Abstract: A method of reforming a negative electrode layer of a secondary lithium battery may include execution of a reforming cycle that reforms a major facing surface of the negative electrode layer by eliminating at least a portion of a lithium dendrite or other lithium-containing surface irregularity that has formed on the major facing surface of the negative electrode layer.

Abstract: A temperature sensor for a battery cell of a rechargeable battery is described, and includes a resistive sensing element, a first electrode, and a second electrode. The resistive sensing element, the first electrode, and the second electrode are affixed to a porous separator. The porous separator is interposed between an anode and a cathode of the battery cell. The resistive sensing element is electrically connected in series between the first electrode and the second electrode, and the resistive sensing element, the first electrode and the second electrode are affixed onto the separator as film layers, and are porous.

Abstract: A reference electrode for a lithium-ion battery cell in the form of a porous ultrathin film that is fabricated from aluminum or an aluminum alloy is described. The aluminum layer is conductive and functions as a current collector for the reference electrode. The alloying elements may include but not limited to one or more of copper, zinc, silver, gold, titanium, chrome, rare earth metals, etc., to achieve target values for electrical, mechanical and chemical properties. Also disclosed is an electrochemical battery cell having an anode, a cathode, and a reference electrode, wherein the reference electrode is interposed between the anode and the cathode, wherein the reference electrode is an electrode layer that is arranged on a current collector, and wherein the current collector is fabricated from an aluminum alloy.

Abstract: A method of making a reference electrode assembly for an electrochemical cell according to various aspects of the present disclosure includes providing a subassembly including a separator layer and a current collector layer coupled to the separator layer. The method further includes providing an electrode ink including an electroactive material, a binder, and a solvent. The method further includes creating a reference electrode precursor by applying an electroactive precursor layer to the current collector layer. The electroactive precursor layer covers greater than or equal to about 90% of a superficial surface area of a surface of the current collector layer. The electroactive precursor layer includes the electrode ink. The method further includes creating the reference electrode assembly by drying the electroactive precursor layer to remove at least a portion of the solvent, thereby forming an electroactive layer. The electroactive layer is solid and porous.

Abstract: A method of making a reference electrode assembly for an electrochemical cell according to various aspects of the present disclosure includes providing a subassembly including a separator layer and a current collector layer coupled to the separator layer. The method further includes providing an electrode ink including an electroactive material, a binder, and a solvent. The method further includes creating a reference electrode precursor by applying an electroactive precursor layer to the current collector layer. The electroactive precursor layer covers greater than or equal to about 90% of a superficial surface area of a surface of the current collector layer. The electroactive precursor layer includes the electrode ink. The method further includes creating the reference electrode assembly by drying the electroactive precursor layer to remove at least a portion of the solvent, thereby forming an electroactive layer. The electroactive layer is solid and porous.

Abstract: A method of making a reference electrode assembly for an electrochemical cell according to various aspects of the present disclosure includes providing a subassembly including a separator layer and a current collector layer coupled to the separator layer. The method further includes providing an electrode ink including an electroactive material, a binder, and a solvent. The method further includes creating a reference electrode precursor by applying an electroactive precursor layer to the current collector layer. The electroactive precursor layer covers greater than or equal to about 90% of a superficial surface area of a surface of the current collector layer. The electroactive precursor layer includes the electrode ink. The method further includes creating the reference electrode assembly by drying the electroactive precursor layer to remove at least a portion of the solvent, thereby forming an electroactive layer. The electroactive layer is solid and porous.

Abstract: A monitoring assembly for an electrochemical cell of a secondary lithium battery includes a porous sensory structure and a transducer. The porous sensory structure includes a sensory layer disposed on a major surface of a porous separator and a buffer layer disposed between the sensory layer and a facing surface of a negative electrode layer. The buffer layer electrically isolates the sensory layer from the facing surface of the negative electrode layer. The sensory layer includes an electrically conductive material and is configured to produce a response to an input signal or to a physical stimulus received within the electrochemical cell. The transducer is configured to process the response produced by the sensory layer to generate an output signal indicative of a diagnostic condition within the electrochemical cell.

Abstract: A method of making a reference electrode assembly for an electrochemical cell according to various aspects of the present disclosure includes providing a subassembly including a separator layer and a current collector layer coupled to the separator layer. The method further includes providing an electrode ink including an electroactive material, a binder, and a solvent. The method further includes creating a reference electrode precursor by applying an electroactive precursor layer to the current collector layer. The electroactive precursor layer covers greater than or equal to about 90% of a superficial surface area of a surface of the current collector layer. The electroactive precursor layer includes the electrode ink. The method further includes creating the reference electrode assembly by drying the electroactive precursor layer to remove at least a portion of the solvent, thereby forming an electroactive layer. The electroactive layer is solid and porous.

Abstract: A reference electrode assembly for an electrochemical cell of a secondary lithium ion battery and methods of manufacturing the same. The reference electrode assembly includes a porous membrane having a major surface and a porous reference structure deposited on the major surface of the porous membrane. The porous reference structure includes a porous carbon layer and a porous reference electrode layer that at least partially overlaps the porous carbon layer on the major surface of the porous membrane.

Abstract: A battery system includes a rechargeable energy storage system and a battery controller. The rechargeable energy storage system has a rapid charging mode and a discharging mode. The battery controller is electrically coupled to the rechargeable energy storage system and is configured to store multiple charging tables that contain multiple charge current limit entries, where each charging table corresponds to a unique one of multiple initial state-of-charge values, determine a starting state-of-charge value of the rechargeable energy storage system in response to entering the rapid charging mode, select up to two charging tables in response to the starting state-of-charge value of the rechargeable energy storage system being adjacent to up to two of the initial state-of-charge values, and control a charging current provided to the rechargeable energy storage system based on the charge current limit entries in the up to two charging tables as selected.

