Abstract: Improved anodes and cells are provided, which enable fast charging rates with enhanced safety due to much reduced probability of metallization of lithium on the anode, preventing dendrite growth and related risks of fire or explosion. Anodes and/or electrolytes have buffering zones for partly reducing and gradually introducing lithium ions into the anode for lithiation, to prevent lithium ion accumulation at the anode electrolyte interface and consequent metallization and dendrite growth. Various anode active materials and combinations, modifications through nanoparticles and a range of coatings which implement the improved anodes are provided.

Abstract: Systems and methods are provided for operating lithium ion devices by setting an operative capacity below a rated capacity value of the lithium ion device, and operating the lithium ion device at the set operative capacity by decreasing a lower voltage cutoff value during discharging and/or by increasing an upper voltage cutoff level during charging—to support operation at the set operative capacity. The systems and methods may utilize residual lithium in device components such as anodes, cathodes, electrolyte etc. or combinations thereof, and/or external lithiation to increase the cycling lifetime of the lithium ion devices, to adapt to user preferences and expected use profiles, and to simplify device status indications to the user. Advantageously, relatively simple circuitry is required to implement the provided methods and systems, and achieve customizable operation of the lithium ion devices.

Abstract: Systems and methods are provided for balancing battery modules following fast charging, particularly with respect to fast charging lithium ion batteries with metalloid-based anodes. Charge balancing among multiple battery modules connected in series may be carried out by short-circuiting fully charged modules while adjusting the voltage and/or current level supplied by a charger, to fully charge remaining modules. A balancing module comprising a controller and switching circuitry may be configured to implement the charge balancing in association with the charger and its battery management system, and monitoring the battery modules. Advantageously, disclosed switching balancing is more efficient than prior art passive balancing and simpler in implementation than prior art active balancing.

Abstract: Methods and systems are provided for optimizing usage of a large number of battery cells, some, most or all of which are fast charging cells, and possibly arranged in battery modules—e.g., for operating an electric vehicle power train. Methods comprise deriving an operation profile for the battery cells/modules for a specified operation scenario and specified optimization parameters, operating the battery cells/modules according to the derived operation profile, and monitoring the operation of the battery cells/modules and adjusting the operation profile correspondingly. Systems may be configured to balance cell/module parameters among modules, to have parallel supplemental modules and/or serial supplementary cells in the modules, and/or have supplemental modules and circuits configured to store excessive charging energy for cells groups and/or modules—to increase the cycling lifetime and possibly the efficiency of the systems. Disclosed redundancy management improves battery performance and lifetime.

Abstract: Li-PAA (lithium poly(acrylic acid)) powders, electrode binders and methods of preparation thereof are provided. The Li-PAA powders have a low PDI (polydispersity index), e.g., smaller than 4 or 5, possibly a high Mw, and are configured to have a lithium content of above 7%, a pH between 8.5 and 9.5, or between 8.7 and 9.1 when dissolved 15% w/w in water and/or possibly a white color. Preparation methods comprise adding a PAA solution into a LiOH solution and stirring a resulting Li-PAA solution, and precipitating Li-PAA from the resulting Li-PAA solution, sieving or filtering and then drying the precipitated Li-PAA to yield the Li-PAA powder, which may be used as binder for forming electrodes. Advantageously, resulting electrodes are uniform and mechanically stable when used with metalloid anode material particles which exhibit high expansion and contraction when used in fast charging lithium ion batteries.

Abstract: Electrodes, production methods and mono-cell batteries are provided, which comprise active material particles embedded in electrically conductive metallic porous structure, dry-etched anode structures and battery structures with thick anodes and cathodes that have spatially uniform resistance. The metallic porous structure provides electric conductivity, a large volume that supports good ionic conductivity, that in turn reduces directional elongation of the particles during operation, and may enable reduction or removal of binders, conductive additives and/or current collectors to yield electrodes with higher structural stability, lower resistance, possibly higher energy density and longer cycling lifetime. Dry etching treatments may be used to reduce oxidized surfaces of the active material particles, thereby simplifying production methods and enhancing porosity and ionic conductivity of the electrodes.

