Abstract: Provided are electrodes that may be used in electrochemical cells that incorporate relatively high loading of active material while also demonstrating excellent adhesion, resistance to mechanical breakdown, and also offer improved capacity retention, particularly at discharge rates of C/72 or greater.

Abstract: Provided are electrode active materials that include a metal oxide or oxynitride with a porous structure that when loaded with sulfur serve as electrochemically superior cathode active materials. The metal nitride or metal oxynitride structures are optionally used on their own, are coated with another material, or itself coats another porous structure such as a porous carbon structure that allows for excellent retention of both sulfur and polysulfides, are conductive themselves, and show long term stability and excellent cycle life.

Abstract: Provided are processes to form microporous silicon useful as mi active material in an electrode of an electrochemical cell the processes including subjecting a mixture of silicon oxide and a metal reducing agent, optionally aluminum, to mechanical milling to form mechanically activated silicon oxide/aluminium, thermally treating the silicon oxide/aluminium to reduce the silicon oxide and form Si/Al2O3 and removing at least a portion of the alumina from the Si to form a microporous silicon. The resulting electrochemically active microporous silicon is also provided with residual alumina present at 15% by weight or less that demonstrates excellent cycle life and safety.

Abstract: Provided are crosslinked or crosslinkable polymeric materials suitable for use as an electrode binder, separator, protector, or other uses in an electrochemical call. In some aspects, electrode materials are provided that include an electrode active material combined with a binder that is formed of crosslinked polymeric material, optionally crosslinked with lithium tetraborate. The binder material offers the ability to form electrodes in an aqueous solvent thereby bypassing the toxic solvents required by may prior binding systems. Also provided are processes of forming an electrode that include combining an electrode active material with a binder formed in part or wholly from a polymer and a crosslinker to form a slurry, and coating an electrically conductive substrate with the slurry to form the electrode.

Abstract: A process of reconditioning a lithium-ion cell is provided that unexpectedly improves cell capacity, reduces cold temperature impedance and increases cold cranking amps. The process involves a reconditioning step of holding a cell at a sub-discharge voltage for a recovery time. The sub-discharge voltage is 1.0V or less in many embodiments, optionally 0.0V. Holding this sub-discharge voltage for a recovery time of several hours will result in recovery of lost capacity that is in excess of that explainable by recovery of ions transferred to an anode overhang.

Abstract: Subassemblies for use in an electrochemical device are provided, as are processes for preparing the subassemblies and electrochemical cells incorporating the subassemblies. In some embodiments, the subassemblies include (a) a first electrode and (b) a separator or a first current collector or both. The first electrode is bonded to the separator or the first current collector or both. In some embodiments, the subassemblies further include a second electrode and a second current collector. In some embodiments, the electrodes or separators are sintered. Bipolar cells are also provided, including a plurality of stacked electrochemical cells that are joined in series. The positive electrode and the negative electrode of each stack include a sintered electrode.

Abstract: A process of reconditioning a lithium-ion cell is provided that unexpectedly improves cell capacity, reduces cold temperature impedance and increases cold cranking amps. The process involves a reconditioning step of holding a cell at a sub-discharge voltage for a recovery time. The sub-discharge voltage is 1.0V or less in many embodiments, optionally 0.0V. Holding this sub-discharge voltage for a recovery time of several hours will result in recovery of lost capacity that is in excess of that explainable by recovery of ions transferred to an anode overhang.

Abstract: Materials useful as electrodes for lithium batteries have very good electronic and ionic conductivities. They are fabricated from a starting mixture which includes a metal, a phosphate ion, and an additive which enhances the transport of lithium ions in the resultant material. The mixture is heated in a reducing environment to produce the material. The additive may comprise a pentavalent metal or a carbon. In certain embodiments the material is a two-phase material. Also disclosed are electrodes which incorporate the materials and lithium batteries which incorporate those electrodes.

Abstract: Materials useful as electrodes for lithium batteries have very good electronic and ionic conductivities. They are fabricated from a starting mixture which includes a metal, a phosphate ion, and an additive which enhances the transport of lithium ions in the resultant material. The mixture is heated in a reducing environment to produce the material. The additive may comprise a pentavalent metal or a carbon. In certain embodiments the material is a two-phase material. Also disclosed are electrodes which incorporate the materials and lithium batteries which incorporate those electrodes.

