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 Melt impregnation of mixed metal oxide

Details
Inventors: Takeuchi, Esther S.; Leising, Randolph A.;
Assignee: Wilson Greatbatch Ltd. (Clarence, NY)
Primary Examiner: Ryan; Patrick
Assistant Examiner: Wills; M.
Attorney, Agent or Firm: Hodgson Russ LLP

The present invention is directed to a process for preparing a cathode active material consisting of a single phase of mixed metal oxide, such as a single phase silver vanadium oxide. The synthesis technique involves first heating the starting materials to melt a decomposable starting constituent. This first heating temperature is held for a period of time sufficient to enable the decomposable starting constituent to melt and completely flow throughout and within the other starting materials. Then, the thusly produced melt impregnated reaction admixture is preferably ground to ensure complete homogeneity of the starting materials, followed by heating to the decomposition temperature of the decomposable starting constituent. To finish the synthesis, the decomposed admixture is heated to an elevated temperature above the decomposition temperature to provide the single phase mixed metal oxide.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An electrochemical cell including a single phase mixed metal oxide synthesized as an electrode active material, such as a cathode active material, according to the present invention preferably comprises an anode of a metal selected from Group IA of the Periodic Table of the Elements.
This group of metals is collectively referred to as the alkali metals and comprises lithium, sodium, potassium, etc.
, and their alloys and intermetallic compounds including, for example, Li--Si, Li--Al, Li--B and Li--Si--B alloys and intermetallic compounds.
The preferred anode comprises lithium.
An alternate anode comprises a lithium alloy, such as a lithium-aluminum alloy.
However, the greater the amount of aluminum present by weight in the alloy, the lower the energy density of the cell.
The form of the anode may vary, but preferably the anode is a thin metal sheet or foil of the anode metal, pressed or rolled on a metallic anode current collector, i.
e.
, preferably comprising nickel, to form an anode component.
In the exemplary cell of the present invention, the anode component has an extended tab or lead of the same material as the anode current collector, i.
e.
, preferably nickel, integrally formed therewith such as by welding and contacted by a weld to a cell case of conductive metal in a case-negative electrical configuration.
Alternatively, the anode may be formed in some other geometry, such as a bobbin shape, cylinder or pellet to allow an alternate low surface cell design.
The electrochemical reaction at the cathode involves conversion of ions which migrate from the anode to the cathode into atomic or molecular forms.
The cathode material of the present invention comprises at least one single phase cathode active material formed from readily decomposable reactant constituent compounds consisting of metals from Groups IB, IIB, IIIB, IVB, VB, VIB, VIIB, as well as from Group VIII of the Periodic Table of the Elements.
The decomposable reactant constituents are first mixed together in a substantially homogeneous mixture



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