Abstract: Electrodes, production methods and mono-cell batteries are provided, which comprise active material particles embedded in electrically conductive metallic porous structure, dry-etched anode structures and battery structures with thick anodes and cathodes that have spatially uniform resistance. The metallic porous structure provides electric conductivity, a large volume that supports good ionic conductivity, that in turn reduces directional elongation of the particles during operation, and may enable reduction or removal of binders, conductive additives and/or current collectors to yield electrodes with higher structural stability, lower resistance, possibly higher energy density and longer cycling lifetime. Dry etching treatments may be used to reduce oxidized surfaces of the active material particles, thereby simplifying production methods and enhancing porosity and ionic conductivity of the electrodes.

Abstract: Electrodes, production methods and mono-cell batteries are provided, which comprise active material particles embedded in electrically conductive metallic porous structure, dry-etched anode structures and battery structures with thick anodes and cathodes that have spatially uniform resistance. The metallic porous structure provides electric conductivity, a large volume that supports good ionic conductivity, that in turn reduces directional elongation of the particles during operation, and may enable reduction or removal of binders, conductive additives and/or current collectors to yield electrodes with higher structural stability, lower resistance, possibly higher energy density and longer cycling lifetime. Dry etching treatments may be used to reduce oxidized surfaces of the active material particles, thereby simplifying production methods and enhancing porosity and ionic conductivity of the electrodes.

Abstract: Improved anodes and cells are provided, which enable fast charging rates with enhanced safety due to much reduced probability of metallization of lithium on the anode, preventing dendrite growth and related risks of fire or explosion. Anodes and/or electrolytes have buffering zones for partly reducing and gradually introducing lithium ions into the anode for lithiation, to prevent lithium ion accumulation at the anode electrolyte interface and consequent metallization and dendrite growth. Various anode active materials and combinations, modifications through nanoparticles and a range of coatings which implement the improved anodes are provided.

Abstract: Methods and systems are provided for estimating and extending the expected cell cycling lifetime for produced lithium ion cells. Methods comprise monitoring charging and/or discharging peak(s) during formation cycles of the cells, which are defined with respect to dQ/dV measurements during the formation cycles, and ending the formation process once the charging and/or discharging peaks disappear, optionally deriving the expected cell cycling lifetime by comparing the monitored peaks to specified thresholds that are correlated to the lifetime. The methods may be implemented by controller(s) at the battery, device and/or factory levels, which may be operated in combination. Formation processes and/or cell operation schemes may be adjusted accordingly, to avoid excessive dQ/dV rates and increase thereby the cell cycling lifetime.

Abstract: Systems and methods are provided, in which the level of metal ions in cells stacks and lithium ion batteries is regulated in situ, with the electrodes of the cell stack(s) in the respective pouches. Regulation of metal ions may be carried out electrochemically by metal ion sources in the pouches, electrically connected to the electrodes. The position and shape of the metal ion sources may be optimized to create uniform metal ion movements to the electrode surfaces and favorable SEI formation. The metal ion sources may be removable, or comprise a lithium source for lithiating the anodes or cathodes during operation of the battery according to SoH parameters. Regulation of metal ions may be carried out from metal ion sources in separate electrolyte reservoir(s), with circulation of the metal-ion-containing electrolyte through the cell stacks in the pouches prior or during the formation.

Abstract: Chargers and methods are provided which increase the charging efficiency of the chargers by implementing voltage amplitude modulation (VAM) instead of voltage frequency modulation. The charging voltage amplitude is modulated using feedback from at least one energy storage device that is being charged by the charger, while maintaining a charging voltage frequency constant at a LLC resonance frequency of the charger. A buck/boost configuration may be used to reduce maximal voltage levels and further optimize the charger's design.

Abstract: Methods, stacks and electrochemical cells are provided, in which the cell separator is surface-treated prior to attachment to the electrode(s) to form binding sites on the cell separator and enhance binding thereof to the electrode(s), e.g., electrostatically. The cell separator(s) may be attached to the electrode(s) by cold press lamination, wherein the created binding sites are configured to stabilize the cold press lamination electrostatically—forming flexible and durable electrode stacks. Electrode slurry may be deposited on a sacrificial film and then attached to current collector films, avoiding unwanted interactions between materials and in particular solvents involved in the respective slurries. Dried electrode slurry layers may be pressed or calendared against each other to yield thinner, smother and more controllably porous electrodes, as well as higher throughput. The produced stacks may be used in electrochemical cells and in any other type of energy storage device.

