Abstract: Alkali (or other active) metal battery and other electrochemical cells incorporating active metal anodes together with aqueous cathode/electrolyte systems. The battery cells have a highly ionically conductive protective membrane adjacent to the alkali metal anode that effectively isolates (de-couples) the alkali metal electrode from solvent, electrolyte processing and/or cathode environments, and at the same time allows ion transport in and out of these environments. Isolation of the anode from other components of a battery cell or other electrochemical cell in this way allows the use of virtually any solvent, electrolyte and/or cathode material in conjunction with the anode. Also, optimization of electrolytes or cathode-side solvent systems may be done without impacting anode stability or performance. In particular, Li/water, Li/air and Li/metal hydride cells, components, configurations and fabrication techniques are provided.

Abstract: Disclosed are ionically conductive membranes for protection of active metal anodes and methods for their fabrication. The membranes may be incorporated in active metal negative electrode (anode) structures and battery cells. In accordance with the invention, the membrane has the desired properties of high overall ionic conductivity and chemical stability towards the anode, the cathode and ambient conditions encountered in battery manufacturing. The membrane is capable of protecting an active metal anode from deleterious reaction with other battery components or ambient conditions while providing a high level of ionic conductivity to facilitate manufacture and/or enhance performance of a battery cell in which the membrane is incorporated.

Abstract: Disclosed are ionically conductive composites for protection of active metal anodes and methods for their fabrication. The composites may be incorporated in active metal negative electrode (anode) structures and battery cells. In accordance with the invention, the properties of different ionic conductors are combined in a composite material that has the desired properties of high overall ionic conductivity and chemical stability towards the anode, the cathode and ambient conditions encountered in battery manufacturing. The composite is capable of protecting an active metal anode from deleterious reaction with other battery components or ambient conditions while providing a high level of ionic conductivity to facilitate manufacture and/or enhance performance of a battery cell in which the composite is incorporated.

Abstract: Electrochemical structures with a protective interlayer for prevention of deleterious reactions between an active metal electrode and polymer electrolytes, and methods for their fabrication. The structures may be incorporated in battery cells. The interlayer is capable of protecting an active metal anode and a polymer electrolyte from deleterious reaction with one another while providing a high level of ionic conductivity to enhance performance of a battery cell in which the structure is incorporated. The interlayer has a high ionic conductivity, at least 10−7 S/cm, generally at least 10−6 S/cm, and as high as 10−3 S/cm or higher. The interlayer may be composed, in whole or in part, of active metal nitrides, active metal phosphides or active metal halides. These materials may be applied preformed, or they may be formed in situ by conversion of applied precursors on contact with the active metal anode material.

Abstract: Disclosed are ionically conductive composites for protection of active metal anodes and methods for their fabrication. The composites may be incorporated in active metal negative electrode (anode) structures and battery cells. In accordance with the invention, the properties of different ionic conductors are combined in a composite material that has the desired properties of high overall ionic conductivity and chemical stability towards the anode, the cathode and ambient conditions encountered in battery manufacturing. The composite is capable of protecting an active metal anode from deleterious reaction with other battery components or ambient conditions while providing a high level of ionic conductivity to facilitate manufacture and/or enhance performance of a battery cell in which the composite is incorporated.

Abstract: A method employing a bonding layer is used to form active metal electrodes having barrier layers. Active metals such as lithium are highly reactive in ambient conditions. The method involves fabricating a lithium electrode or other active metal electrode without depositing the barrier layer on a layer of metal. Rather a smooth barrier layer is formed on a smooth substrate such as a web carrier or polymeric electrolyte. A bonding or alloying layer is formed on top of the barrier layer. Lithium or other active material is then attached to the bonding layer to form the active metal electrode. A current collector may also be attached to the lithium or active metal during the process.

Abstract: Disclosed are oxidizer-treated lithium electrodes, battery cells containing such oxidizer-treated lithium electrodes, battery cell electrolytes containing oxidizing additives, and methods of treating lithium electrodes with oxidizing agents and battery cells containing such oxidizer-treated lithium electrodes. Battery cells containing SO2 as an electrolyte additive in accordance with the present invention exhibit higher discharge capacities after cell storage over cells not containing SO2. Pre-treating the lithium electrode with SO2 gas prior to battery assembly prevented cell polarization. Moreover, the SO2 treatment does not negatively impact sulfur utilization and improves the lithium's electrochemical function as the negative electrode in the battery cell.

Abstract: Disclosed are oxidizer-treated lithium electrodes, battery cells containing such oxidizer-treated lithium electrodes, battery cell electrolytes containing oxidizing additives, and methods of treating lithium electrodes with oxidizing agents and battery cells containing such oxidizer-treated lithium electrodes. Battery cells containing SO2 as an electrolyte additive in accordance with the present invention exhibit higher discharge capacities after cell storage over cells not containing SO2. Pre-treating the lithium electrode with SO2 gas prior to battery assembly prevented cell polarization. Moreover, the SO2 treatment does not negatively impact sulfur utilization and improves the lithium's electrochemical function as the negative electrode in the battery cell.

