Abstract: A porous membrane may be manufactured with a high content of filler material and a polymer binder. After forming the membrane, the membrane may be post processed to reform the polymer binder into a stronger yet still porous membrane. The post processing may include bringing the membrane above the melt temperature of the polymer or by immersing the membrane in a solvent. Photomicrographs show that the structure may change, yet the performance of the material in batteries and other electrochemical cells may remain the same or even improve.

Abstract: An electrochemical cell may have a PVDF microporous membrane that may be adhesively bonded to electrodes. The adhesive may be a mixture of a solvent and non-solvent that may cause the PVDF membrane to become tacky and adhere to an electrode without collapsing. An adhesively bonded cell may be constructed using multiple layers of adhesively bonded membranes and electrodes. In some embodiments, the adhesive solution may be used as a sizing to prepare electrodes for bonding.

Abstract: A microporous membrane may be manufactured using a polymer binder and a filler material using a liquid pore forming agent having a surface free energy that is lower than that of the filler and higher than that of the polymer. The repulsion of the pore forming agent to the polymer may form the pores of the membrane, while the attraction of the polymer to the filler may encapsulate the filler into the structure of the membrane. The filler may be particles that are on the order of or smaller than the wall thickness of the microporous structure.

Abstract: An electrochemical cell may have a PVDF microporous memberane that may be adhesively bonded to electrodes. The adhesive may be a mixture of a solvent and non-solvent that may cause the PVDF membrane to become tacky and adhere to an electrode without collapsing. An adhesively bonded cell may be constructed using multiple layers of adhesively bonded membranes and electrodes. In some embodiments, the adhesive solution may be used as a sizing to prepare electrodes for bonding.

Abstract: A porous membrane may have a high concentration of spherical fillers with a polymer binder. The polymer binder may have an affinity for the filler materials and may hold the filler materials together in a porous structure with high tortuosity and consistent pore size. The membrane may be manufactured with a reinforcing web, such as non-woven web. The membrane may be greater than 50% porous with a less than 1 micron pore size. Within the pore walls that may be less than 0.02 microns in width, a densely packed filler material may have an average diameter of less than 0.005 microns.

Abstract: An electrochemical cell may have a PVDF microporous membrane that may be adhesively bonded to electrodes. The adhesive may be a mixture of a solvent and non-solvent that may cause the PVDF membrane to become tacky and adhere to an electrode without collapsing. An adhesively bonded cell may be constructed using multiple layers of adhesively bonded membranes and electrodes. In some embodiments, the adhesive solution may be used as a sizing to prepare electrodes for bonding.

Abstract: The present invention provides microporous polymers and methods for producing and using the same. In particular, microporous polymers of the present invention are highly porous as indicated by a Gurley air permeability flow rate of about 4 seconds or less per mL of air flow per 25 micron of microporous polymer thickness per square inch.

Abstract: A porous membrane may have a high concentration of spherical fillers with a polymer binder. The polymer binder may have an affinity for the filler materials and may hold the filler materials together in a porous structure with high tortuosity and consistent pore size. The membrane may be manufactured with a reinforcing web, such as non-woven web. The membrane may be greater than 50% porous with a less than 1 micron pore size. Within the pore walls that may be less than 0.02 microns in width, a densely packed filler material may have an average diameter of less than 0.005 microns.

Abstract: A porous membrane may be manufactured with a high content of filler material and a polymer binder. After forming the membrane, the membrane may be post processed to reform the polymer binder into a stronger yet still porous membrane. The post processing may include bringing the membrane above the melt temperature of the polymer or by immersing the membrane in a solvent. Photomicrographs show that the structure may change, yet the performance of the material in batteries and other electrochemical cells may remain the same or even improve.

Abstract: A microporous membrane may be manufactured using a polymer binder and a filler material using a liquid pore forming agent having a surface free energy that is lower than that of the filler and higher than that of the polymer. The repulsion of the pore forming agent to the polymer may form the pores of the membrane, while the attraction of the polymer to the filler may encapsulate the filler into the structure of the membrane. The filler may be particles that are on the order of or smaller than the wall thickness of the microporous structure.

Abstract: The present invention provides microporous polymers and methods for producing and using the same. In particular, microporous polymers of the present invention are highly porous as indicated by a Gurley air permeability flow rate of about 4 seconds or less per mL of air flow per 25 micron of microporous polymer thickness per square inch.

