Patent US6153337A successfully refreshed from Google Patents.
US6153337A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Separators for electrochemical cells
Assignee: Sion Power Corp
•
Filing: 1997-12-19
•
Granted: 2000-11-28
•
Expires: 2017-12-19
Abstract
Abstract This invention pertains to separators for electrochemical cells which comprise a microporous pseudo-boehmite layer; electrolyte elements comprising such separators; electrical current producing cells comprising such separators; and methods of making such separators, electrolyte elements and cells.
Inventors
- 👤 Steven A. Carlson
- 👤 Zhongyi Deng
- 👤 Qicong Ying
- 👤 Terje A. Skotheim
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 11:52
CPC Classifications
H; H01; H01M; H01M10/00; H01M10/05; H01M10/052; H01M10/0525; H01M50/00; H01M50/40; H01M50/46; B; B01; B01D; B01D71/00; B01D71/02; B01D71/024; B01D71/025; H01M10/056; H01M10/0561; H01M10/0563; H01M10/0564; H01M10/0565; H01M4/00; H01M4/02; H01M4/13; H01M4/136; H01M50/409; H01M50/431; H01M50/434; H01M50/443; H01M6/00; H01M6/14; H01M2300/00; H01M2300/0017; H01M2300/0065; H01M2300/0068; Y; Y02; Y02E; Y02E60/00; Y02E60/10; Y02P; Y02P70/00; Y02P70/50; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49108; Y10T29/49115
Claims Analysis
Total Claims: 118
Claim 1
Independent Claim
111 words
A separator for an electric current producing cell, wherein said separator comprises a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, and further wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer, wherein said separator is produced by a process comprising: (a) coating onto a substrate a liquid mixture comprising a boehmite sol and a binder; (b) drying the coating formed in step (a) to yield said microporous pseudo-boehmite layer; and (c) delaminating said pseudo-boehmite layer from said substrate, to provide a free-standing separator comprising said pseudo-boehmite layer.
Claim 2
Dependent Claim
111 words
A separator for an electric current producing cell, wherein said separator comprises a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, and further wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer, wherein said separator is produced by a process comprising: (a) coating onto a substrate a liquid mixture comprising a boehmite sol and a binder; (b) drying the coating formed in step (a) to yield said microporous pseudo-boehmite layer; and (c) delaminating said pseudo-boehmite layer from said substrate, to provide a free-standing separator comprising said pseudo-boehmite layer.
Claim 3
Dependent Claim
20 words
The separator of claim 1, wherein said pseudo-boehmite layer has a pore volume from 0.3 to 1.0 cm 3 /g.
Claim 4
Dependent Claim
20 words
The separator of claim 1, wherein said pseudo-boehmite layer has a pore volume from 0.4 to 0.7 cm 3 /g.
Claim 5
Dependent Claim
21 words
The separator of claim 1, wherein the average pore diameter of said pseudo-boehmite layer is from 2 nm to 30 nm.
Claim 6
Dependent Claim
21 words
The separator of claim 1, wherein the average pore diameter of said pseudo-boehmite layer is from 3 nm to 10 nm.
Claim 7
Dependent Claim
27 words
The separator of claim 1, wherein said binder is present in the amount of 5 to 70% of the weight of the pseudo-boehmite in said pseudo-boehmite layer.
Claim 8
Dependent Claim
26 words
The separator of claim 1, wherein said binder is selected from the group consisting of: polyvinyl alcohols, polyethylene oxides, polyvinyl pyrrolidones, copolymers thereof, and mixtures thereof.
Claim 9
Dependent Claim
19 words
The separator of claim 1, wherein said pseudo-boehmite layer has a thickness of from 1 micron to 50 microns.
Claim 10
Dependent Claim
19 words
The separator of claim 1, wherein said pseudo-boehmite layer has a thickness of from 1 micron to 25 microns.
Claim 11
Dependent Claim
19 words
The separator of claim 1, wherein said pseudo-boehmite layer has a thickness of from 5 microns to 15 microns.