Abstract: Disclosed are methods for forming active metal battery alloy electrodes having protective layers (“encapsulated electrodes”). Charged and uncharged encapsulated alloy electrodes and methods for their fabrication are provided.

Abstract: Batteries including a lithium anode stabilized with a metal-lithium alloy and battery cells comprising such anodes are provided. In one embodiment, an electrochemical cell having an anode and a sulfur electrode including at least one of elemental sulfur, lithium sulfide, and a lithium polysulfide is provided. The anode includes a lithium core and an aluminum-lithium alloy layer over the lithium core. In another embodiment, a surface coating, which is effective to increase cycle life and storageability of the electrochemical cell, is formed on the anode. In a more particular embodiment, the anode is in an electrolyte solution, and, more particularly, an electrolyte solution including either elemental sulfur, a sulfide, or a polysulfide where the surface coating is composed of Al2S3.

Abstract: Batteries including a lithium anode stabilized with a metal-lithium alloy and battery cells comprising such anodes are provided. In one embodiment, an electrochemical cell having an anode and a sulfur electrode including at least one of elemental sulfur, lithium sulfide, and a lithium polysulfide is provided. The anode includes a lithium core and a ternary alloy layer over the lithium core where the ternary alloy comprises lithium and two other metals. The ternary alloy layer is effective to increase cycle life and storageability of the electrochemical cell. In a more particular embodiment, the ternary alloy layer is comprised of lithium, copper and tin.

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: A method employing a bonding layer is used to form active metal electrodes having barrier layers. Active metals such as lithium are highly reactive in ambient conditions. The method involves fabricating a lithium electrode or other active metal electrode without depositing the barrier layer on a layer of metal. Rather a smooth barrier layer is formed on a smooth substrate such as a web carrier or polymeric electrolyte. A bonding or alloying layer is formed on top of the barrier layer. Lithium or other active material is then attached to the bonding layer to form the active metal electrode. A current collector may also be attached to the lithium or active metal during the process.

Abstract: A method employing a bonding layer is used to form active metal electrodes having barrier layers. Active metals such as lithium are highly reactive in ambient conditions. The method involves fabricating a lithium electrode or other active metal electrode without depositing the barrier layer on a layer of metal. Rather a smooth barrier layer is formed on a smooth substrate such as a web carrier or polymeric electrolyte. A bonding or alloying layer is formed on top of the barrier layer. Lithium or other active material is then attached to the bonding layer to form the active metal electrode. A current collector may also be attached to the lithium or active metal during the process.

Abstract: A method for forming lithium electrodes having protective layers involves plating lithium between a lithium ion conductive protective layer and a current collector of an “electrode precursor.” The electrode precursor is formed by depositing the protective layer on a very smooth surface of a current collector. The protective layer is a glass such as lithium phosphorus oxynitride and the current collector is a conductive sheet such as a copper sheet. During plating, lithium ions move through the protective layer and a lithium metal layer plates onto the surface of the current collector. The resulting structure is a protected lithium electrode. To facilitate uniform lithium plating, the electrode precursor may include a “wetting layer” which coats the current collector.

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: A high performance lithium-sulfur battery cell includes the following features: (a) a negative electrode including a metal or an ion of the metal; (b) a positive electrode comprising an electronically conductive material; and (c) a liquid catholyte including a solvent and dissolve electrochemically active material comprising sulfur in the form of at least one of a sulfide of the metal and a polysulfide of the metal. Such battery cells are characterized by an energy density, calculated based upon a laminate weight, of at least about 400 Watt-hours/kilogram when discharged at a rate of at least 0.1 mA/cm2. Cells meeting these criteria often find use as primary cells.

Abstract: A method for forming lithium electrodes having protective layers involves plating lithium between a lithium ion conductive protective layer and a current collector of an “electrode precursor.” The electrode precursor is formed by depositing the protective layer on a very smooth surface of a current collector. The protective layer is a glass such as lithium phosphorus oxynitride and the current collector is a conductive sheet such as a copper sheet. During plating, lithium ions move through the protective layer and a lithium metal layer plates onto the surface of the current collector. The resulting structure is a protected lithium electrode. To facilitate uniform lithium plating, the electrode precursor may include a “wetting layer” which coats the current collector.

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 dioxolane-treated lithium electrodes, battery cells containing such dioxolane-treated lithium electrodes, battery cell electrolytes containing dioxolane, and methods of treating lithium electrodes with dioxolane and battery cells containing such dioxolane-treated lithium electrodes. Treating lithium with dioxolane prevents the lithium from reacting with a wide range of substances which can contaminate battery cells, particularly moisture and other protic impurities, that might otherwise react with the lithium to the detriment of its function as a negative electrode in a battery cell. Battery cells containing dioxolane as an electrolyte co-solvent in accordance with the present invention exhibit improved cycling performance over cells not containing dioxolane. Moreover, the dioxolane treatment does not negatively impact sulfur utilization and improves the lithium's electrochemical function as the negative electrode in the battery cell.