Abstract: Methods, stacks and electrochemical cells are provided, which improve production processes and yield flexible and durable electrode stacks. Methods comprise depositing an electrode slurry on a sacrificial film to form an electrode thereupon, wherein the electrode slurry comprises a first solvent, attaching (e.g., laminating) a current collector film, which is produced at least partly using a second solvent, onto the formed electrode, to yield a stack, wherein a binding strength of the electrode to the current collector film is higher than a binding strength of the electrode to the sacrificial film, and delaminating the sacrificial film from the electrode while maintaining the attachment of the electrode to the current collector film. Additional layers such as a cell separator and an additional electrode may be further attached using similar steps.

Abstract: Lithium ion batteries and cells, as well as operating and testing methods are provided, which utilize a transparent pouch to monitor the battery in operational condition and/or in operation. Transparent parts of the pouch may be used for direct sensing of cell elements. Removable covers may be used to protect battery components from illumination damage. Indicators in the transparent pouch may be associated with cell components such as electrodes and electrolyte to indicate their condition. External sensors may be used to derive data from the indicators, and bi-directional electromagnetic (e.g., optical) communication may be established through the transparent pouch, to enhance monitoring and spare physical electrical connections. For example, the transparent pouch may be used to monitor and enhance battery safety and/or to modify operational parameters non-destructively, during operation of the battery.

Abstract: Methods, systems and battery modules are provided, which increase the cycling lifetime of fast charging lithium ion batteries. During the formation process, the charging currents are adjusted to optimize the cell formation, possibly according to the characteristics of the formation process itself, and discharge extents are partial and optimized as well, as is the overall structure of the formation process. During operation, voltage ranges are initially set to be narrow, and are broadened upon battery deterioration to maximize the overall lifetime. Current adjustments are applied in operation as well, with respect to the deteriorating capacity of the battery. Various formation and operation strategies are disclosed, as basis for specific optimizations.

Abstract: Charging methods and systems are provided which charge multiple cells directly from an AC source, by adjusting, momentarily, the number of charged cells to the momentary voltage level provided by the AC source. Cells are rapidly switched in and out to correspond to the provided voltage level, and the charging level of each cell is regulated by the switching order of the cells—determined according to cell characteristics such as state of charge and state of health. Advantageously, charging losses are reduced significantly in the disclosed systems and methods, and an additional level of cell control is provided. The charged assembly of cells may be arranged and re-arranged in various configurations to optimize the charging scheme, e.g., to equalize the charging states of the cells to simplify the use and improve the efficiency of the cell stack.

Abstract: Methods, systems and battery modules are provided, which increase the cycling lifetime of fast charging lithium ion batteries. During the formation process, the charging currents are adjusted to optimize the cell formation, possibly according to the characteristics of the formation process itself, and discharge extents are partial and optimized as well, as is the overall structure of the formation process. During operation, voltage ranges are initially set to be narrow, and are broadened upon battery deterioration to maximize the overall lifetime. Current adjustments are applied in operation as well, with respect to the deteriorating capacity of the battery. Various formation and operation strategies are disclosed, as basis for specific optimizations.

Abstract: Cathodes for a fast charging lithium ion battery, processes for manufacturing thereof and corresponding batteries are provided. Cathode formulations comprise spinel and/or layered structure cathode material with 5-10% of cathode material having an olivine-based structure as polymerization initiator, binder material, and monomer and/or oligomer material selected to polymerize into a conductive polymer upon partial delithiation of the olivine-based structure cathode material during at least a first charging cycle of a cell having a cathode made of the cathode formulation. When the cathode is used in a battery, polymerization is induced in-situ (in-cell) during first charging cycle(s) of the battery to provide a polymer matrix which is evenly dispersed throughout the cathode.

Abstract: Electrodes, production methods and mono-cell batteries are provided, which comprise active material particles embedded in electrically conductive metallic porous structure, dry-etched anode structures and battery structures with thick anodes and cathodes that have spatially uniform resistance. The metallic porous structure provides electric conductivity, a large volume that supports good ionic conductivity, that in turn reduces directional elongation of the particles during operation, and may enable reduction or removal of binders, conductive additives and/or current collectors to yield electrodes with higher structural stability, lower resistance, possibly higher energy density and longer cycling lifetime. Dry etching treatments may be used to reduce oxidized surfaces of the active material particles, thereby simplifying production methods and enhancing porosity and ionic conductivity of the electrodes.