Abstract: A thin, flexible, porous polymer composite film useful as a separator for a molten-salt thermal battery having a lower temperature electrolyte melt formulation 150-250° C. typical of molten alkyl nitrate/nitrite comprises 5-50 weight percent of electrically non-conductive ceramic comprising a thermoplastic in the range of 50-95 weight percent. The high-surface-area ceramic is comprised of MgO (preferred), Al2O3, AlSiO2, BN, AlN, or a mixture of two or more of the foregoing; and providing a porous network having a porosity of not less than 30 percent by volume. Likewise, the electrodes can be manufactured with polymer-bonded particulates of porous ceramic such as MgO. Cells for thermal batteries are fabricated in the uncharged state, e.g., Carbon/lithiated metal oxide. Additionally, a polymer-based thermal battery construction can free design from the rigid stacked-pellet battery design. Alternatively, a porous ceramic composite film of MgO coated non-conductive ceramic fibers may be used as a separator.

Abstract: An improved housing for a rolled-ribbon electrochemical device is provided. The housing comprises a fastener that aligns first and second cups during assembly and maintains electrode contact independent of external pressure on the housing eliminating the possibility of an open circuit state for a cell. In one alternative embodiment, the fastener comprises a stem that fits into a hollow tube and resists detachment from the tube. In another alternative embodiment, the fastener comprises a stem that fits into a grommet and resists detachment from the grommet. In yet another alternative embodiment, the fastener comprises a tube that fits into a grommet and resists detachment from the grommet.

Abstract: The present invention is directed toward a laminated electrode and porous separator film combination including a solid electrolyte salt within the porous separator film, the combination comprising layer of powdered cathode material adhering to a surface of a separator film with a solid electrolyte therebetween; the separator film comprising 50% to 95% by weight of electrically non-conductive ceramic fibers having a coating of magnesium oxide on the surface of the fibers in an amount in the range of 5% to 50% by weight; wherein the ceramic fibers comprise Al2O3, AlSiO2, BN, AlN, or a mixture of two or more of the foregoing; and the magnesium oxide coating interconnects the ceramic fibers providing a porous network of magnesium oxide-coated fibers having a porosity of not less than 50% by volume; the pores of the network containing a solid electrolyte salt in an amount of up to 95% by volume based on pore volume of the network.

Abstract: The present invention is directed toward a laminated electrode and porous separator film combination including a solid electrolyte salt within the porous separator film, the combination comprising layer of powdered cathode material adhering to a surface of a separator film with a solid electrolyte therebetween; the separator film comprising 50% to 95% by weight of electrically non-conductive ceramic fibers having a coating of magnesium oxide on the surface of the fibers in an amount in the range of 5% to 50% by weight; wherein the ceramic fibers comprise Al2O3, AlSiO2, BN, AlN, or a mixture of two or more of the foregoing; and the magnesium oxide coating interconnects the ceramic fibers providing a porous network of magnesium oxide-coated fibers having a porosity of not less than 50% by volume; the pores of the network containing a solid electrolyte salt in an amount of up to 95% by volume based on pore volume of the network.

Abstract: A thin, flexible, porous ceramic composite (PCC) film useful as a separator for a molten-salt thermal battery comprises 50% to 95% by weight of electrically non-conductive ceramic fibers comprising a coating of magnesium oxide on the surface of the fibers in an amount in the range of 5% to 50% by weight. The ceramic fibers comprise Al2O3, AlSiO2, BN, AlN, or a mixture of two or more of the foregoing; and the magnesium oxide coating interconnects the ceramic fibers providing a porous network of magnesium oxide-coated fibers having a porosity of not less than 50% by volume. The pores of the film optionally can include a solid electrolyte salt. A laminated electrode/PCC film combination is also provided, as well as a thermal battery cell comprising the PCC film as a separator.

Abstract: An electrochemical device comprising alternating layers of positive and negative electrodes separated from each other by separator layers. The electrode layers extend beyond the periphery of the separator layers providing superior contact between the electrodes and battery terminals, eliminating the need for welding the electrode to the terminal. Electrical resistance within the battery is decreased and thermal conductivity of the cell is increased allowing for superior heat removal from the battery and increased efficiency. Increased internal pressure within the battery can be alleviated without damaging or removing the battery from service while keeping the contents of the battery sealed off from the atmosphere by a pressure release system. Nonoperative cells within a battery assembly can also be removed from service by shorting the nonoperative cell thus decreasing battery life.

Abstract: An electrochemical device comprising alternating layers of positive and negative electrodes separated from each other by separator layers. The electrode layers extend beyond the periphery of the separator layers providing superior contact between the electrodes and battery terminals, eliminating the need for welding the electrode to the terminal. Electrical resistance within the battery is decreased and thermal conductivity of the cell is increased allowing for superior heat removal from the battery and increased efficiency. Increased internal pressure within the battery can be alleviated without damaging or removing the battery from service while keeping the contents of the battery sealed off from the atmosphere by a pressure release system. Nonoperative cells within a battery assembly can also be removed from service by shorting the nonoperative cell thus decreasing battery life.

Abstract: An electrochemical device comprising alternating layers of positive and negative electrodes separated from each other by separator layers. The electrode layers extend beyond the periphery of the separator layers providing superior contact between the electrodes and battery terminals, eliminating the need for welding the electrode to the terminal. Electrical resistance within the battery is decreased and thermal conductivity of the cell is increased allowing for superior heat removal from the battery and increased efficiency. Increased internal pressure within the battery can be alleviated without damaging or removing the battery from service while keeping the contents of the battery sealed off from the atmosphere by a pressure release system. Nonoperative cells within a battery assembly can also be removed from service by shorting the nonoperative cell thus decreasing battery life.

