A section on the BBC's 'Material World' today about a new process for making Li-Ion batteries such that the risk of thermal runaway is reduced. Apparently the electrodes are continuously extruded, which may reduce production costs too.
It's a BBC poscast, which means it's available indefinitely, and (I think) worldwide. Look for the 2011-09-01 episode at http://www.bbc.co.uk/podcasts/series/material, the item is the second they cover, about 7 minutes in.
[I was interrupted by a phone call whilst listening to this in the car, so Imay have missed a salient detail somewhere...]