Abstract: Protected anode architectures have ionically conductive protective membrane architectures that, in conjunction with compliant seal structures and anode backplanes, effectively enclose an active metal anode inside the interior of an anode compartment. This enclosure prevents the active metal from deleterious reaction with the environment external to the anode compartment, which may include aqueous, ambient moisture, and/or other materials corrosive to the active metal. The compliant seal structures are substantially impervious to anolytes, catholyes, dissolved species in electrolytes, and moisture and compliant to changes in anode volume such that physical continuity between the anode protective architecture and backplane are maintained. The protected anode architectures can be used in arrays of protected anode architectures and battery cells of various configurations incorporating the protected anode architectures or arrays.

Abstract: Protected anode architectures provide a hermetic enclosure for an active metal (e.g., alkali metal, such as lithium) anode inside an anode compartment. The compartment is substantially impervious to ambient moisture and battery components such as catholyte (electrolyte about the cathode, and in some aspects catholyte may also comprise dissolved or suspended redox active species and redox active liquids), and prevents volatile components of the protected anode, such as anolyte (electrolyte about the anode), from escaping, while allowing for active metal ion transport between the anode and cathode into and out of the anode compartment.

Abstract: Protected anode architectures have ionically conductive protective membrane architectures that, in conjunction with compliant seal structures and anode backplanes, effectively enclose an active metal anode inside the interior of an anode compartment. This enclosure prevents the active metal from deleterious reaction with the environment external to the anode compartment, which may include aqueous, ambient moisture, and/or other materials corrosive to the active metal. The compliant seal structures are substantially impervious to anolytes, catholyes, dissolved species in electrolytes, and moisture and compliant to changes in anode volume such that physical continuity between the anode protective architecture and backplane are maintained. The protected anode architectures can be used in arrays of protected anode architectures and battery cells of various configurations incorporating the protected anode architectures or arrays.

Abstract: Protected anode architectures have ionically conductive protective membrane architectures that, in conjunction with compliant seal structures and anode backplanes, effectively enclose an active metal anode inside the interior of an anode compartment. This enclosure prevents the active metal from deleterious reaction with the environment external to the anode compartment, which may include aqueous, ambient moisture, and/or other materials corrosive to the active metal. The compliant seal structures are substantially impervious to anolytes, catholyes, dissolved species in electrolytes, and moisture and compliant to changes in anode volume such that physical continuity between the anode protective architecture and backplane are maintained. The protected anode architectures can be used in arrays of protected anode architectures and battery cells of various configurations incorporating the protected anode architectures or arrays.

Abstract: Protected anode architectures have ionically conductive protective membrane architectures that, in conjunction with compliant seal structures and anode backplanes, effectively enclose an active metal anode inside the interior of an anode compartment. This enclosure prevents the active metal from deleterious reaction with the environment external to the anode compartment, which may include aqueous, ambient moisture, and/or other materials corrosive to the active metal. The compliant seal structures are substantially impervious to anolytes, catholytes, dissolved species in electrolytes, and moisture and compliant to changes in anode volume such that physical continuity between the anode protective architecture and backplane are maintained. The protected anode architectures can be used in arrays of protected anode architectures and battery cells of various configurations incorporating the protected anode architectures or arrays.

Abstract: Protected anode architectures have ionically conductive protective membrane architectures that, in conjunction with compliant seal structures and anode backplanes, effectively enclose an active metal anode inside the interior of an anode compartment. This enclosure prevents the active metal from deleterious reaction with the environment external to the anode compartment, which may include aqueous, ambient moisture, and/or other materials corrosive to the active metal. The compliant seal structures are substantially impervious to anolytes, catholyes, dissolved species in electrolytes, and moisture and compliant to changes in anode volume such that physical continuity between the anode protective architecture and backplane are maintained. The protected anode architectures can be used in arrays of protected anode architectures and battery cells of various configurations incorporating the protected anode architectures or arrays.

