate to form a thin film. Finally, the coated film is dried to form the electrode in such a manner that the electrode components do not significantly redistribute.

Abstract: Disclosed are positive electrodes containing active-sulfur-based composite electrodes. The cells include active-sulfur, an electronic conductor, and an ionic conductor. These materials are provided in a manner allowing at least about 10% of the active-sulfur to be available for electrochemical reaction. Also disclosed are methods for fabricating active-sulfur-based composite electrodes. The method begins with a step of combining the electrode components in a slurry. Next, the slurry is homogenized such that the electrode components are well mixed and free of agglomerates. Thereafter, before the electrode components have settled or separated to any significant degree, the slurry is coated on a substrate to form a thin film. Finally, the coated film is dried to form the electrode in such a manner that the electrode components do not significantly redistribute.

Abstract: Disclosed are methods of making solid-phase active-sulfur-based composite electrodes. The method begins with a step of combining the electrode components (including an electrochemically active material, an electronic conductor, and an ionic conductor) in a slurry. Next, the slurry is homogenized such that the electrode components are well mixed and free of agglomerates. Very soon thereafter, before the electrode components have settled or separated to any significant degree, the slurry is coated on a substrate to form a thin film. Finally, the coated film is dried to form the electrode in such a manner that the electrode components do not significantly redistribute.

Abstract: Disclosed are battery cells comprising a sulfur-based positive composite electrode. Preferably, said cells are secondary cells, and more preferably thin film secondary cells. In one aspect, the cells can be in a solid-state or gel-state format wherein either a solid-state or gel-state electrolyte separator is used. In another aspect of the invention, the cells are in a liquid format wherein the negative electrode comprises carbon, carbon inserted with lithium or sodium, or a mixture of carbon with lithium or sodium. The novel battery systems of this invention have a preferred operating temperature range of from -40.degree. C. to 145.degree. C. with demonstrated energies and powers far in excess of state-of-the-art high-temperature battery systems.

Abstract: Disclosed are battery cells comprising a sulfur-based positive composite electrode. Preferably, said cells are secondary cells, and more preferably thin film secondary cells. In one aspect, the cells can be in a solid-state or gel-state format wherein either a solid-state or gel-state electrolyte separator is used. In another aspect of the invention, the cells are in a liquid format wherein the negative electrode comprises carbon, carbon inserted with lithium or sodium, or a mixture of carbon with lithium or sodium. The novel battery systems of this invention have a preferred operating temperature range of from -40.degree. C. to 145.degree. C. with demonstrated energies and powers far in excess of state-of-the-art high-temperature battery systems.

Abstract: A novel battery cell is disclosed which is characterized by a metal-organosulfur positive electrode which has one or more metal-sulfur bonds wherein when the positive electrode is charged and discharged, the formal oxidation state of the metal is changed. The positive electrode has the general formula(M'.sup.z.spsp.+.sub.(c/z) [M.sub.q (RS.sub.y).sub.x.sup.c- ]).sub.nwhereinz=1 or 2; y=1 to 20; x=1 to 10; c=0 to 10; n.gtoreq.