Abstract: Methods and systems of dielectric film materials to be used in capacitors. At least some of the illustrative embodiments are dielectric materials in the form of polymer film comprising a blend of polyvinylidene fluoride (PVDF) and at least one selected from the group consisting of: polyethylene terephthalate (PET); polycarbonate (PC); polyethylene naphthalate (PEN); polyphenylene sulfide (PPS); polytetrafluoroethylene (PTFE); polystyrene (PST); polysulphone (PS); polyethermide (PEM); and polyimide (PI).

Abstract: The specification discloses a consecutively wound or stacked battery system and a method for making these devices. In one aspect, battery cells are wound consecutively, separated by insulating layers, to form an integral battery system capable of producing multiple voltages. In a second, but related, aspect, multiple battery cells are wound consecutively on a large diameter mandrel, cut in a radial plane, and laid flat to form stacked battery systems capable of producing multiple voltages. Whether remaining in the consecutively wound configuration, or being cut to become a stacked cell configuration, each cell in these configurations may be selectively coupled to other cells within its consecutive winding or stack to produce desired output voltages and current ratings. In the case of the stacked battery system, this battery system may be selectively cut to provide amperage capacities to order.

Abstract: A primary reserve thermal battery includes a primarily CFx cathode, a lithium-based anode, and a solid electrolyte between the cathode and the anode. A high heat source positioned proximate the electrolyte is capable upon activation to heat the electrolyte to a temperature below about 250° C., and more precisely to the melting point of the electrolyte. At that point, the electrolyte undergoes rapid melting and becomes highly conductive, whereupon to cause the battery to produce a burst of power for delivery to an external load.

Abstract: An electrical power system for a spacecraft or other vehicle or structure comprising a structural member containing an integrated solid-state power source is disclosed. The power source includes a solar cell system and an energy storage system that are combined into a single unit or package, and in certain embodiments, are configured into the shape of a flexible aerobot balloon or a rigid nanosat surface panel. The power components of a preferred lightweight power unit, include thinly layered photovoltaic cells, a rechargeable lithium solid polymer electrolyte battery, a capacitor, electronics and thermal management capability.

Abstract: A lithium ion battery includes an anode, a cathode, and an electrolyte between the two. When the battery is in its initial charged state, as it is upon exiting the manufacturing process, the anode is composed of a first portion of lithium-deficient electrode material, and a second portion of lithium-rich or lithium-intercalated material coated on at least a part of the surface of the first portion. And the cathode is composed of lithium-deficient material adapted to react reversibly with lithium ions from the lithium-rich second portion of the anode during subsequent discharge of the battery from its initial charged state as the second portion becomes fully consumed.

Abstract: A thermal battery for operation at temperatures below about 250° C. and preferably not above about 200° C. includes a primarily CFx cathode, an electrolyte, and a lithium-based anode. The electrolyte is an organoborate lithium salt or an ionically conductive solid polymer electrolyte.

Abstract: The specification discloses a consecutively wound or stacked battery system and a method for making these devices. In one aspect, battery cells are wound consecutively, separated by insulating layers, to form an integral battery system capable of producing multiple voltages. In a second, but related, aspect, multiple battery cells are wound consecutively on a large diameter mandrel, cut in a radial plane, and laid flat to form stacked battery systems capable of producing multiple voltages. Whether remaining in the consecutively wound configuration, or being cut to become a stacked cell configuration, each cell in these configurations may be selectively coupled to other cells within its consecutive winding or stack to produce desired output voltages and current ratings. In the case of the stacked battery system, this battery system may be selectively cut to provide amperage capacities to order.

Abstract: The specification discloses a consecutively wound or stacked battery system and a method for making these devices. In one aspect, battery cells are wound consecutively, separated by insulating layers, to form an integral battery system capable of producing multiple voltages. In a second, but related, aspect, multiple battery cells are wound consecutively on a large diameter mandrel, cut in a radial plane, and laid flat to form stacked battery systems capable of producing multiple voltages. Whether remaining in the consecutively wound configuration, or being cut to become a stacked cell configuration, each cell in these configurations may be selectively coupled to other cells within its consecutive winding or stack to produce desired output voltages and current ratings. In the case of the stacked battery system, this battery system may be selectively cut to provide amperage capacities to order.