Claim 12
Dependent Claim
17 words
The separator of claim 1, wherein said binder is present within the pores of said psuedo-boehmite layer.
Claim 13
Dependent Claim
75 words
A separator for an electric current producing cell, wherein said separator comprises a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, and further wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer, wherein said pseudo-boehmite layer is impregnated with an ionic conductive polymer, and wherein said pseudo-boehmite layer further comprises a binder.
Claim 14
Dependent Claim
75 words
A separator for an electric current producing cell, wherein said separator comprises a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, and further wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer, wherein said pseudo-boehmite layer is impregnated with an ionic conductive polymer, and wherein said pseudo-boehmite layer further comprises a binder.
Claim 15
Dependent Claim
39 words
The separator of claim 12, wherein said ionic conductive polymer comprises a polymer resin which has been cured by an energy source selected from the group consisting of: heat, ultraviolet light, visible light, infrared radiation, and electron beam radiation.
Claim 16
Dependent Claim
32 words
An electrolyte element for an electric current producing cell, wherein said electrolyte element comprises: (a) a microporous pseudo-boehmite layer; and, (b) an organic electrolyte contained within the pores of said pseudo-boehmite layer.
Claim 17
Dependent Claim
32 words
An electrolyte element for an electric current producing cell, wherein said electrolyte element comprises: (a) a microporous pseudo-boehmite layer; and, (b) an organic electrolyte contained within the pores of said pseudo-boehmite layer.
Claim 18
Dependent Claim
21 words
The electrolyte element of claim 14, wherein said pseudo-boehmite layer has a pore volume from 0.02 to 2.0 cm 3 /g.
Claim 19
Dependent Claim
21 words
The electrolyte element of claim 14, wherein said pseudo-boehmite layer has a pore volume from 0.3 to 1.0 cm 3 /g.
Claim 20
Dependent Claim
21 words
The electrolyte element of claim 14, wherein said pseudo-boehmite layer has a pore volume from 0.4 to 0.7 cm 3 /g.
Claim 21
Dependent Claim
22 words
The electrolyte element of claim 14, wherein the average pore diameter of said pseudo-boehmite layer is from 1 nm to 300 nm.
Claim 22
Dependent Claim
22 words
The electrolyte element of claim 14, wherein the average pore diameter of said pseudo-boehmite layer is from 2 nm to 30 nm.
Claim 23
Dependent Claim
22 words
The electrolyte element of claim 14, wherein the average pore diameter of said pseudo-boehmite layer is from 3 nm to 10 nm.
Claim 24
Dependent Claim
14 words
The electrolyte element of claim 14, wherein said pseudo-boehmite layer further comprises a binder.
Claim 25
Dependent Claim
28 words
The electrolyte element of claim 21, wherein said binder is present in the amount of 5 to 70% of the weight of the pseudo-boehmite in said pseudo-boehmite layer.
Claim 26
Dependent Claim
27 words
The electrolyte element of claim 21, wherein said binder is selected from the group consisting of: polyvinyl alcohols, polyethylene oxides, polyvinyl pyrrolidones, copolymers thereof, and mixtures thereof.
Claim 27
Dependent Claim
18 words
The electrolyte element of claim 21, wherein said binder is present within the pores of said pseudo-boehmite layer.
Claim 28
Dependent Claim
30 words
The electrolyte element of claim 14, wherein said organic electrolyte comprises one or more materials selected from the group consisting of: liquid electrolytes, gel polymer electrolytes, and solid polymer electrolytes.
Claim 29
Dependent Claim
45 words
The electrolyte element of claim 25, wherein said gel polymer electrolyte or said solid polymer electrolyte comprises a polymer resin which has been cured by an energy source selected from the group consisting of: heat, ultraviolet light, visible light, infrared radiation, and electron beam radiation.
Claim 30
Dependent Claim
39 words
A method of forming an electric current producing cell, said method comprising the steps of: (a) providing an anode; (b) providing a cathode; and, (c) interposing an electrolyte element according to claim 14 between said anode and said cathode.