Abstract: A cell-mounted application specific integrated circuit (ASIC) system for a vehicle includes a battery pack having multiple individual battery cells. An individual cell-mounted application specific integrated circuit (ASIC) is in communication with each of the individual battery cells, with the ASIC drawing power for operation directly from the individual battery cell. A battery control unit is in communication with the ASIC. A central electronics control unit is in communication with the ASIC. The ASIC communicates wirelessly with the battery control unit and the central electronics control unit.

Abstract: A method of manufacturing a component for a reference electrode assembly according to various aspects of the present disclosure includes providing a separator having first and second opposing surfaces. The method further includes sputtering a first current collector layer to the first surface via magnetron or ion beam sputtering deposition. A porosity of the separator is substantially unchanged by the sputtering. In one aspect, the method further includes sputtering a second current collector layer to the second surface via magnetron or ion beam sputtering deposition. In one aspect, the first current collector layer includes nickel and defines a first thickness of greater than or equal to about 200 nm to less than or equal to about 300 nm and the second current collector layer includes gold and defines a second thickness of greater than or equal to about 25 nm to less than or equal to about 100 nm.

Abstract: Management system for a rechargeable energy storage device in an electric vehicle and corresponding method is disclosed. The rechargeable energy storage device has one or more battery packs each having a plurality of modules with one or more respective cells. A respective module management unit is embedded in each of the plurality of modules through respective microcircuits and configured to determine one or more local parameters. A supervisory controller is configured for two-way communication with the respective module management unit. The supervisory controller is configured to receive the local parameters, determine one or more global pack parameters based in part on the local parameters and transmit the global pack parameters back to the respective management unit. The supervisory controller is configured to control operation of the rechargeable energy storage device based in part on the global pack parameters and the local parameters.

Abstract: A method of forming a separator for a lithium-ion battery includes arranging a polymer film in contact with a sacrificial layer to form a cutting stack. The method includes disposing the cutting stack between a first vitreous substrate and a second vitreous substrate. The method includes applying an infrared laser to the cutting stack through the first vitreous substrate to generate heat at the sacrificial layer. The method also includes transferring heat from the sacrificial layer to the polymer film to thereby cut out a portion of the polymer film and form the separator. A method of cutting a polymer film and a cutting system are also explained.

Abstract: Composite reference electrode substrates and relating methods are provided. The composite reference electrode substrate includes a separator portion and a current collector portion adjacent to the separator portion. A method for forming the reference electrode substrate includes anodizing one or more surfaces of a first side of an aluminum foil so as to form a porous separator portion disposed adjacent to a porous current collector portion. The porous separator portion includes aluminum oxide, and the current collector portion includes the aluminum foil. The separator portion and the current collector portion each have a porosity of greater than or equal to about 10 vol. % to less than or equal to about 80 vol. %.

Abstract: Presented are vehicle charging systems and control logic for provisioning vehicle grid integration (VGI) activities, methods for making/using such charging systems, and electric-drive vehicles with intelligent vehicle charging and VGI capabilities. A method of controlling charging operations of electric-drive vehicles includes a vehicle controller detecting if a vehicle is coupled to an electric vehicle supply equipment (EVSE), and determining if the vehicle's current mileage exceeds a calibrated mileage threshold. Responsive to the vehicle being connected to the EVSE and the vehicle's current mileage exceeding the calibrated mileage threshold, the controller determines the current remaining life of the vehicle's traction battery pack and the current time in service of the vehicle. The vehicle controller determines if the current remaining battery life exceeds a predicted remaining battery life corresponding to the current time in service.

Abstract: A temperature sensor for a battery cell of a rechargeable battery is described, and includes a resistive sensing element, a first electrode, and a second electrode. The resistive sensing element, the first electrode, and the second electrode are affixed to a porous separator. The porous separator is interposed between an anode and a cathode of the battery cell. The resistive sensing element is electrically connected in series between the first electrode and the second electrode, and the resistive sensing element, the first electrode and the second electrode are affixed onto the separator as film layers, and are porous.

Abstract: Disclosed is an electrode assembly, comprising: an electrode; and an electrode tab, wherein the electrode tab is attached to the electrode, wherein the electrode tab comprises: a center portion, wherein the center portion comprises an attachment mechanism, wherein the electrode tab is attached to the electrode via the attachment mechanism; a protrusion portion, wherein the protrusion portion extends from the center portion and protrudes beyond a perimeter of the electrode; and a rounded portion, wherein the rounded portion extends from the center portion in a direction opposite the protrusion portion.

Abstract: A method for battery capacity estimation is provided. The method includes monitoring a sensor, collecting a plurality of data points including a voltage-based state of charge value and an integrated current value, defining within the data points a first data set collected during a first time period and a second data set collected during a second time period, determining an integrated current error related to the second data set, comparing the integrated current error related to the second data set to a threshold integrated current error. When the error related to the second data set exceeds the threshold, the method further includes resetting the second data set based upon an integrated current value from the first time period. The method further includes combining the data sets to create a combined data set and determining a voltage slope capacity estimate as a change in integrated current versus voltage-based state of charge.

Abstract: Management system for a rechargeable energy storage device in an electric vehicle and corresponding method is disclosed. The rechargeable energy storage device has one or more battery packs each having a plurality of modules with one or more respective cells. A respective module management unit is embedded in each of the plurality of modules through respective microcircuits and configured to determine one or more local parameters. A supervisory controller is configured for two-way communication with the respective module management unit. The supervisory controller is configured to receive the local parameters, determine one or more global pack parameters based in part on the local parameters and transmit the global pack parameters back to the respective management unit. The supervisory controller is configured to control operation of the rechargeable energy storage device based in part on the global pack parameters and the local parameters.