Abstract: Voltage delay in an active metal anode/liquid cathode battery cell can be significantly reduced or completely alleviated by coating the active metal anode (e.g., Li) surface with a thin layer of an inorganic compound with Li-ion conductivity using chemical treatment of Li surface. Particularly, preferred examples of such compounds include lithium phosphate, lithium metaphosphate, and/or their mixtures or solid solutions with lithium sulphate. These compounds can be formed on the Li surface by treatment with diluted solutions of the following individual acids: H3PO4, HPO3 and H2SO4, their acidic salts, or their binary or ternary mixtures in a dry organic solvent compatible with Li, for instance in 1,2-DME; by various deposition techniques. Such chemical protection of the Li or other active metal electrode significantly reduces the voltage delay due to protected anode's improved stability toward the electrolyte.

Abstract: Electro-winning of active metal (e.g., lithium) ions from a variety of sources including industrial waste, and recycled lithium and lithium-ion batteries is accomplished with an electrolyzer having a protected cathode that is stable against aggressive solvents, including water, aqueous electrolytes, acid, base, and a broad range of protic and aprotic solvents. The electrolyzer has a highly ionically conductive protective membrane adjacent to the alkali metal cathode that effectively isolates (de-couples) the alkali metal electrode from solvent, electrolyte processing and/or cathode environments, and at the same time allows ion transport in and out of these environments. Isolation of the cathode from other components of a battery cell or other electrochemical cell in this way allows the use of virtually any solvent, electrolyte and/or anode material in conjunction with the cathode. The electrolyzer can be configured and operated to claim or reclaim lithium or other active metals from such sources.

Abstract: Voltage delay in an active metal anode/liquid cathode battery cell can be significantly reduced or completely alleviated by coating the active metal anode (e.g., Li) surface with a thin layer of an inorganic compound with Li-ion conductivity using chemical treatment of Li surface. Particularly, preferred examples of such compounds include lithium phosphate, lithium metaphosphate, and/or their mixtures or solid solutions with lithium sulphate. These compounds can be formed on the Li surface by treatment with diluted solutions of the following individual acids: H3PO4, HPO3 and H2SO4, their acidic salts, or their binary or ternary mixtures in a dry organic solvent compatible with Li, for instance in 1,2-DME; by various deposition techniques. Such chemical protection of the Li or other active metal electrode significantly reduces the voltage delay due to protected anode's improved stability toward the electrolyte.

Abstract: Voltage delay in an active metal anode/liquid cathode battery cell can be significantly reduced or completely alleviated by coating the active metal anode (e.g., Li) surface with a thin layer of an inorganic compound with Li-ion conductivity using chemical treatment of Li surface. Particularly, preferred examples of such compounds include lithium phosphate, lithium metaphosphate, and/or their mixtures or solid solutions with lithium sulphate. These compounds can be formed on the Li surface by treatment with diluted solutions of the following individual acids: H3PO4, HPO3 and H2SO4, their acidic salts, or their binary or ternary mixtures in a dry organic solvent compatible with Li, for instance in 1,2-DME; by various deposition techniques. Such chemical protection of the Li or other active metal electrode significantly reduces the voltage delay due to protected anode's improved stability toward the electrolyte.

Abstract: Protected anode architectures have ionically conductive protective membrane architectures that, in conjunction with compliant seal structures and anode backplanes, effectively enclose an active metal anode inside the interior of an anode compartment. This enclosure prevents the active metal from deleterious reaction with the environment external to the anode compartment, which may include aqueous, ambient moisture, and/or other materials corrosive to the active metal. The compliant seal structures are substantially impervious to anolytes, catholytes, dissolved species in electrolytes, and moisture and compliant to changes in anode volume such that physical continuity between the anode protective architecture and backplane are maintained. The protected anode architectures can be used in arrays of protected anode architectures and battery cells of various configurations incorporating the protected anode architectures or arrays.