Claim 31
Dependent Claim
33 words
The method of claim 27, wherein the organic electrolyte of said electrolyte element comprises one or more materials selected from the group consisting of liquid electrolytes, gel polymer electrolytes, and solid polymer electrolytes.
Claim 32
Dependent Claim
38 words
The method of claim 28, wherein, after step (c), there is a subsequent step (d) comprising the imbibition of a solution comprising one or more ionic electrolyte salts and one or more electrolyte solvents into said electrolyte element.
Claim 33
Dependent Claim
22 words
The method of claim 29, wherein said organic electrolyte after step (c) and prior to step (d) comprises no ionic electrolyte salt.
Claim 34
Independent Claim
119 words
A method of making a separator for an electric current producing cell, said separator comprising a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, wherein said method comprises the steps of: (a) coating onto a substrate a liquid mixture comprising a boehmite sol, wherein said substrate comprises a cathode coating layer on at least one outermost surface and the liquid mixture comprising said boehmite sol is coated onto said cathode coating layer; and (b) drying the coating formed in step (a) to yield said microporous pseudo-boehmite layer, wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer.
Claim 35
Independent Claim
119 words
A method of making a separator for an electric current producing cell, said separator comprising a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, wherein said method comprises the steps of: (a) coating onto a substrate a liquid mixture comprising a boehmite sol, wherein said substrate comprises a cathode coating layer on at least one outermost surface and the liquid mixture comprising said boehmite sol is coated onto said cathode coating layer; and (b) drying the coating formed in step (a) to yield said microporous pseudo-boehmite layer, wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer.
Claim 36
Dependent Claim
19 words
The method of claim 31, wherein said pseudo-boehmite layer has a thickness of from 1 micron to 50 microns.
Claim 37
Dependent Claim
19 words
The method of claim 31, wherein said pseudo-boebmite layer has a thickness of from 1 micron to 25 microns.
Claim 38
Dependent Claim
19 words
The method of claim 31, wherein said pseudo-boehmite layer has a thickness of from 5 microns to 15 microns.
Claim 39
Independent Claim
104 words
A method of making a separator for an electric current producing cell, said separator comprising a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, wherein said method comprises: (a) coating onto a substrate a liquid mixture comprising a boehmite sol; (b) drying the coating formed in step (a) to yield said microporous pseudo-boehmite layer, wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer; and (c) delaminating said pseudo-boehmite layer from said substrate, to provide a free-standing separator comprising said pseudo-boehmite layer.
Claim 40
Independent Claim
104 words
A method of making a separator for an electric current producing cell, said separator comprising a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, wherein said method comprises: (a) coating onto a substrate a liquid mixture comprising a boehmite sol; (b) drying the coating formed in step (a) to yield said microporous pseudo-boehmite layer, wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer; and (c) delaminating said pseudo-boehmite layer from said substrate, to provide a free-standing separator comprising said pseudo-boehmite layer.
Claim 41
Independent Claim
154 words
A method of making a separator for an electric current producing cell, said separator comprising a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, wherein said method comprises: (a) coating onto a substrate a liquid mixture comprising a boehmite sol; (b) drying the coating formed in step (a) to yield said microporous pseudo-boehmite layer, wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer; (c) contacting the surface of said pseudo-boehmite layer with heat- or radiation-curable monomers or oligomers to thereby cause the infusion of said monomers or said oligomers into the pores of said pseudo-boehmite layer; and (d) curing said monomers or said oligomers with an energy source selected from the group consisting of: heat, ultraviolet light, visible light, infrared radiation, and electron beam radiation; thereby forming an ionic conductive polymer.
Claim 42
Independent Claim
154 words
A method of making a separator for an electric current producing cell, said separator comprising a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, wherein said method comprises: (a) coating onto a substrate a liquid mixture comprising a boehmite sol; (b) drying the coating formed in step (a) to yield said microporous pseudo-boehmite layer, wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer; (c) contacting the surface of said pseudo-boehmite layer with heat- or radiation-curable monomers or oligomers to thereby cause the infusion of said monomers or said oligomers into the pores of said pseudo-boehmite layer; and (d) curing said monomers or said oligomers with an energy source selected from the group consisting of: heat, ultraviolet light, visible light, infrared radiation, and electron beam radiation; thereby forming an ionic conductive polymer.
