Abstract: A current collector including: a polymer film including a first major surface, an opposite second major surface, and a plurality of openings extending through a thickness of the polymer film; a first layer on the first major surface of the polymer film; a second layer on the second major surface of the polymer film; and a third layer on an inner surface of an opening of the plurality of openings, wherein the third layer contacts the first layer and the second layer, and wherein the first layer, the second layer, and the third layer each independently has an electrical conductivity of greater than 10 Siemens per meter.

Abstract: A liquid retaining pressure relief valve for electrochemical battery cells is provided including a pressure regulator and a membrane vent that are mounted to the top and bottom ends of a threaded valve housing or plug. The valve housing or plug screws into the cell cover from the outside of the cell such that the membrane vent is internal to the cell. The membrane vent includes a thin gas permeable liquid repellant membrane that is molded into the body of the vent. The membrane is preferably composed of an expanded polytetraflouroethylene (ePTFE) polymer.

Abstract: A non-aqueous electric current producing electrochemical cell is provided comprising an anode and a cathode, an ionically permeable separator interposed between the anode and the cathode, and a non-aqueous electrolyte, the electrolyte comprising an ionically conducting salt in a non-aqueous medium, the ionically conducting salt corresponding to the formula: M+(Z*(J*)j(X*)x)?, wherein: M is a lithium atom, Z* is an anion group containing two or more Lewis basic sites and comprising less than 50 atoms not including hydrogen atoms, J* independently each occurance is a Lewis acid coordinated to at least one Lewis basic site of Z*, and optionally two or more such J* groups may be joined together in a moiety having multiple Lewis acidic functionality, X* independently each occurrence is selected from the group consisting of H, C1-C4 alkyl, alkoxide, halide and mixtures thereof, j is an integer from 2 to 12, and x is an integer from 0 to 4.

Abstract: A negative electrode material is provided for a rechargeable lithium-ion electrochemical cell comprising an intimate mixture of finely-divided elemental nickel and tin particles characterized in that the total oxygen content of said material is less than about 6 percent by weight of the mixture. Preferably, the negative electrode material comprises from about 5 to 90 percent by weight nickel particles and from about 10 to 95 percent by weight tin particles, the nickel and tin particles being composed of discrete, non-spherical, smooth particles of a size ranging from about 1 to 10 micrometers and having a density which is greater than about 5 grams per milliter and a specific surface area of less than about 1 square meter per gram.

Abstract: An anhydrous inorganic gel-polymer electrolyte is prepared using a non-aqueous sol-gel process. The inorganic gel-polymer is prepared by reacting a metal halide (SiCl4) and an alcohol (tert-butyl alcohol) in a diluent solution containing a lithium salt (lithium bisperfluoroethanesulfonimide) and at least one carbonate. The resulting porous silicon oxide network encapsulates the liquid electrolyte. The gel polymer electrolyte can serve as both a separator and an electrolyte in a Li-ion cell. The material is stable and has demonstrated minimal flammability. Lithium-ion electrochemical cells made with the inorganic gel-polymer electrolyte function similarly to Li-ion cells made with a liquid electrolyte. The cells have low capacity fade, 0.69%, and low irreversible capacity, 7.6%.

Abstract: A solid polymer electrolyte for an electrolytic cell is prepared by a sol-gel process in which an active metal ion conducting liquid electrolyte, e.g. a lithium-ion electrolyte, containing a salt which is stable in the presence of water, e.g. lithium bisperfluoroethanesulfonimide, LiN(SO2C2F5)2, is admixed in aqueous solution with an alkoxide, e.g. silica alkoxide, to form a liquid precursor which is added to the electrolytic cell between the anode and cathode thereof and allowed to solidify in situ to form the solid electrolyte.

Abstract: A negative electrode material is provided for a rechargeable lithium-ion electrochemical cell comprising an intimate mixture of finely-divided elemental nickel and tin particles characterized in that the total oxygen content of said material is less than about 6 percent by weight of the mixture. Preferably, the negative electrode material comprises from about 5 to 90 percent by weight nickel particles and from about 10 to 95 percent by weight tin particles, the nickel and tin particles being composed of discrete, non-spherical, smooth particles of a size ranging from about 1 to 10 micrometers and having a density which is greater than about 5 grams per milliter and a specific surface area of less than about 1 square meter per gram.

Abstract: A novel and improved polymeric coating composition and method for applying adherent film coatings to metallic substrates is provided wherein a finely divided or powdered coating material, such as ceramic powders, carbon powders or metallic particles, is substantially uniformly dispersed within a polymeric binder comprising a host polymer and a suitable bonding promoter. The use of a bonding promoter allows a significant amount of cross-linking to occur in situ after the coating composition has been applied to the metallic substrate thereby achieving good adherence between the coating and the substrate and improving the robustness of the coating.