Abstract: Subassemblies for use in an electrochemical device are provided, as are processes for preparing the subassemblies and electrochemical cells incorporating the subassemblies. In some embodiments, the subassemblies include (a) a first electrode and (b) a separator or a first current collector or both. The first electrode is bonded to the separator or the first current collector or both. In some embodiments, the subassemblies further include a second electrode and a second current collector. In some embodiments, the electrodes or separators are sintered. Bipolar cells are also provided, including a plurality of stacked electrochemical cells that are joined in series. The positive electrode and the negative electrode of each stack include a sintered electrode.

Abstract: Materials useful as electrodes for lithium batteries have very good electronic and ionic conductivities. They are fabricated from a starting mixture which includes a metal, a phosphate ion, and an additive which enhances the transport of lithium ions in the resultant material. The mixture is heated in a reducing environment to produce the material. The additive may comprise a pentavalent metal or a carbon. In certain embodiments the material is a two-phase material. Also disclosed are electrodes which incorporate the materials and lithium batteries which incorporate those electrodes.

Abstract: A composite material includes a first phase which comprises LixMy(PO4)z wherein M is at least one metal, y and z are independently 0, and x is less than or equal to 1. The material includes a second phase which has an electronic and/or lithium ion conductivity greater than that of the first phase. The material is prepared by heating a starting mixture which includes lithium, iron, a phosphate ion, and a catalyst in a reducing atmosphere. Also disclosed are electrodes which incorporate the material and batteries which utilize those electrodes as cathodes.

Abstract: A composite material includes a first phase which is present in the form of a plurality of particles comprised of a material having the general formula LixMy(PO4)z wherein M is at least one metal, x is equal to or greater than zero, and y and z are each, independently, greater than zero. The material includes a second phase which is at least partially present in the form of a plurality of elongated filaments which extend between and establish electrical contact with at least two particles of the first phase. The filaments are comprised of a material which includes phosphorus and at least one of the at least one metal M. The material of the second phase has an electrical conductivity which is greater than the electrical conductivity of the material of the first phase. Also disclosed are methods for manufacturing the material. The material has utility as an electrode material for devices such as lithium batteries.

Abstract: A composite material which may be used as an electrode for a battery or other electrochemical device, or as a catalyst, has a matrix which is one or more metal carbide, metal nitride, metal boride, metal silicide or intermetallic compound. A metallic component is dispersed in the matrix. The metallic component comprises a metal and an agent which increases the melting point of the metal. The metallic component may be nanodispersed in the matrix. A specific material comprises a nanodispersion of tin, alloyed with an element which increases its melting point to at least 600° C., disposed in a matrix of a transition metal carbide or nitride. This material has very good utility as an anode material for lithium batteries. Also disclosed are other compositions as well as methods for manufacturing the compositions.

Abstract: A proton exchange membrane for a fuel cell is prepared from a polyimidazole polymer having the formula: wherein R1-R3 are independently H, a halogen, an alkyl or a substituted alkyl. X1 and X2 are independently or an electron withdrawing group such as CN. The membrane may be doped to alter its conductivity. The membrane may be prepared from a copolymer of the polyimidazole. Also disclosed is a fuel cell incorporating the membrane.

Abstract: A proton exchange membrane for a fuel cell is prepared from a polyimidazole polymer having the formula: 1

Abstract: A multiphase material comprises a ceramic matrix material having one or more of Sn, Sb, Bi, Pb, Ag, In, Si and Ge nanodispersed in the matrix. The ceramic matrix is preferably based upon carbides, nitrides and oxides of group IV-VI transition metals taken singly or in combination.

Abstract: A catalyst comprises an electrically conductive ceramic substrate having at least one noble metal supported thereupon. The substrate may be a transition metal based ceramic such as a carbide, nitride, boride, or silicide of a transition metal, and the noble metal may comprise a mixture of noble metals. The substrate may comprise a high surface area ceramic. Also disclosed are fuel cells incorporating the catalysts.

Abstract: A transition metal based ceramic material having the general formula Li&agr;M1−&bgr;T&bgr;NxO67, wherein M is a transition metal, T is a dopant metal, and wherein x is greater than 0 and less than or equal to l, &dgr; is 0, or less than or equal to 4; &agr; is less than or equal to 3−x, and &bgr; is less than 1 is disclosed. The ceramic material has utility as a cathode material for rechargeable lithium batteries.