Claim 43
Dependent Claim
42 words
The method of claim 36, further comprising, subsequent to step (d), the step of: (e) delaminating said pseudo-boehmite layer from said substrate, to provide a free standing separator comprising said pseudo-boehmite layer, wherein said pseudo-boehmite layer further comprises an ionic conductive polymer.
Claim 44
Independent Claim
122 words
A method of making a separator for an electric current producing cell, said separator comprising a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, wherein said method comprises: (a) coating onto a substrate a liquid mixture comprising a boehmite sol and a binder, wherein said substrate comprises a cathode coating layer on at least one outermost surface and the liquid mixture comprising said boehmite sol and said binder is coated onto said cathode coating layer; and (b) drying the coating formed in step (a) to yield said microporous pseudo-boehmite layer, wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer.
Claim 45
Independent Claim
122 words
A method of making a separator for an electric current producing cell, said separator comprising a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, wherein said method comprises: (a) coating onto a substrate a liquid mixture comprising a boehmite sol and a binder, wherein said substrate comprises a cathode coating layer on at least one outermost surface and the liquid mixture comprising said boehmite sol and said binder is coated onto said cathode coating layer; and (b) drying the coating formed in step (a) to yield said microporous pseudo-boehmite layer, wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer.
Claim 46
Dependent Claim
26 words
The method of claim 38, wherein said binder is present in the amount of 5 to 70% of weight of the pseudo-boehmite in said pseudo-boehmite layer.
Claim 47
Dependent Claim
26 words
The method of claim 38, wherein said binder is selected from the group consisting of: polyvinyl alcohols, polyethylene oxides, polyvinyl pyrrolidones, copolymers thereof, and mixtures thereof.
Claim 48
Dependent Claim
17 words
The method of claim 38, wherein said binder is present within the pores of said pseudo-boehmite layer.
Claim 49
Dependent Claim
19 words
The method of claim 38, wherein said pseudo-boehmite layer has a thickness of from 1 micron to 50 microns.
Claim 50
Dependent Claim
19 words
The method of claim 38, wherein said pseudo-boehmite layer has a thickness of from 1 micron to 25 microns.
Claim 51
Dependent Claim
19 words
The method of claim 38, wherein said pseudo-boehmite layer has a thickness of from 5 microns to 15 microns.
Claim 52
Independent Claim
107 words
A method of making a separator for an electric current producing cell, said separator comprising a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, wherein said method comprises: (a) coating onto a substrate a liquid mixture comprising a boehmite sol and a binder; and (b) drying the coating formed in step (a)to yield said microporous pseudo-boehmite layer, wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer; and (c) delaminating said pseudo-boehmite layer from said substrate, to provide a free-standing separator comprising said pseudo-boehmite layer.
Claim 53
Independent Claim
107 words
A method of making a separator for an electric current producing cell, said separator comprising a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, wherein said method comprises: (a) coating onto a substrate a liquid mixture comprising a boehmite sol and a binder; and (b) drying the coating formed in step (a)to yield said microporous pseudo-boehmite layer, wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer; and (c) delaminating said pseudo-boehmite layer from said substrate, to provide a free-standing separator comprising said pseudo-boehmite layer.
Claim 54
Dependent Claim
27 words
The method of claim 45, wherein said binder is present in the amount of 5 to 70% of the weight of the pseudo-boehmite in said pseudo-boehmite layer.
Claim 55
Dependent Claim
26 words
The method of claim 45, wherein said binder is selected from the group consisting of: polyvinyl alcohols, polyethylene oxides, polyvinyl pyrrolidones, copolymers thereof, and mixtures thereof.
Claim 56
Dependent Claim
19 words
The method of claim 45, wherein said pseudo-boehmite layer has a thickness of from 1 micron to 50 microns.
