Abstract: In a system for applying material to a substrate, a first material is applied to the substrate and the substrate coated with the first material is drawn between a pair of rollers to form a material layer. The roller which contacts the first material is grounded and an electrostatic charging device sprays electrostatically charged particles of a second material onto the roller such that the particles are evenly dispersed on the surface of the roller. The particles of the second material on the roller tend to prevent the first material from adhering to the roller and are preferably incorporated into the second material.

Abstract: The invention provides a new family of compounds and a method of making the compounds. The new compounds are useful as ion conductive salts, and particularly useful as salts for batteries. The compounds of the invention are prepared from three principal reagents, bis (trifluoromethanesufonyl) methane (CF.sub.3 SO.sub.2).sub.2 CH.sub.2 ; benzoyl chloride; and pyridine which facilitates reaction and then is removed. A precursor sodium salt (CF.sub.3 SO.sub.2).sub.2 CHNa is first prepared. Then, equimolar amounts of the precursor sodium salt and pyridine are dissolved in anhydrous acetonitrile. A stoichiometric amount of the selected substitute benzoyl chloride is then added drop by drop. After addition of Li.sub.3 PO.sub.4, there is pyridine release and formation of the product of the aforesaid two reagents. In the benzene ring, R.sub.1, R.sub.2, R.sub.3, R.sub.4, and R.sub.5 are each identical or different and are each independently selected from hydrogen and an electron withdrawing substituent.

Abstract: Improved adhesion of an electrode layer with an electrolyte or separator layer can be achieved by substantially preventing polymer binder and plasticizer from absorbing into the substrate. This is achieved by impregnating the substrate with polymer and plasticizer prior to applying the electrode mixture which contains an electrode active material, polymer binder, plasticizer, and solvent onto the substrate. Alternatively, prior to applying the electrode mixture, a coating containing a mixture of polymer and plasticizer is applied unto the substrate to form a coated substrate wherein the coating is substantially pervious to solvent and is substantially impervious to said polymer and plasticizer.

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: This invention is directed to a solid electrolyte containing an alkane multifunctional acrylate polymeric matrix, a salt, a solvent, and preferably a viscosifier, as well as, electrolytic cells prepared from such solid electrolytes.

Abstract: A method of making a lithium manganese oxide intercalation compound in powder form comprises forming a solution of a manganese compound and a lithium compound in a solvent; and spray-drying the solution by atomizing the solution to form droplets thereof and contacting the droplets with a stream of non-oxidizing hot gas at a first elevated temperature to evaporate at least a major portion by weight of the solvent present in the solution thereby providing a precursor powder. The precursor powder is heated at a second elevated temperature which is below the melting point of the lithium manganese oxide compound. The second temperature is sufficient to cause reaction among constituents in the precursor powder thereby providing the lithium manganese oxide compound having a spinel unit structure.

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 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: An electrochemical cell comprising a first electrode; a counter-electrode which forms an electrochemical couple with the first electrode; and an electrolyte comprising a solvent and a solute. The solvent comprises a dialkyl carbonate of the formula R'OCOOR" where each of R' and R' represents an alkyl, and having at least one of R' and R" selected from the group consisting of non-linear, branched alkyls where R' and R" are preferably different from one another.

Abstract: Blisters or air bubbles between battery layers can be a problem with the lamination of battery layers. The blistering can be reduced by a two-step pressure-applying method. In the first step, a relatively small first pressure is applied to the battery layers. The relatively small first pressure is done such that air bubbles between the battery layers are not formed. Next, a second larger pressure is applied to the battery layers to laminate the battery layers together. In an alternate embodiment, the pressure applied to the battery layers is changed from a low pressure to laminating pressures in one step.

Abstract: The invention provides a battery having an electrode active material comprising a mixed-metal sulfate compound. The mixed-metal consists of at least one alkali metal and at least one transition metal. Preferably, the sulfate compound is a polysulfate having more than one SO.sub.4 group. The invention also provides novel lithium-metal-sulfate compounds and electrodes comprising such novel compounds.

Abstract: Disclosed herein is a safety feature for batteries comprising an integrated series of lithium-ion bi-cells. Each individual bi-cell comprises, sequentially, an anode, a film separator, a cathode, a film separator, and an anode. When multiple bi-cells are joined within a single package an insulator element, preferably an electrolyte permeable insulator element, is placed between anode elements of adjoining bi-cells. This insulator element appears to restrict internal shorting during crushing of the battery, thus avoiding undesirable effects of shorting such as thermal run-away and producing a safer battery.

Abstract: Electrochemical cells with improved adhesion of the laminant components can be fabricated by forming an electrode directly on the surface of electrolyte or separator film. This process obviates the need to prepare the anode or cathode in a separate procedure.

Abstract: The invention provides an electrochemical cell which comprises a first electrode and a second electrode which is a counter electrode to said first electrode. The first electrode comprises a phosphorous compound of the general formula, Li.sub.3 M'M" (PO.sub.4).sub.3. M' and M" are the same or different from one another. Where M' and E" are the same, they are metals having more than one oxidation state. Where M' and M" are different from one another, they are selected from the group of metals where at least one of M' and M" has more than one oxidation state.

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.

Abstract: The present invention provides a novel composition and method for preventing decomposition of one or more electrochemical cell components comprising an electrode having an active material, and an electrolyte. The method of the invention, for the first time, effectively overcomes problems which arise between the interaction of cell components and contaminate water retained in a cell. Such contaminate water reacts with the electrolyte which comprises a salt of lithium in a solvent. Solubilizing of the salt in solution with attendant interaction between the salt and water causes formation of hydrogen-containing acids. The method of the invention effectively blocks decomposition of a lithium metal oxide cathode active material, and particularly lithium manganese oxide (LMO, nominally LiMn.sub.2 O.sub.4).

Abstract: Non-aqueous solid electrochemical cells with improved performance can be fabricated by employing an electrolyte having an electrolyte solvent which contains a carbonate having the structure R'OCOOR" where R' and R" are independently selected from branched alkyl groups with 3 to 7 carbons. A preferred solvent includes diisopropyl carbonate. The cells are particularly suited for low and high temperature applications.

Abstract: Provided by the present invention is a new anode material comprised of a carbon obtained by pyrolyzing a polymer of a conjugated vinyl monomer. The carbon is suitable for a lithium intercalated anode as it offers potential advantages of high capacity. The economics of manufacturing such anodes are also beneficial.