Abstract: A multi-fold rechargeable battery cell structure comprising electrode elements and separator elements, wherein relief slots are formed along the fold axes of the outermost electrode elements in order to relieve folding stresses which could result in damage and impairment of the operation of the cell. The slots are formed adjacent to regions of intact electrode material in each outermost electrode element and are arranged such that the slots of one electrode element are aligned with the regions of intact electrode material of the other electrode element. In this manner, electrode element planar integrity is maintained while the effective laminate fold region thickness is reduced.

Abstract: A method of fabricating electrochemical cells and batteries wherein the successive anode and cathode layers are separated by a polymeric electrolyte layer having a protruding polymer edge around its perimeter which reduces the likelihood of inadvertent contact between the anode and cathode current collectors is provided. The polymer edge functions as a non-conducting physical barrier positioned between adjacent current collectors. An apparatus for preparing electrochemical cells is also disclosed.

Abstract: In one embodiment, the invention provides a novel composition which is stabilized against decomposition when used as an active material for an electrochemical cell. The active material of the present invention comprises particles of spinel lithium manganese oxide (LMO) enriched with lithium by a decomposition product of lithium hydroxide forming a part of each of the LMO particles. The spinel LMO product formed by the decomposition of lithium hydroxide in the presence of the LMO is characterized by a reduced surface area and increased capacity retention (reduced capacity fading) as compared to the initial, non-treated, non-enriched spinel. In another aspect, the treated spinel LMO product is combined with lithium carbonate in a cathode mixture.

Abstract: Conditioning secondary lithium ion cells at elevated temperatures above ambient reduces the time required to complete this process and produces cells and batteries which demonstrate improved electrochemical performance. Conditioning includes subjecting an electrochemical cell to at least one full charge/discharge cycle whereby gases generated and removed before the cell is sealed and ready for use. The cell is placed in an environment that is maintained at a temperature of at least 30° C., charged and discharged, and sealed.

Abstract: The invention provides an electrochemical cell which comprises an electrode having a lithium metal phosphorous compound.

Abstract: The present invention provides a novel electrolyte solvent which is usable with a variety of carbonaceous and metal oxide electrode active materials, providing improved performance over a broad temperature range, and which is stabilized to maintain cell capacity over a number of cycles.

Abstract: Single cell laminated polymeric rechargeable battery sheets are folded in irregularly alternating directions about parallel fold axes to provide battery cell structures presenting available terminal locations requiring reduced collector element current travel distance to thereby significantly reduce battery impedance. An embodiment enables the use of equilateral cell sheets which are folded about orthogonal axes in two dimensions to yield battery cells with exceptionally high ratios of active area to collector-origin impedance.

Abstract: A method for producing a battery cell having a plurality of film layers, a plurality of current collector layers, and at least one separator layer, with each current collector layer including a predetermined lead portion. The method includes the steps of providing at least one notch in each layer, and stacking the layers with the notches positioned with respect to one another to expose the predetermined lead portion of each current collector layer. A battery cell including an electrode having an area defined by a perimeter including an edge, a counter electrode having an area defined by a perimeter including an edge, and a separator having an area defined by a perimeter including an edge is also provided. The separator is sandwiched between the electrode and the counter electrode in a layered relationship with at least portions of the edges being continuous.

Abstract: A Li-ion battery cell comprising a polymeric matrix positive electrode layer member, a polymeric matrix negative electrode layer member, and an interposed microporous polyolefin separator layer member is laminated into a unitary, flexible cell structure by means of heat and pressure without necessity of applied interlayer adhesive. A volatile vehicle solution of a primary plasticizer for the electrode member polymer matrix is applied to the microporous separator member where it is absorbed into the porous structure. Evaporation of the volatile vehicle solvent deposits the plasticizer upon and within the pores of the separator member. During the lamination operation the plasticizer is forced into contact with the electrode member polymer where it softens the polymer into a thermoplastic adhesive in the region of the electrode/separator interface, thereby enabling the electrode polymer alone to form a strong bond to the separator upon cooling.

Abstract: The invention provides an electrochemical cell having an electrolyte which comprises a solute, a solvent, and an additive. The additive is a dialkylamide. The dialkylamide lessens the extent of decomposition of the solute, which is a lithium salt. The ionic species of the lithium salt are thereby preserved. The additive also prevents damage to active material by absorbing excess charge energy below the breakdown potential of the active material.