Claim 57
Dependent Claim
19 words
The method of claim 45, wherein said pseudo-boehmite layer has a thickness of from 1 micron to 25 microns.
Claim 58
Dependent Claim
19 words
The method of claim 45, wherein said pseudo-boehmite layer has a thickness of from 5 microns to 15 microns.
Claim 59
Dependent Claim
17 words
The method of claim 45, wherein said binder is present within the pores of said pseudo-boehmite layer.
Claim 60
Independent Claim
157 words
A method of making a separator for an electric current producing cell, said separator comprising a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, wherein said method comprises: (a) coating onto a substrate a liquid mixture comprising a boehmite sol and a binder; (b) drying the coating formed in step (a) to yield said microporous pseudo-boehmite layer, wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer; (c) contacting the surface of said pseudo-boehmite layer with heat- or radiation-curable monomers or oligomers to thereby cause the infusion of said monomers or said oligomers into the pores of said pseudo-boehmite layer; and (d) curing said monomers or said oligomers with an energy source selected from the group consisting of: heat, ultraviolet light, visible light, infrared radiation, and electron beam radiation; thereby forming an ionic conductive polymer.
Claim 61
Independent Claim
157 words
A method of making a separator for an electric current producing cell, said separator comprising a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, wherein said method comprises: (a) coating onto a substrate a liquid mixture comprising a boehmite sol and a binder; (b) drying the coating formed in step (a) to yield said microporous pseudo-boehmite layer, wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer; (c) contacting the surface of said pseudo-boehmite layer with heat- or radiation-curable monomers or oligomers to thereby cause the infusion of said monomers or said oligomers into the pores of said pseudo-boehmite layer; and (d) curing said monomers or said oligomers with an energy source selected from the group consisting of: heat, ultraviolet light, visible light, infrared radiation, and electron beam radiation; thereby forming an ionic conductive polymer.
Claim 62
Dependent Claim
42 words
The method of claim 52, further comprising, subsequent to step (d), the step of: (e) delaminating said pseudo-boehmite layer from said substrate, to provide a free standing separator comprising said pseudo-boehmite layer, wherein said pseudo-boehmite layer further comprises an ionic conductive polymer.
Claim 63
Independent Claim
75 words
A method of making an electrolyte element for use in an electric current producing cell, said method comprising the steps of: (a) coating onto a substrate a liquid mixture comprising a boehmite sol; (b) drying the coating formed in step (a) to yield a microporous pseudo-boehmite layer; and, (c) contacting the surface of said microporous pseudo-boehmite layer with an organic electrolyte, thereby causing the infusion of said electrolyte into the pores of said pseudo-boehmite layer.
Claim 64
Independent Claim
75 words
A method of making an electrolyte element for use in an electric current producing cell, said method comprising the steps of: (a) coating onto a substrate a liquid mixture comprising a boehmite sol; (b) drying the coating formed in step (a) to yield a microporous pseudo-boehmite layer; and, (c) contacting the surface of said microporous pseudo-boehmite layer with an organic electrolyte, thereby causing the infusion of said electrolyte into the pores of said pseudo-boehmite layer.
Claim 65
Dependent Claim
17 words
The method of claim 54, wherein the liquid mixture comprising said boehmite sol further comprises a binder.
Claim 66
Dependent Claim
17 words
The method of claim 55, wherein said binder is present within the pores of said pseudo-boehmite layer.
Claim 67
Dependent Claim
27 words
The method of claim 55, wherein said binder is present in the amount of 5 to 70% of the weight of the pseudo-boehmite in said pseudo-boehmite layer.
Claim 68
Dependent Claim
26 words
The method of claim 55, wherein said binder is selected from the group consisting of: polyvinyl alcohols, polyethylene oxides, polyvinyl pyrrolidones, copolymers thereof, and mixtures thereof.
Claim 69
Dependent Claim
29 words
The method of claim 54, wherein said organic electrolyte comprises one or more materials selected from the group consisting of: liquid electrolytes, gel polymer electrolytes, and solid polymer electrolytes.