Abstract: An anhydrous inorganic gel-polymer electrolyte is prepared using a non-aqueous sol-gel process. The inorganic gel-polymer is prepared by reacting a metal halide (SiCl4) and an alcohol (tert-butyl alcohol) in a diluent solution containing a lithium salt (lithium bisperfluoroethanesulfonimide) and at least one carbonate. The resulting porous silicon oxide network encapsulates the liquid electrolyte. The gel polymer electrolyte can serve as both a separator and an electrolyte in a Li-ion cell. The material is stable and has demonstrated minimal flammability. Lithium-ion electrochemical cells made with the inorganic gel-polymer electrolyte function similarly to Li-ion cells made with a liquid electrolyte. The cells have low capacity fade, 0.69%, and low irreversible capacity, 7.6%.

Abstract: A solid polymer electrolyte for an electrochemical cell is prepared by a sol-gel process in which an active metal ion conducting liquid electrolyte, e.g. a lithium-ion electrolyte, containing a salt which is stable in the presence of water, e.g. lithium bisperfluoroethanesulfonimide, LiN(SO2C2F5)2, is admixed in aqueous solution with an alkoxide, e.g. silica alkoxide, to form a liquid precursor which is added to the electrochemical cell between the anode and cathode thereof and allowed to solidify in situ to form the solid electroyte.

Abstract: Substantial improvements to the cycle life of silverzinc cells were obtained by the addition of small amounts of bismuth oxide (Bi.sub.2 O.sub.3) to the negative zinc electrode, in conjunction with cadmium oxide (CdO) and lead oxide (PbO). These improvements, which can be extended to other zinc-based alkaline batteries, especially nickel-zinc and zinc-air, can also be realized in conjunction with other metal oxides and hydroxides, particularly indium hydroxide ?In(OH).sub.3 !, which, like Bi.sub.2 O.sub.3, has the additional advantage of being non-toxic.

Abstract: There is disclosed a double-layer capacitor having electrodes formed of a current collector positioned against a non-woven web of non-activated carbon fibers impregnated with carbon particles and positioned on either side of a porous layer within a container including a suitable electrolyte and having a conductor connected to each current collector of each electrode wherein the carbon fibers are of a surface area of less than 100 m.sup.2 /g, preferably less than 5 m.sup.2 /g.

Abstract: A novel and improved rechargeable, lithium-ion battery system is composed of a plurality of individual electrochemical cells having positive and negative electrodes disposed in opposite face-to-face arrangement with a porous separator containing electrolyte therebetween, and wherein the positive and negative electrodes of adjacent cells are disposed in contact respectively with opposite sides of a common current-collecting element forming a unitary bipolar structure. The negative electrode comprises a layer of carbon adhered to one side of the current-collecting element while the positive electrode comprises a layer containing a lithium transition metal oxide or sulfide compound adhered to the other opposite side of the element. The unitary bipolar structures containing the positive and negative electrodes of adjacent cells include outer peripheral, electrically-insulating seal members, preferably in the form of plastic insulating rings, which are joined together in a sealed stacked array.

Abstract: A process for controlling the hydrogen that evolves as a parasitic by-product during the operation of a metal/air fuel cell which comprises feeding into a catalytic recombiner a gaseous stream containing hydrogen being discharged from the metal/air cell together with an amount of oxygen sufficient to convert the hydrogen to water, said oxygen gas concentration being monitored and adjusted to maintain an oxygen concentration in the gaseous stream entering the recombiner in the range of 1.5 to 2.5% by volume. The process is of particular value in closed system aluminum/oxygen fuel cells in which small amounts of hydrogen must be removed, e.g. the sealed hull of an underwater vehicle.

Abstract: A high discharge rate electrochemical battery structure is disclosed as having a perforated disc electrode stack comprising pluralities of disc electrodes respectively connected to a pair of busbars. Each disc electrode has a tab with two fins which are bent at 90 degrees to the disc electrode. Each fin is inserted between two parts of the corresponding busbar and welded thereto. The design of the busbars and disc electrodes provides for redundancy of electrical contact, high thermal and electrical conductivity and improved resistance to mechanical shock.

Abstract: A getter electrode is provided to prevent dendrite formation and growth in electrochemical cells having alkali metal anodes such as lithium. The getter electrode includes a relatively thin, for example, about 2 mil thick layer of active material selected from the group consisting of carbon, graphite and mixtures thereof disposed on an inert substrate such as glass fiber separator paper. The getter electrode is positioned between the anode and the cathode in the cell and is separated from the anode and cathode by separators of fiberglass paper or the like. The getter electrode functions as a cathode with low rate capabilities. When dendrites arrive at the getter electrode from the anode or cathode, they are immediately discharged and not allowed to grow beyond the getter electrode. The result is a dramatic improvement in the cell cycle life and capacity retention.