Abstract: A thin, flexible, porous ceramic composite (PCC) film useful as a separator for a molten-salt thermal battery comprises 50% to 95% by weight of electrically non-conductive ceramic fibers comprising a coating of magnesium oxide on the surface of the fibers in an amount in the range of 5% to 50% by weight. The ceramic fibers comprise Al2O3, AlSiO2, BN, AlN, or a mixture of two or more of the foregoing; and the magnesium oxide coating interconnects the ceramic fibers providing a porous network of magnesium oxide-coated fibers having a porosity of not less than 50% by volume. The pores of the film optionally can include a solid electrolyte salt. A laminated electrode/PCC film combination is also provided, as well as a thermal battery cell comprising the PCC film as a separator.

Abstract: An electrochemical device comprising alternating layers of positive and negative electrodes separated from each other by separator layers. The electrode layers extend beyond the periphery of the separator layers providing superior contact between the electrodes and battery terminals, eliminating the need for welding the electrode to the terminal. Electrical resistance within the battery is decreased and thermal conductivity of the cell is increased allowing for superior heat removal from the battery and increased efficiency. Increased internal pressure within the battery can be alleviated without damaging or removing the battery from service while keeping the contents of the battery sealed off from the atmosphere by a pressure release system. Nonoperative cells within a battery assembly can also be removed from service by shorting the nonoperative cell thus decreasing battery life.

Abstract: A thin, fibrous ceramic article useful as a separator for a molten-salt thermal battery. A film of ceramic fiber and a bonding constituent that in processing enhances the strength flexibility and molten electrolyte retention of the film when used as a separator layer. The bonding constituent becomes a significant portion of the separator, such that the separator's chemical properties are a reflection of the binder. MgO is a preferred binder, but other electrically-insulating ceramics, e.g., AlN, are available. The ceramic fiber separator becomes a carrier element in a fabrication process, which allows the formation of dense electrode without the use of high-tonnage hydraulic presses.

Abstract: An electrochemical device comprising alternating layers of positive and negative electrodes separated from each other by separator layers. The electrode layers extend beyond the periphery of the separator layers providing superior contact between the electrodes and battery terminals, eliminating the need for welding the electrode to the terminal. Electrical resistance within the battery is decreased and thermal conductivity of the cell is increased allowing for superior heat removal from the battery and increased efficiency. Increased internal pressure within the battery can be alleviated without damaging or removing the battery from service while keeping the contents of the battery sealed off from the atmosphere by a pressure release system. Nonoperative cells within a battery assembly can also be removed from service by shorting the nonoperative cell thus decreasing battery life.

Abstract: A carbonate electrolyte of the Li/Na or CaBaLiNa system. The Li/Na carbonate has a composition displaced from the eutectic composition to diminish segregation effects in a molten carbonate fuel cell. The CaBaLiNa system includes relatively small amounts of Ca.sub.2 CO.sub.3 and BaCO.sub.3, and preferably of equimolar amounts. The presence of both Ca and BaCO.sub.3 enables lower temperature fuel cell operation.

Abstract: A cell or battery of cells having improved overcharge tolerance and increased power capability, and methods for the construction of such cells or batteries, via electrolyte modification.

Abstract: Ceramic materials which exhibit stability in severely-corrosive environments having high alkali-metal activity, high sulfur/sulfide activity and/or molten halides at temperatures of 200.degree.-550.degree. C. or organic salt (including SO.sub.2 and SO.sub.2 Cl.sub.2) at temperatures of 25.degree.-200.degree. C. These sulfide ceramics form stoichiometric (single-phase) compounds with sulfides of Ca, Li, Na, K, Al, Mg, Si, Y, La, Ce, Ga, Ba, Zr and Sr and show melting-points that are sufficiently low and have excellent wettability with many metals (Fe, Ni, Mo) to easily form metal/ceramic seals. Ceramic compositions are also formulated to adequately match thermal expansion coefficient of adjacent metal components.

Abstract: A method of making a negative electrode, the electrode made thereby and a secondary electrochemical cell using the electrode. Lithium, silicon and nickel is alloyed in a prescribed proportion forming an electroactive material, to provide an improved electrode and cell.

Abstract: A molten salt electrolyte/separator for battery and related electrochemical systems including a molten electrolyte composition and an electrically insulating solid salt dispersed therein, to provide improved performance at higher current densities and alternate designs through ease of fabrication.

Abstract: Ceramic materials which exhibit stability in severely-corrosive environments having high alkali-metal activity, high sulfur/sulfide activity and/or molten halides at temperatures of 200.degree.-550.degree. C. or organic salt (including SO.sub.2 and SO.sub.2 Cl.sub.2) at temperatures of 25.degree.-200.degree. C. These sulfide ceramics form stoichiometric (single-phase) compounds with sulfides of Ca, Li, Na, K, Al, Mg, Si, Y, La, Ce, Ga, Ba, Zr and Sr and show melting-points that are sufficiently low and have excellent wettability with many metals (Fe, Ni, Mo) to easily form metal/ceramic seals. Ceramic compositions are also formulated to adequately match thermal expansion coefficient of adjacent metal components.

Abstract: A compact, hermetic feedthrough apparatus comprising interfitting sleeve portions constructed of chemically-stable materials to permit unique battery designs and increase battery life and performance.

Abstract: An electrochemical device comprises a plurality of cells, each cell including a laminate cell membrane, made up of a separator/electrolyte means interposed between alternating positive and negative electrodes, each type of electrode being respectively in common contact to a single current collector.