Claim 70
Dependent Claim
16 words
The method of claim 54, wherein said organic electrolyte comprises heat- or radiation-curable monomers or oligomers.
Claim 71
Dependent Claim
51 words
The method of claim 60, wherein, after step (c), there is a subsequent step (d) comprising curing the heat- or radiation-curable monomers or oligomers with an energy source selected from the group consisting of: heat, ultraviolet light, visible light, infrared radiation, and electron beam radiation; thereby forming an ionic conductive polymer.
Claim 72
Dependent Claim
34 words
The method of claim 54, wherein the substrate comprises a cathode coating layer on at least one outermost surface and the liquid mixture comprising said boehmite sol is coated onto said cathode coating layer.
Claim 73
Dependent Claim
45 words
An electric current producing cell comprising a cathode, an anode and an electrolyte element interposed between said cathode and said anode, wherein said electrolyte element comprises: (a) a microporous pseudo-boehmite layer; and, (b) an organic electrolyte contained within the pores of said microporous pseudo-boehmite layer.
Claim 74
Dependent Claim
45 words
An electric current producing cell comprising a cathode, an anode and an electrolyte element interposed between said cathode and said anode, wherein said electrolyte element comprises: (a) a microporous pseudo-boehmite layer; and, (b) an organic electrolyte contained within the pores of said microporous pseudo-boehmite layer.
Claim 75
Dependent Claim
20 words
The cell of claim 63, wherein said pseudo-boehmite layer has a pore volume from 0.02 to 2.0 cm 3 /g.
Claim 76
Dependent Claim
20 words
The cell of claim 63, wherein said pseudo-boehmite layer has a pore volume from 0.3 to 1.0 cm 3 /g.
Claim 77
Dependent Claim
20 words
The cell of claim 63, wherein said pseudo-boehmite layer has a pore volume from 0.4 to 0.7 cm 3 /g.
Claim 78
Dependent Claim
21 words
The cell of claim 63, wherein the average pore diameter of said pseudo-boehmite layer is from 1 nm to 300 nm.
Claim 79
Dependent Claim
21 words
The cell of claim 63, wherein the average pore diameter of said pseudo-boehmite layer is from 2 nm to 30 nm.
Claim 80
Dependent Claim
21 words
The cell of claim 63, wherein the average pore diameter of said pseudo-boehmite layer is from 3 nm to 10 nm.
Claim 81
Dependent Claim
15 words
The cell of claim 63, wherein said cell is a secondary electric current producing cell.
Claim 82
Dependent Claim
71 words
The cell of claim 70, wherein said anode comprises one or more anode active materials selected from the group consisting of: lithium metal, lithium-aluminum alloys, lithium-tin alloys, lithium-intercalated carbons, and lithium-intercalated graphites; and wherein said cathode comprises an electroactive sulfur-containing cathode material, wherein said electroactive sulfur-containing cathode material, in its oxidized state, comprises a polysulfide moiety of the formula, --S m --, wherein m is an integer from 3 to 10.
Claim 83
Dependent Claim
13 words
The cell of claim 71, wherein said sulfur-containing cathode material comprises elemental sulfur.
Claim 84
Dependent Claim
39 words
The cell of claim 71, wherein said sulfur-containing cathode material comprises a carbon-sulfur polymer material which, in its oxidized state, comprises a polysulfide moiety of the formula, --S m --, wherein m is an integer from 3 to 10.
Claim 85
Dependent Claim
41 words
The cell of claim 71, wherein said sulfur-containing cathode material comprises a carbon-sulfur polymer material, which, in its oxidized state, comprises a polysulfide moiety of the formula, --S m --, wherein m is an integer equal to or greater than 6.
Claim 86
Dependent Claim
18 words
The cell of claim 73, wherein the polymer backbone chain of said carbon-sulfur polymer material comprises conjugated segments.
Claim 87
Dependent Claim
38 words
The cell of claim 73, wherein said polysulfide moiety, --S m --, is covalently bonded by one or both of its terminal sulfur atoms on a side group to the polymer backbone chain of said carbon-sulfur polymer material.