Abstract: Disclosed are compositions and methods for alleviating the problem of reaction of lithium or other alkali or alkaline earth metals with incompatible processing and operating environments by creating an ionically conductive chemical protective layer on the lithium or other reactive metal surface. Such a chemically produced surface layer can protect lithium metal from reacting with oxygen, nitrogen or moisture in ambient atmosphere thereby allowing the lithium material to be handled outside of a controlled atmosphere, such as a dry room. Production processes involving lithium are thereby very considerably simplified. One example of such a process is the processing of lithium to form negative electrodes for lithium metal batteries.

Abstract: Active metal and active metal intercalation electrode structures and battery cells having ionically conductive protective architecture including an active metal (e.g., lithium) conductive impervious layer separated from the electrode (anode) by a porous separator impregnated with a non-aqueous electrolyte (anolyte). This protective architecture prevents the active metal from deleterious reaction with the environment on the other (cathode) side of the impervious layer, which may include aqueous or non-aqueous liquid electrolytes (catholytes) and/or a variety electrochemically active materials, including liquid, solid and gaseous oxidizers. Safety additives and designs that facilitate manufacture are also provided.

Abstract: A pre-fabricated electrochemical device having a dense electrolyte disposed between an anode and a cathode preferably deposited as thin films is bonded to a porous electrically conductive support. A second porous electrically conductive support may be bonded to a counter electrode of the electrochemical device. Multiple electrochemical devices may be bonded in parallel to a single porous support, such as a perforated sheet to provide a planar array. Planar arrays may be arranged in a stacked interconnected array. A method of making a supported electrochemical device is disclosed wherein the method includes a step of bonding a pre-fabricated electrochemical device layer to an existing porous metal or porous metal alloy layer.

Abstract: The process described herein provides a simple and cost effective method for making crack free, high density thin ceramic film. The steps involve depositing a layer of a ceramic material on a porous or dense substrate. The deposited layer is compacted and then the resultant laminate is sintered to achieve a higher density than would have been possible without the pre-firing compaction step.

Abstract: Multiple stacks of tubular electrochemical cells having a dense electrolyte disposed between an anode and a cathode preferably deposited as thin films arranged in parallel on stamped conductive interconnect sheets or ferrules. The stack allows one or more electrochemical cell to malfunction without disabling the entire stack. Stack efficiency is enhanced through simplified gas manifolding, gas recycling, reduced operating temperature and improved heat distribution.

Abstract: Protected anode architectures for active metal anodes have a polymer adhesive seal that provides an hermetic enclosure for the active metal of the protected anode inside an anode compartment. The compartment is substantially impervious to ambient moisture and battery components such as catholyte (electrolyte about the cathode), and prevents volatile components of the protected anode, such as anolyte (electrolyte about the anode), from escaping. The architecture is formed by joining the protected anode to an anode container. The polymer adhesive seals provide an hermetic seal at the joint between a surface of the protected anode and the container.

Abstract: Protected anode architectures have ionically conductive protective membrane architectures that, in conjunction with compliant seal structures and anode backplanes, effectively enclose an active metal anode inside the interior of an anode compartment. This enclosure prevents the active metal from deleterious reaction with the environment external to the anode compartment, which may include aqueous, ambient moisture, and/or other materials corrosive to the active metal. The compliant seal structures are substantially impervious to anolytes, catholyes, dissolved species in electrolytes, and moisture and compliant to changes in anode volume such that physical continuity between the anode protective architecture and backplane are maintained. The protected anode architectures can be used in arrays of protected anode architectures and battery cells of various configurations incorporating the protected anode architectures or arrays.

Abstract: Battery cells having lithium intercalation anodes protected by surface coatings and active sulfur cathodes, and methods for their fabrication, provide improved battery cell performance.

Abstract: Active metal electrochemical structure, in particular an active metal negative electrode (anode) protected with an ionically conductive protective architecture incorporating a glassy, ceramic or glass-ceramic solid electrolyte material based on lithium hafnium phosphate, and associated electrochemical devices and methods, provides advantages over conventional structures. The protective architecture prevents the active metal from deleterious reaction with the environment on the other (cathode) side of the architecture, which may include aqueous, air or organic liquid electrolytes and/or electrochemically active materials.