Abstract: The present invention provides an electrochemical cell or battery, which has a nonmetal negative electrode (anode). That is, no solid metal active material is used in the cell. Rather than the conventional solid lithium metal anode, the active material of the new anode comprises a compound of vanadium oxide. Accordingly, the lithium cell of the invention comprises a positive electrode and a negative electrode, where the negative electrode comprises a compound of vanadium oxide which in a fully discharged state is represented by the nominal general formula V.sub.6 O.sub.13 or Li.sub.y V.sub.6 O.sub.13, y equal to 0; and, in a fully or partially lithiated, fully or partially charged state, is represented by the nominal general formula Li.sub.y V.sub.6 O.sub.13, where y is greater than 0 and less than or equal to 8. The unique negative electrode of the invention demonstrates exceptional performance without the disadvantages of metallic lithium negative electrodes.

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: Electrochemical cells having a current collector that includes a redox polymer film affords overdischarge protection. The redox polymers can reversibly insert anions and/or cations during oxidation and/or reduction thereby rendering the polymers conductive relatively to their neutral state.

Abstract: A method of fabricating polymeric matrices suitable for use in non-aqueous electrochemical cells is provided. The method includes forming an organic emulsion comprising an organic solvent and having a polar phase comprising polar polymer precursors and a non-polar phase comprising non-polar polymer precursors wherein the polar phase is substantially immiscible in the non-polar phase, said emulsion further including an effective amount of surfactant to maintain said emulsion; and initiating polymerization of said polar polymer precursors to form first polymers and of said non-polar polymer precursors to form second polymers wherein said first polymers are crosslinked by said second polymers to form a polymeric matrix. The polymeric matrix will have superior physical strength and puncture resistance.

Abstract: The present invention provides an electrochemical cell or battery which has a non-metallic negative electrode (anode). That is, no solid metal, free metal, active material is used in the cell. Rather than the conventional solid lithium metal anode, the active material of the new electrode comprises substituted carbon active material. The substituted carbon is carbonaceous material arranged in a disordered or ordered graphite structure, where atoms of carbon have been substituted in such structure by at least one other element. The invention also provides carbonaceous materials which are non-graphitic and considered amorphous, non-crystalline, highly disordered, which also have substituted therein elements other than carbon. The invention also provides a process for making such substituted carbons and for preparing an anode containing the substituted carbon.

Abstract: A method of preparing an electrochemical cell wherein the composite electrode material adheres to the metal current collector to create good electrical contact is provided. The electrode/current collector comprises a current collector, a layer of an electrically conductive adhesion promoter formed on at least one surface of the current collector which comprises an electrically conductive material and an adhesive polymer; and a composite electrode selected from the group consisting of composite cathode and composite anode, wherein the thickness of said electrically conductive adhesive promoter is sufficient to bind the composite electrode to said current collector.

Abstract: In a preferred method, a lithium compound is reacted with a manganese compound in the presence of gaseous ammonia produced by the decomposition of an ammonium compound. In the preferred method, the decomposition of the ammonium compound is initiated before the reaction occurs to form the lithium manganese oxide product spinel. It is also possible to have the decomposition initiated at about the same time as the reaction. It is possible to have the decomposition continue while the reaction to form the spinel occurs. The reaction to form the spinel occurs at an elevated temperature to provide a product of the desired nominal general formula, having a quantity of lithium corresponding to more than 1 atomic units of lithium for every 2 atomic units of manganese. This lithium-rich product, having greater than a 1:1 ratio of Mn.sup.+3 to Mn.sup.+4 is made possible by the presence of the ammonia decomposition gas.

Abstract: A solid secondary lithium electrochemical cell comprises a physical mixture of Li.sub.x n.sub.2 O.sub.4 (spinel) (0<x.ltoreq.2) and at least one second compound selected from LiFeO.sub.3, .alpha.LiFe.sub.5 O.sub.8, .beta.-LiFe.sub.5 O.sub.8, LiFe.sub.3 O.sub.4, LiFe.sub.2 O.sub.3, Li.sub.1+w, Fe.sub.5 O.sub.8 (0<w<4), Li.sub.y V.sub.2 O.sub.5 (0<y<2), and Li.sub.z FeV.sub.2 O.sub.5 (0<z<2). The cell is particularly suitable for use with anodes carbon materials.

Abstract: Non-aqueous solid electrochemical cells with improved performance can be fabricated by employing intercalation based carbon anodes comprising graphite, coke, or mixtures thereof, and an electrolyte having an electrolyte solvent formed of propylene carbonate and 4,5-dichloroethylene carbonate. The cells are particularly suited for low temperature applications.