Claim 88
Dependent Claim
34 words
The cell of claim 73, wherein said polysulfide moiety, --S m --, is incorporated into the polymer backbone chain of said carbon-sulfur polymer material by covalent bonding of said polysulfide moiety's terminal sulfur atoms.
Claim 89
Dependent Claim
18 words
The cell of claim 73, wherein said carbon-sulfur polymer material comprises greater than 75 weight percent of sulfur.
Claim 90
Dependent Claim
29 words
The cell of claim 63, wherein said organic electrolyte comprises one or more materials selected from the group consisting of: liquid electrolytes, gel polymer electrolytes, and solid polymer electrolytes.
Claim 91
Dependent Claim
13 words
The cell of claim 63, wherein said organic electrolyte comprises a liquid electrolyte.
Claim 92
Dependent Claim
14 words
The cell of claim 63, wherein said organic electrolyte comprises a gel polymer electrolyte.
Claim 93
Dependent Claim
14 words
The cell of claim 63, wherein said organic electrolyte comprises a solid polymer electrolyte.
Claim 94
Dependent Claim
31 words
An electrolyte element for an electric current producing cell, wherein said electrolyte element comprises: (a) a microporous pseudo-boehmite layer; and (b) an electrolyte contained with the pores of said pseudo-boehmite layer.
Claim 95
Dependent Claim
31 words
An electrolyte element for an electric current producing cell, wherein said electrolyte element comprises: (a) a microporous pseudo-boehmite layer; and (b) an electrolyte contained with the pores of said pseudo-boehmite layer.
Claim 96
Dependent Claim
13 words
The electrolyte element of claim 83, wherein said electrolyte is an aqueous electrolyte.
Claim 97
Dependent Claim
39 words
A method of forming an electric current producing cell, said method comprising the steps of: (a) providing an anode; (b) providing a cathode; and (c) interposing an electrolyte element according to claim 83 between said anode and said cathode.
Claim 98
Dependent Claim
12 words
The method of claim 85, wherein said electrolyte is an aqueous electrolyte.
Claim 99
Independent Claim
74 words
A method of making an electrolyte element for use in an electric current producing cell, said method comprising the steps of: (a) coating onto a substrate a liquid mixture comprising a boehmite sol; (b) drying the coating formed in step (a) to yield a microporous pseudo-boehmite layer; and (c) contacting the surface of said microporous pseudo-boehmite layer with an electrolyte, thereby causing the infusion of said electrolyte into the pores of said pseudo-boehmite layer.
Claim 100
Independent Claim
74 words
A method of making an electrolyte element for use in an electric current producing cell, said method comprising the steps of: (a) coating onto a substrate a liquid mixture comprising a boehmite sol; (b) drying the coating formed in step (a) to yield a microporous pseudo-boehmite layer; and (c) contacting the surface of said microporous pseudo-boehmite layer with an electrolyte, thereby causing the infusion of said electrolyte into the pores of said pseudo-boehmite layer.
Claim 101
Dependent Claim
12 words
The method of claim 87, wherein said electrolyte is an aqueous electrolyte.
Claim 102
Dependent Claim
44 words
An electric current producing cell comprising a cathode, an anode and an electrolyte element interposed between said cathode and said anode, wherein said electrolyte element comprises: (a) a microporous pseudo-boehmite layer; and (b) an electrolyte contained within the pores of said microporous pseudo-boehmite layer.
Claim 103
Dependent Claim
44 words
An electric current producing cell comprising a cathode, an anode and an electrolyte element interposed between said cathode and said anode, wherein said electrolyte element comprises: (a) a microporous pseudo-boehmite layer; and (b) an electrolyte contained within the pores of said microporous pseudo-boehmite layer.
Claim 104
Dependent Claim
12 words
The cell of claim 89, wherein said electrolyte is an aqueous electrolyte.
Claim 105
Dependent Claim
15 words
The cell of claim 89, wherein said cell is a secondary electric current producing cell.
Claim 106
Dependent Claim
15 words
The cell of claim 89, wherein said cell is a primary electric current producing cell.
