Abstract: The invention is directed to an electrochemical cell having at least one of its electrodes produced by coating a slurry mixture of an active material, possibly a conductive additive, and a binder dispersed in a solvent and contacted to a perforated current collector foil. It is particularly important that the active slurry does not move through the perforations of the current collector. For this reason, a barrier is placed against the opposite side of the current collector to block the perforations as the current collector is being coated with the slurry. After volatilizing the solvent, a second, different active material is coated to the opposite side of the current collector, either as a slurry, a pressed powder, a pellet or a free standing sheet. An example of this is a cathode having a configuration of: SVO/current collector CFx. The opposed active materials on the current collector can also be of the same chemistry.

Abstract: A drop-fill assembly and method for uniformly distributing electrode active particles onto a current collector is described. The drop-fill assembly comprises a conduit containing two or more spaced apart sifting screens. A funnel is located upstream of the sifting screens to distribute an electrode active powder into the center of the conduit with a downward velocity. The mesh of any one sifting screen is out of direct alignment with respect to the next or previous screen. The electrode active powder is poured into the funnel and distributed across the conduit's cross-section as it bounces off and passes through the misaligned sifting screens. The powder exits at the bottom of the conduit lying in a thin, uniform layer on a current collector, taking on the shape of the desired electrode due to the boundary of the conduit and pressing fixtures located above and beneath the current collector. The powder layer is then pressed on to the current collector to produce an electrode.

Abstract: The minimization or elimination of swelling in lithium cells containing CFx as part of the cathode electrode and discharged under high rate applications is described. When CFx materials are synthesized from fibrous carbonaceous materials, in comparison to petroleum coke, cell swelling is greatly reduced, and in some cases eliminated. Preferred precursors are carbon fibers and MCMB.

Abstract: A pin to plate joint and method of making the joint comprising a plate comprising an entry side and an exit side with the plate defining cutouts, and the pin movable through the plate from the entry side to the exit side and in doing so pushes tab members at angles to the exit side of the plate at bends. The bends in the plate define an opening in the plate, and flow spaces are defined between the pin sidewall and the bends in the plate, with the tab members being heated to form melted tab material and flowing the melted tab material into the flow spaces and cooling, forming a pin to plate joint.

Abstract: The present invention is directed to providing a lithium carbonate passivation layer on lithium through exposure of the active material to gaseous carbon dioxide prior to cell assembly. This results in an electrochemical cell which possesses improved safety and voltage delay characteristics in comparison to prior art cells comprising unexposed lithium. The preferred cell is of a lithium oxyhalide chemistry.

Abstract: An autoclavable elctrochemical cell which may be used in an implantable medical device. The anode active material is lithium or other material from groups IA and IIA of the Periodic Table and having a melting point greater than about 150 degrees C. The cathode active material is silver vanadium oxide or other metal oxide or carbon monoflouride. The solvent for the electrolyte has a boiling point greater than about 100 degrees C. and a dielectric constant greater than about 5 so that the cell. may be dimensionally and chemically stable during repeated exposures of about one hour each to the autoclaving temperatures.

Abstract: An alkali metal/solid cathode electrochemical cell, such as of a Li/SVO couple, having the cathode material supported on a titanium current collector screen coated with a carbonaceous material is described. The thusly-coated titanium current collector provides the cell with higher rate capability in comparison to cells of a similar chemistry having the cathode active material contacted to an uncoated titanium current collector.

Abstract: A resistance welding electrode that is particularly suited for resistance spot welding a workpiece to a substrate without cross-contaminating specific portions of the workpiece is described. This is done by sheathing an internal surface of the welding electrode with a thermoplastic polymeric material. Then, there is only contact between the welding electrode and the workpiece at the very distal end of the electrode adjacent to where the workpiece is to be connected to the substrate. Contamination in this area is not detrimental because subsequent workpiece plating does not take place there.

Abstract: Miniature defibrillators and cardioverters detect abnormal heart rhythms and automatically apply electrical therapy to restore normal heart function. Critical components in these devices are aluminum electrolytic capacitors, which store and deliver one or more life-saving bursts of electric charge to a heart of a patient. This type of capacitor requires regular “reform” to preserve its charging efficiency over time. Because reform expends valuable battery life, manufacturers developed wet-tantalum capacitors, which are generally understood not to require reform. Yet, the present inventors discovered through extensive study that wet-tantalum capacitors exhibit progressively worse charging efficiency over time. Accordingly, to address this problem, the inventors devised unique reform techniques for wet-tantalum capacitors.

Abstract: A reverse mismatched compression glass-to-metal seal is described. In this seal, the coefficient of thermal expansion of the insulating glass is lower than that of the terminal lead and, the ferrule or casing body has a similar or higher coefficient of thermal expansion than that of the terminal lead.

