Abstract: Disclosed is a method and apparatus for making a lithium-ion electrochemical cell component by advancing a substrate for a lithium ion cell between opposing first and second calendering rolls, depositing by atmospheric plasma deposition particles of electrode material comprising an active electrode material and a metal into a gap between a first side of the substrate and the first calendering roll, wherein the metal is surface-activated by the atmospheric plasma; and pressing the deposited particles of the active electrode material and the metal particles between the first and second calendering rolls into an electrode layer on the first side of the substrate.

Abstract: Disclosed is a method for making a lithium-ion cell by depositing from an atmospheric plasma deposition device inorganic oxide particles produced from a precursor in an atmospheric plasma as a coating on a surface of a lithium-ion electrochemical cell component. The coating formed by the inorganic oxide particles may be an insulating coating or may provide dimensional stability during a thermal runaway.

Abstract: Disclosed is a method for making a lithium-ion cell by depositing from an atmospheric plasma deposition device inorganic oxide particles produced from a precursor in an atmospheric plasma as a coating on a surface of a lithium-ion electrochemical cell component. The coating formed by the inorganic oxide particles may be an insulating coating or may provide dimensional stability during a thermal runaway.

Abstract: A method of making an electrode material for a lithium-ion electrochemical cell includes sputtering a wire of metal or metal alloy in an atmospheric plasma to produce activated particles of metal or metal alloy and contacting the activated particles of the metal or metal alloy with particles of a lithium-ion cell active electrode material to produce composite particles in which particles of the first lithium-ion cell active electrode material are adhered to particles of the metal or metal alloy.

Abstract: Disclosed is a method and apparatus for making a lithium-ion electrochemical cell component by advancing a substrate for a lithium ion cell between opposing first and second calendering rolls, depositing by atmospheric plasma deposition particles of electrode material comprising an active electrode material and a metal into a gap between a first side of the substrate and the first calendering roll, wherein the metal is surface-activated by the atmospheric plasma; and pressing the deposited particles of the active electrode material and the metal particles between the first and second calendering rolls into an electrode layer on the first side of the substrate.

Abstract: Disclosed is a method for making a lithium-ion cell by depositing from an atmospheric plasma deposition device inorganic oxide particles produced from a precursor in an atmospheric plasma as a coating on a surface of a lithium-ion electrochemical cell component. The coating formed by the inorganic oxide particles may be an insulating coating or may provide dimensional stability during a thermal runaway.

Abstract: An anode component for a lithium-ion cell is formed using an atmospheric plasma deposition. The anode component has an anode material layer comprising high lithium-intercalating capacity silicon particles as active anode material in pores of a bonded layer of metal particles. The atmospheric plasma deposition process deposits metal particles and smaller silicon-containing particles concurrently or sequentially on an anode current collector substrate or polymeric separator substrate for the lithium-ion cell. The anode material layer may optionally be lithiated in the atmospheric plasma deposition process. The plasma deposition process is used to form a porous electrode layer on the substrate consisting essentially of a porous metal matrix containing smaller particles of the electrode material particles supported and carried in the pores of the matrix. When the anode component is assembled into a cell, remaining pore capacity is filled with a lithium-ion containing liquid electrolyte solution.

Abstract: An anode component for a lithium-ion cell is formed using an atmospheric plasma deposition. The anode component has an anode material layer comprising high lithium-intercalating capacity silicon particles as active anode material in pores of a bonded layer of metal particles. The atmospheric plasma deposition process deposits metal particles and smaller silicon-containing particles concurrently or sequentially on an anode current collector substrate or polymeric separator substrate for the lithium-ion cell. The anode material layer may optionally be lithiated in the atmospheric plasma deposition process. The plasma deposition process is used to form a porous electrode layer on the substrate consisting essentially of a porous metal matrix containing smaller particles of the electrode material particles supported and carried in the pores of the matrix. When the anode component is assembled into a cell, remaining pore capacity is filled with a lithium-ion containing liquid electrolyte solution.

Abstract: An anode component for a lithium-ion cell is formed using an atmospheric plasma deposition. The anode component has an anode material layer comprising high lithium-intercalating capacity silicon particles as active anode material in pores of a bonded layer of metal particles. The atmospheric plasma deposition process deposits metal particles and smaller silicon-containing particles concurrently or sequentially on an anode current collector substrate or polymeric separator substrate for the lithium-ion cell. The anode material layer may optionally be lithiated in the atmospheric plasma deposition process. The plasma deposition process is used to form a porous electrode layer on the substrate consisting essentially of a porous metal matrix containing smaller particles of the electrode material particles supported and carried in the pores of the matrix. When the anode component is assembled into a cell, remaining pore capacity is filled with a lithium-ion containing liquid electrolyte solution.