Claim 107
Dependent Claim
129 words
A separator for an electric current producing cell, wherein said separator comprises a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, wherein said pseudo-boehmite layer further comprises a binder, wherein said separator is produced by a process comprising: (a) coating onto a substrate a liquid mixture comprising a boehmite sol and a binder, wherein said substrate comprises a cathode coating layer on at least one outermost surface and said liquid mixture comprising said boehmite sol is coated onto said cathode coating layer; and (b) drying the coating formed in step (a) to yield said microporous pseudo-boehmite layer, wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer.
Claim 108
Dependent Claim
129 words
A separator for an electric current producing cell, wherein said separator comprises a microporous pseudo-boehmite layer having pores connected in a substantially continuous fashion through said pseudo-boehmite layer, wherein said pseudo-boehmite layer further comprises a binder, wherein said separator is produced by a process comprising: (a) coating onto a substrate a liquid mixture comprising a boehmite sol and a binder, wherein said substrate comprises a cathode coating layer on at least one outermost surface and said liquid mixture comprising said boehmite sol is coated onto said cathode coating layer; and (b) drying the coating formed in step (a) to yield said microporous pseudo-boehmite layer, wherein the layer of pseudo-boehmite, which pseudo-boehmite comprises said pores, has an average pore diameter from 1 nm to 300 nm for said pseudo-boehmite layer.
Claim 109
Dependent Claim
20 words
The separator of claim 93, wherein said pseudo-boehmite layer has a pore volume from 0.3 to 1.0 cm 3 /g.
Claim 110
Dependent Claim
20 words
The separator of claim 93, wherein said pseudo-boehmite layer has a pore volume from 0.4 to 0.7 cm 3 /g.
Claim 111
Dependent Claim
21 words
The separator of claim 93, wherein the average pore diameter of said pseudo-boehmite layer is from 2 nm to 30 nm.
Claim 112
Dependent Claim
21 words
The separator of claim 93, wherein the average pore diameter of said pseudo-boehmite layer is from 3 nm to 10 nm.
Claim 113
Dependent Claim
27 words
The separator of claim 93, wherein said binder is present in the amount of 5 to 70% of the weight of the pseudo-boehmite in said pseudo-boehmite layer.
Claim 114
Dependent Claim
26 words
The separator of claim 93, wherein said binder is selected from the group consisting of polyvinyl alcohols, polyethylene oxides, polyvinyl pyrrolidones, copolymers thereof, and mixtures thereof.
Claim 115
Dependent Claim
19 words
The separator of claim 93, wherein said pseudo-boehmite layer has a thickness of from 1 micron to 50 microns.
Claim 116
Dependent Claim
19 words
The separator of claim 93, wherein said pseudo-boehmite layer has a thickness of from 1 micron to 25 microns.
Claim 117
Dependent Claim
19 words
The separator of claim 93, wherein said pseudo-boehmite layer has a thickness of from 5 microns to 15 microns.
Claim 118
Dependent Claim
17 words
The separator of claim 93, wherein said binder is present within the pores of said psuedo-boehmite layer.
References Cited (Backward Citations)
US3647554A
Cited
US4361620A
Cited
EP0144097A1
Cited
US5312789A
Cited
WO1991002385A1
Cited
WO1991003080A1
Cited
US5178849A
Cited
EP0523840A1
Cited
EP0524626A1
Cited
US5194341A
Cited
US5326391A
Cited
EP0600718A2
Cited
US5824434A
Cited
US5418091A
Cited
US5597659A
Cited
US5691005A
Cited
US5549989A
Cited
US5538812A
Cited
US5601947A
Cited
US5690702A
Cited
US5529860A
Cited
US5605750A
Cited
US5782940A
Cited
EP0814520A2
Cited
EP0875950A2
Cited
US5882721A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2003-11-28 | 2004-05-29 | 2004-11-28 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2007-11-28 | 2008-05-29 | 2008-11-28 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2011-11-28 | 2012-05-29 | 2012-11-28 | $7700.00 | Window Closed / Lapsed |