The invention relates to a method for producing an electrochemical cell comprising at least one porous electrode (2′), the method comprising at least the following method steps: (a) providing an electrode composition in the form of a homogeneous mixture comprising (i) at least one particulate active material (3); (ii) at least one particulate binder (5); (iii) at least one particulate pore-forming agent (4); and (iv) optionally at least one conducting additive (6); (b) forming a mouldable mass from the electrode composition; (c) applying the electrode composition to at least one surface of a substrate (1) to obtain a compact electrode (2); (d) producing an electrochemical cell comprising at least one compact electrode (2) which comprises the electrode composition according to method step (a); and (e) heating the at least one compact electrode (2) to liquefy the at least one particulate pore-forming agent (4); and/or (f) bringing the compact electrode (2) into contact with at least one liquid electrolyte composition or at least one liquid constituent of an electrolyte composition for an electrochemical cell which is capable of at least partially dissolving the at least one particulate pore-forming agent (4) to obtain a porous electrode (2), wherein method steps (a), (b), (c), (d) and (e) are carried out substantially without solvents.

Articles and methods including layers for protection of electrodes in electrochemical cells are provided. As described herein, a layer, such as a protective layer for an electrode, may comprise a plurality of particles (e.g., crystalline inorganic particles, amorphous inorganic particles). In some aspects, at least a portion of the plurality of particles (e.g., inorganic particles) are fused to one another. For instance, in some aspects, the layer may be formed by aerosol deposition or another suitable process that involves subjecting the particles to a relatively high velocity such that fusion of particles occurs during deposition. In some cases, the protective layer may be porous.

Articles and methods including layers for protection of electrodes in electrochemical cells are provided. As described herein, a layer, such as a protective layer for an electrode, may comprise a plurality of particles (e.g., crystalline inorganic particles, amorphous inorganic particles). In some aspects, at least a portion of the plurality of particles (e.g., inorganic particles) are fused to one another. For instance, in some aspects, the layer may be formed by aerosol deposition or another suitable process that involves subjecting the particles to a relatively high velocity such that fusion of particles occurs during deposition. In some cases, the protective layer may be porous.

A lithium secondary battery includes a cathode formed of a cathode active material including a lithium metal oxide particle having a concentration gradient, and a coating formed on the lithium metal oxide particle, the coating including aluminum, titanium and zirconium, an anode, and a separator interposed between the cathode and the anode. The cathode active material includes 2,000 ppm to 4,000 ppm of aluminum, 4,000 ppm to 9,000 ppm of titanium and 400 ppm to 700 ppm of zirconium, based on the total weight of the cathode active material. The performance of the secondary battery may be maintained under a high temperature condition.

A lithium ion battery is provided that includes: a positive electrode; a negative electrode; a separator comprising a material having a melt temperature of greater than 150° C.; and an electrolyte including an organic solvent and a lithium salt. A method for sterilizing a lithium ion battery is also provided that includes: providing a lithium ion battery (particularly one as described herein); either charging or discharging the battery to a state of charge (SOC) of 20% to 100%; and steam sterilizing the battery to form a sterilized lithium ion battery.

A submicron sized Si based powder having an average primary particle size between 20 nm and 200 nm, wherein the powder has a surface layer comprising SiO.sub.x, with 0<x<2, the surface layer having an average thickness between 0.5 nm and 10 nm, and wherein the powder has a total oxygen content equal or less than 3% by weight at room temperature. The method for making the powder comprises a step where a Si precursor is vaporized in a gas stream at high temperature, after which the gas stream is quenched to obtain Si particles, and the Si particles are quenched at low temperature in an oxygen containing gas.

A battery comprising an acidified metal oxide (“AMO”) material, preferably in monodisperse nanoparticulate form 20 nm or less in size, having a pH <7 when suspended in a 5 wt % aqueous solution and a Hammett function H.sub.0 >−12, at least on its surface.

A battery comprising an acidified metal oxide (“AMO”) material, preferably in monodisperse nanoparticulate form 20 nm or less in size, having a pH <7 when suspended in a 5 wt % aqueous solution and a Hammett function H.sub.0 >−12, at least on its surface.

Solid-state lithium ion electrolytes of lithium metal nitride based compounds are provided which contain an anionic framework capable of conducting lithium ions. Materials of specific formulae are provided and methods to alter the materials with inclusion of aliovalent ions shown. Lithium batteries containing the composite lithium ion electrolytes are provided. Electrodes containing the lithium metal nitride based composites are also provided.

Solid-state lithium ion electrolytes of lithium metal nitride based compounds are provided which contain an anionic framework capable of conducting lithium ions. Materials of specific formulae are provided and methods to alter the materials with inclusion of aliovalent ions shown. Lithium batteries containing the composite lithium ion electrolytes are provided. Electrodes containing the lithium metal nitride based composites are also provided.