Abstract: A microporous battery separator may be laminated to electrodes and manipulated through manufacturing on a continuous roll of material. Batteries may be constructed by layering the laminated electrodes and separator into various configurations, including flat and wound cell batteries. The separator may or may not contain a nonwoven or other reinforcement, and may be laminated to the electrodes using several different methods.

Abstract: An electrochemical cell may have a PVDF microporous membrane that may be adhesively bonded to electrodes. The adhesive may be a mixture of a solvent and non-solvent that may cause the PVDF membrane to become tacky and adhere to an electrode without collapsing. An adhesively bonded cell may be constructed using multiple layers of adhesively bonded membranes and electrodes. In some embodiments, the adhesive solution may be used as a sizing to prepare electrodes for bonding.

Abstract: The present invention provides microporous polymers and methods for producing and using the same. In particular, microporous polymers of the present invention are highly porous as indicated by a Gurley air permeability flow rate of about 4 seconds or less per mL of air flow per 25 micron of microporous polymer thickness per square inch.

Abstract: An electrochemical device is proposed that uses a novel electrolyte system technology, based on the use of conventional electrodes with high specific capacity selected to provide operating cell potentials within a range of approximately between 1.2 and 2.4 volts along with the use of an unconventional electrolyte solution. Specifically, his novel electrolyte system is based on the use of an aqueous electrolyte solution that has a window of voltage stability above the range of conventional aqueous electrolytes. Any of a variety of acid, neutral or basic aqueous solutions or gels with or without any of a variety of co-solvents, inorganic or organic salts or ionic liquids may be employed provided the conductivity and stability of the electrolytes are compatible with the selected electrochemical couples so as to provide high cell capacity, high rate capability and long term stability.

Abstract: A method for forming an open celled membrane. A gelled polymer is formed of a polymer having a known polymer interfacial tension and a known polymer melting point. A first liquid into which the polymer is soluble, the first liquid being selected to have a first liquid interfacial tension to be 95% or less than the polymer interfacial tension is mixed with a second liquid that is miscible in the first liquid to form a mixture. The second liquid is selected to have a second liquid interfacial tension to be 105% or greater than the polymer interfacial tension. The polymer is dissolved into the mixture to form a saturated solution. The saturated solution reaches a solution forming temperature which is less than the polymer melting point. The saturated solution is spread on a substrate. The first liquid from the saturated solution to form the gelled polymer.

Abstract: A microporous fire resistant film may be coated or laminated to form a composite textile may be used as a component for various types of apparel. The film may form a vapor permeable barrier that has a hydrostatic head and may repel liquid. The film may form a highly tortuous mechanical barrier to allergens, pathogens, particles, or biological organisms. The film may also serve as a high capacity reservoir for active materials such as antimicrobial materials, UV absorbers, scent dispersers, organism terminating or repelling materials, or other active or passive agents.

Abstract: A component for an electrochemical cell is formed using centrifugal forces to densify an electrode or electrode material. In some embodiments, a binding agent may be used to mechanically bind active material for processing and normal operation. The binding agent may be a dispersed solid material as well as a pore forming material. Centrifugal casting may be used to densify electrode films for lithium ion batteries, as well as densification of other materials in various forms used in batteries, capacitors, fuel cells, sensors, and other electrochemical devices. In some embodiments, multiple layers of a device may be constructed using single or plural centrifugal processing steps.

Abstract: Improved anodes having active materials consisting substantially of one or more lithium insertion compounds further consisting of transition metal chalcogenides or oxides capable of reversibly intercalating lithium ions are disclosed. Cells utilizing these anodes are also disclosed.

Abstract: An active metal non-aqueous electrochemical cell including a lithium anode, an organic electrolyte system, a cathode contained in a cell housing, and at least one hermetically sealed pin-type lead extending through a cell header is provided with an hermetically sealed, pressure and/or temperature actuated, snap-action header diaphragm disconnect mechanism fixed to, and which snaps outward to disconnect, the pin terminal from the internal cell lead in response to elevated internal pressure reaching a sufficient amount to operate the snap-action mechanism. The position of the snap-action header diaphragm is visible outside of the cell.