Abstract: A dimensionally stable, highly resilient, hybrid copolymer solid-solution electrolyte-retention film for use in a lithium ion battery in one preferred embodiment has a predominantly amorphous structure and mechanical strength despite contact with liquid solvent electrolyte. The film is a thinned (stretched), cast film of a homogeneous blend of two or more polymers, one of which is selected for its pronounced solvent retention properties. A very high surface area inorganic filler dispersed in the blend during formation thereof serves to increase the porosity of the film and thereby enhance electrolyte retention. The film is soaked in a solution of liquid polymer with liquid organic solvent electrolyte and lithium salt, for absorption thereof. Use of a cross-linked liquid polymer enhances trapping of molecules of the electrolyte into pores of the film. The electrolyte film is sandwiched between flexible active anode and cathode layers to form the lithium ion battery.

Abstract: A dimensionally stable, highly resilient, hybrid copolymer solid-solution electrolyte-retention film for use in a lithium ion battery in one preferred embodiment has a predominantly amorphous structure and mechanical strength despite contact with liquid solvent electrolyte. The film is a thinned (stretched), cast film of a homogeneous blend of two or more polymers, one of which is selected for its pronounced solvent retention properties. A very high surface area inorganic filler dispersed in the blend during formation thereof serves to increase the porosity of the film and thereby enhance electrolyte retention. The film is soaked in a solution of liquid polymer with liquid organic solvent electrolyte and lithium salt, for absorption thereof. Use of a cross-linked liquid polymer enhances trapping of molecules of the electrolyte into pores of the film. The electrolyte film is sandwiched between flexible active anode and cathode layers to form the lithium ion battery.

Abstract: A lithium ion battery includes an anode, a cathode, and an electrolyte between the two. When the battery is in its initial charged state, as it is upon exiting the manufacturing process, the anode is composed of a first portion of lithium-deficient electrode material, and a second portion of lithium-rich or lithium-intercalated material coated on at least a part of the surface of the first portion. And the cathode is composed of lithium-deficient material adapted to react reversibly with lithium ions from the lithium-rich second portion of the anode during subsequent discharge of the battery from its initial charged state as the second portion becomes fully consumed.

Abstract: An electrochemical capacitor includes a polymer thin film, a liquid electrolyte absorbed in the polymer thin film, and thin flexible active electrode layers constituting anode and cathode composed of energy dense material of high intrinsic surface area positioned at either side of the electrolyte-retaining polymer thin film to tightly sandwich it between the electrode layers. In one embodiment, the capacitor includes a polymer electrolyte in which a polymer thin film is cast from the base polymer and impregnated with the electrolyte solution, which contains a salt for ionic conduction. In another embodiment, the base polymer material includes an ionically conducting polymer, a perfluorocarbon polymer backbone to which sulfonic acid sites are permanently anchored. The energy dense material of the electrode layers may be physically mixed with battery active material to enhance the capacity and discharge time of the capacitor.

Abstract: All-solid-state electrochemical cells and batteries employing very thin film, highly conductive polymeric electrolyte and very thin electrode structures are disclosed, along with economical and high-speed methods of manufacturing. A preferred embodiment is a rechargeable lithium polymer electrolyte battery. New polymeric electrolytes employed in the devices are strong yet flexible, dry and non-tacky. The new, thinner electrode structures have strength and flexibility characteristics very much like thin film capacitor dielectric material that can be tightly wound in the making of a capacitor. A wide range of polymers, or polymer blends, characterized by high ionic conductivity at room temperature, and below, are used as the polymer base material for making the solid polymer electrolytes. The preferred polymeric electrolyte is a cationic conductor. In addition to the polymer base material, the polymer electrolyte compositions exhibit a conductivity greater than 1×10−4 S/cm at 25° C.

Abstract: A thermal battery for operation at temperatures below about 250° C. and preferably not above about 200° C. includes a primarily CFx cathode, an electrolyte, and a lithium-based anode. The electrolyte is an organoborate lithium salt or an ionically conductive solid polymer electrolyte.