Abstract: Superior bonding of an electrode layer to a separator layer can be achieved by applying a coat of pre-lamination solvent on the surface of the electrode and/or separator prior to attachment in fabricating electrochemical cells. The amount of solvent added is effective to dissolve at least a portion of the polymer material on the surface coated so that upon attachment the electrode and separator layers develop excellent adhesion. Preferred pre-lamination solvent has a boiling point higher than about 50.degree. C. at 760 mm of Hg. Preferred pre-lamination solvents include, for example, N,N-dimethyl formamide, N,N-dimethylacetamide, 1,3-dioxolane dioxane, methyl ethyl ketone, and mixtures thereof. Acetone can be included in the pre-lamination solvent.

Abstract: A method of fabricating electrochemical cells wherein precursors thereof can be stored for extended periods of time following extraction of plasticizer therefrom to form porous structures in the polymeric layer and the polymer binder materials of the anode and cathode is provided. Electrochemical cells are produced when the precursors are activated by the addition of an electrolyte solvent and salt.

Abstract: Heat and pressure can be used to re-flow active material at the edges of an electrode section to coat burrs at the edges of the electrode section. These burrs are typically formed in the cutting of the current collector and active material to form the electrode sections. By coating the burrs with the active material, shorts are prevented when the electrode sections are laminated with the other battery sections to form a battery stack.

Abstract: The present invention provides a method of preparing an intercalation compound of the nominal general formula Li.sub.x Mn.sub.2 O.sub.4, where x is greater than 0 and less than 2, which comprises providing a manganese compound and a lithium compound and mixing such compounds in proportion which provides the desired amount of x demonstrated by the nominal general formula. The mixed compounds are then irradiated with electromagnetic radiation, desirably microwave frequency or infrared radiation whereby manganese, lithium, and oxygen combine to form the Li.sub.x Mn.sub.2 O.sub.4 having the desired quantity x of lithium. It is desired that the heating by radiation be conducted in air. Preferably, the radiation is microwave radiation and such radiation is at a frequency which causes atomic bonds to vibrate within at least a portion of the precursor compounds and/or the solvent contained in the mixture.

Abstract: A new technique for securing into place a plurality of layers which make a battery body, and for preventing electrical short-circuits within the battery by retarding the formation of dendritic growths is disclosed. A radiation curable layer of material is coated onto a portion of at least one outwardly exposed face of a battery body, whereupon the layer of material is then cured. The cured layer of material is positioned relative to the body such that the cured layer provides support to the body in a manner to secure in place a plurality of layers which make up the battery body, thereby ensuring proper electrical contact between the plurality of layers. In addition, the cured layer of material is also positioned such that the cured layer inhibits formation of short circuiting electrical paths between the anode and cathode layers of the battery, the paths being caused by formation of dendritic growths extending out from the anode layer towards the cathode layer.

Abstract: A method for reducing capacity fading of an LiMn.sub.2 O.sub.4 spinel electrode active material comprising substituting a minor amount of Z for Mn in the LiMn.sub.2 O.sub.4 active material, where Z is a metal element having a +4 (IV) valence state and is characterized by an ability to form tetravalent chlorides. The Z substituted LiMn.sub.2 O.sub.4 active material is further characterized by a lesser rate of capacity loss with cycling as compared to LiMn.sub.2 O.sub.4 active material.

Abstract: The invention provides an electrochemical cell which is at least partially charged and which comprises a first electrode having an active material in particle form consisting essentially of at least partially lithiated graphite. The lithiated graphite particles are prepared by chemically or electrochemically inserting lithium ions into the particles prior to assembly of the cell. A second electrode which is a counter electrode to the first electrode has an active material consisting essentially of vanadium oxide.

Abstract: A method of improving the structural integrity of the binder and polymeric matrix components of electrochemical cell precursors by employing polymer blends comprising fluoropolymers is provided. The method forms porous polymeric structures that enhances the mass transport of ions in the cell which results in improved electrochemical performance. Films or webs of electrochemical cell precursors comprising the fluoropolymer blends are flexible which enhances processability.

Abstract: A method of increasing the amount of alkali metal that is available during charge/discharge of an electrochemical cell that employs carbon based intercalation anodes is provided. The method comprises of prealkaliation of the carbon anode. By subjecting the anode carbon to the prealkaliation process prior to packaging the electrochemical cell, substantially all the alkali metal (e.g., lithium) which is originally present in the cathode will be available for migration between the anode and cathode during charge/discharge.

Abstract: A battery and circuitry for monitoring state of charge of the battery are housed in a single housing. A display may be provided for displaying an indication of the state of charge, and a communication circuit may be provided for communicating electrical signals representing the state of charge to the exterior of the housing. Preferably, the battery module additionally includes a switch device for connecting the battery to terminals external to the housing and control circuitry responsive to the monitoring circuitry for causing the battery to be connected to and disconnected from the terminals. The control circuitry operates in accordance with thresholds to prevent deep discharge and overcharge.

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.