Abstract: A lithium ion electrochemical cell having high charge/discharge capacity, long cycle life and exhibiting a reduced first cycle irreversible capacity, is described. The stated benefits are realized by the addition of at least one carbonate additive to an electrolyte comprising an alkali metal salt dissolved in a solvent mixture including ethylene carbonate, dimethyl carbonate, ethyl methyl carbonate and diethyl carbonate. The preferred additive is either a linear or cyclic carbonate containing covalent O—X and O—Y bonds on opposite sides of a carbonyl group wherein at least one of the O—X and the O—Y bonds has a dissociation energy less than about 80 kcal/mole.

Abstract: A mixture of polymeric binders that is insoluble in nonaqueous organic electrolytes activating alkali metal or alkali metal ion electrochemical cells, is described. The mixed binder formulation provides electrodes that are flexible and non-brittle, and cells incorporating the electrodes are dischargeable at elevated temperatures. A preferred binder formulation is a mixture of polyvinylidene and polyimide binders.

Abstract: An alkali metal secondary electrochemical cell, and preferably a lithium ion cell, activated with an equilibrated quaternary solvent system, is described. The solvent system comprises a mixture of dialkyl carbonates and cyclic carbonates, and preferably a quaternary mixture of dimethyl carbonate, diethyl carbonate, ethylmethyl carbonate and ethylene carbonate with dimethyl carbonate, diethyl carbonate and ethylmethyl carbonate in an equilibrated molar mixture. Lithium ion cells activated with this electrolyte have good room temperature cycling characteristics and excellent low temperature discharge behavior.

Abstract: An electrode having the configuration: first active material/current collector/second active material is described. One of the electrode active materials in a cohesive form of active particles being firmly held together as part of the same mass is incapable of moving through the current collector to the other side thereof. However, in an un-cohesive form of active particles not being firmly held together as part of a mass, the one electrode active material is capable of communication through the current collector. The other or second active material is in a form in-capable of communication through the current collector, whether it is in a cohesive or un-cohesive powder form. Then, the assembly of first active material/current collector/second active material is pressed from either the direction of the first electrode active material to the second electrode active material, or visa versa.

Abstract: The invention includes a method of using a cell, such as a battery. In a method according to the invention, the cell is charged, discharged, and a voltage of the cell is measured after the discharge period. The measured voltage is compared to a standard voltage, and then the cell is charged again.

Abstract: The present invention relates to a new sandwich cathode design having two cathode active materials provided on opposite sides of a current collector. The respective active materials are similar in terms of, for example, their rate capability, their energy density, or some other parameter. However, one material may have an advantage over the other in one characteristic, but is disadvantageous in another. The cathode is built in a sandwich configuration having a first one of the active materials sandwiched between two current collectors. Then, the second active material is provided in contact with at least the other side of one of the current collectors, and preferably facing the anode. An exemplary cathode has the following configuration: MnO2/current collector/SVO/current collector/MnO2.

Abstract: A method for improving the electrical conductivity of a substrate of metal, metal alloy or metal oxide comprising depositing a small or minor amount of metal or metals from Group VIIIA metals (Fe, Ru, Os, Co, Rh, Ir, Ni, Pd, Pt) or from Group IA metals (Cu, Ag, Au) on a substrate of metal, metal alloys and/or metal oxide from Group IVA metals (Ti, Zr, Hf), Group VA metals (V, Nb, Ta), Group VIA metals (Cr, Mo, W) and Al, Mn, Ni and Cu and then directing a high energy beam onto the substrate to cause an intermixing of the deposited material with the native oxide of the substrate metal or metal alloy. The native oxide layer is changed from electrically insulating to electrically conductive. The step of depositing can be carried out, for example, by ion beam assisted deposition, electron beam deposition, chemical vapor deposition, physical vapor deposition, plasma assisted, low pressure plasma and plasma spray deposition and the like.

Abstract: A new sandwich negative electrode design for a secondary cell is provided comprising a “sacrificial” alkali metal along with a carbonaceous anode material. In the case of a hard carbon anode material, the sacrificial alkali metal is preferably lithium and is sized to compensate for the initial irreversible capacity of this anode material. Upon activating the cells, the lithium metal automatically intercalates into the hard carbon anode material. That way, the sacrificial lithium is consumed and compensates for the generally unacceptable irreversible capacity of hard carbon. The superior cycling longevity of hard carbon now provides a secondary cell of extended use beyond that know for conventional secondary cells having only graphitic anode materials.

Abstract: An electrode component for an electrochemical cell or a capacitor is described wherein the electrode is produced by physical vapor depositing an electrode active material onto a substrate to coat the substrate. The thusly produced electrode is useful as a cathode in a primary electrochemical cell and as a cathode and an anode in a secondary cell, and as an electrode in an electrochemical capacitor and an electrolytic capacitor.

Abstract: The negative electrode or anode for a secondary electrochemical cell comprising a mixture of graphite or “hairy carbon” and a lithiated metal oxide, a lithiated mixed metal oxide or a lithiated metal sulfide, and preferably a lithiated metal vanadium oxide, is described. A most preferred formulation is graphite mixed with lithiated silver vanadium oxide or lithiated copper silver vanadium oxide.