Abstract: A wide range of solid polymer electrolytes characterized by high ionic conductivity at room temperature, and below, are disclosed. These all-solid-state polymer electrolytes are suitable for use in electrochemical cells and batteries. A preferred polymer electrolyte is a cationic conductor which is flexible, dry, non-tacky, and lends itself to economical manufacture in very thin film form. Solid polymer electrolyte compositions which exhibit a conductivity of at least approximately 10−3-10−4 S/cm at 25° C. comprise a base polymer or polymer blend containing an electrically conductive polymer, a metal salt, a finely divided inorganic filler material, and a finely divided ion conductor.

Abstract: The specification discloses a consecutively wound or stacked battery system and a method for making these devices. In one aspect, battery cells are wound consecutively, separated by insulating layers, to form an integral battery system capable of producing multiple voltages. In a second, but related, aspect, multiple battery cells are wound consecutively on a large diameter mandrel, cut in a radial plane, and laid flat to form stacked battery systems capable of producing multiple voltages. Whether remaining in the consecutively wound configuration, or being cut to become a stacked cell configuration, each cell in these configurations may be selectively coupled to other cells within its consecutive winding or stack to produce desired output voltages and current ratings. In the case of the stacked battery system, this battery system may be selectively cut to provide amperage capacities to order.

Abstract: A dimensionally stable, highly resilient, hybrid copolymer solid-solution electrolyte-retention film for use in a lithium ion battery in one preferred embodiment has a predominantly amorphous structure and mechanical strength despite contact with liquid solvent electrolyte. The film is a thinned (stretched), cast film of a homogeneous blend of two or more polymers, one of which is selected for its pronounced solvent retention properties. A very high surface area inorganic filler dispersed in the blend during formation thereof serves to increase the porosity of the film and thereby enhance electrolyte retention. The film is soaked in a solution of liquid polymer with liquid organic solvent electrolyte and lithium salt, for absorption thereof. Use of a cross-linked liquid polymer enhances trapping of molecules of the electrolyte into pores of the film. The electrolyte film is sandwiched between flexible active anode and cathode layers to form the lithium ion battery.

Abstract: An electrical power system for a spacecraft or other vehicle or structure comprising a structural member containing an integrated solid-state power source is disclosed. The power source includes a solar cell system and an energy storage system that are combined into a single unit or package, and in certain embodiments, are configured into the shape of a flexible aerobot balloon or a rigid nanosat surface panel. The power components of a preferred lightweight power unit, include thinly layered photovoltaic cells, a rechargeable lithium solid polymer electrolyte battery, a capacitor, electronics and thermal management capability.

Abstract: An electrochemical capacitor includes a polymer thin film, a liquid electrolyte absorbed in the polymer thin film, and thin flexible active electrode layers constituting anode and cathode composed of energy dense material of high intrinsic surface area positioned at either side of the electrolyte-retaining polymer thin film to tightly sandwich it between the electrode layers. In one embodiment, the capacitor includes a polymer electrolyte in which a polymer thin film is cast from the base polymer and impregnated with the electrolyte solution, which contains a salt for ionic conduction. In another embodiment, the base polymer material includes an ionically conducting polymer, a perfluorocarbon polymer backbone to which sulfonic acid sites are permanently anchored. The energy dense material of the electrode layers may be physically mixed with battery active material to enhance the capacity and discharge time of the capacitor.

Abstract: An electrochemical capacitor includes an ionically conductive polymer thin film, a liquid electrolyte absorbed in the polymer thin film, and thin flexible active electrode layers constituting anode and cathode composed of energy dense material of high intrinsic surface area positioned at either side of the electrolyte-retaining polymer thin film to tightly sandwich it between the electrode layers. In one embodiment, the capacitor includes a polymer electrolyte in which a polymer thin film is cast from the base polymer and impregnated with the electrolyte solution, which contains a salt for ionic conduction. In another embodiment, the base polymer material includes an ionically conducting polymer, a perfluorocarbon polymer backbone to which sulfonic acid sites are permanently anchored. The energy dense material of the electrode layers may be physically mixed with battery active material to enhance the capacity and discharge time of the capacitor.