Abstract: A Li-ion battery cell comprising a polymeric matrix positive electrode layer member, a polymeric matrix negative electrode layer member, and an interposed microporous polyolefin separator layer member is laminated into a unitary, flexible cell structure by means of heat and pressure without necessity for applied interlayer adhesive. A primary plasticizer for the electrode member matrix polymer is included in the electrode layer compositions. During the lamination operation, which may be carried out at a moderate-temperature that does not compromise the thermal shutdown capability of the microporous separator, the plasticizer softens the polymer into a thermoplastic adhesive which forms an effective bond to the untreated polyolefin surface in the region of the electrode/separator interface.

Abstract: The invention provides new and novel lithium-metal-fluorophosphates which, upon electrochemical interaction, release lithium ions, and are capable of reversibly cycling lithium ions. The invention provides a rechargeable lithium battery which comprises an electrode formed from the novel lithium-metal-fluorophosphates. The lithium-metal-fluorophosphates comprise lithium and at least one other metal besides lithium.

Abstract: A method for removing HF from a solid electrolyte using alumina is disclosed. The solid electrolyte contains a polymeric matrix, a salt, a solvent, and a toughening agent. The toughening agent may include alumina, silica, zeolite, and metal oxides (e.g., calcium oxide and magnesium oxide), and mixtures thereof. The toughening agent acts as a drying agent to remove excess solvent in the electrolyte. The solid electrolytes have improved mechanical strength and adherence to the anode and cathode.

Abstract: A laminate structure or precursor paste thereof characterized by being formed from a composition comprising a polymeric material and a plasticizer. The plasticizer being at least one compound represented by the following general formula where R is a low alkyl selected from the group consisting of methyl, ethyl, butyl, pentyl and hexyl.

Abstract: A method for treating a separator for use in laminated multi-layer electrochemical cell device structures. The devices comprise positive and negative electrode layer members of polymeric matrix composition having the microporous polyolefin membrane separator member interposed therebetween wherein the separator membrane includes a polymer coating layer. The separator is treated to provide a deposited coating of a primary plasticizer for the polymer coating layer. The device electrode and separator members are then assembled and laminated at a compressive force and temperature at which the plasticizer film softens the polymer coating of the separator member sufficiently to establish a strong interfacial bond with the matrix polymers of the electrode members and thereby form a laminated unitary cell structure. In another embodiment, the primary plasticizer comprises a component of the electrode polymeric matrix compositions.

Abstract: A method of making a laminated multi-layer electrochemical cell device structure comprising positive and negative electrode layer members of polymeric matrix composition having a microporous polyolefin membrane separator member interposed therebetween wherein the separator membrane includes a polymer coating layer. The separator is treated to provide a deposited coating of a primary plasticizer for the polymer coating layer. The device electrode and separator members are then assembled and laminated at a compressive force and temperature at which the plasticizer film softens the polymer coating of the separator member sufficiently to establish a strong interfacial bond with the matrix polymers of the electrode members and thereby form a laminated unitary cell structure. In another embodiment, the primary plasticizer comprises a component of the electrode polymeric matrix compositions.

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 of making a composition of the nominal general formula NayKxV3O8, with a unit structure of preferred nominal general formula Na1−xKxV3O8, such structure being able to accept lithium ions. The method as exemplified by the formation of Na1−xKxV3O8, comprises forming a mixture of hydroxides of sodium and potassium and then adding vanadium pentoxide (V2O5) in an amount sufficient to provide a stoichiometric ratio of approximately 1:3 of Na1−xKx to vanadium and preferably heating the mixture while stirring to cause formation of a precipitate product of the formula Na1−xKxV3O8. The new composition preferably contains x greater than or equal to 0.3 and less than or equal to 0.4. Preferred compositions have the nominal general formula Na0.7K0.3V3O8 and Na0.6K0.4V3O8.

Abstract: The use of a polymer mesh made of material that melts under thermal runaway helps improve the safety of an electrochemical device. The mesh material can increase the impedance of the battery during the thermal runaway and absorb some of the heat produced.

Abstract: Apparatus and process for continuously coating a web of current collectors with an electrically conductive adhesive material for electrochemical cells and batteries. The apparatus includes: (a) a source of the web of current collector material; (b) a reservoir containing the liquid composition; (c) a first rotatable roller having an exterior surface that is at least partially submerged in the liquid composition whereby liquid composition adheres to the exterior surface of the first rotatable roller which comes into contact with the liquid composition; and (d) a second rotatable roller that is positioned adjacent to the first rotatable roller and wherein an exterior surface of the second rotatable roller and an exterior surface of the first rotatable roller defines a nip through which the web of current collector material traverses.