Abstract: Electrochemical cells for a lithium-ion battery are formed on a conductive wire substrate drawn through a multi-chamber deposition reactor, then assembled together in series and parallel connection to create a fail-safe battery. The wire substrate acts as current-limiting fuse that melts when there is a short affecting that cell, while remaining cells of the battery continue to operate. Each cell has solid-state thin film layers concentrically nucleated and grown over a length of the wire substrate as it is drawn through the successive deposition sections, including at least a first electrochemical active material layer, ion-exchange material layer, a second electrochemical active material layer, which is followed by deposition of a conductive layer forming an outer current collector and hermetic seal for the cell. The active material layers form electrodes (cathode and anode), wherein the anode may be formed as a multi-layer composite with stress-absorbing compliant layers.

Abstract: Electrochemical cells for a lithium-ion battery are formed on a conductive wire substrate drawn through a multi-chamber deposition reactor, then assembled together in series and parallel connection to create a fail-safe battery. The wire substrate acts as current-limiting fuse that melts when there is a short affecting that cell, while remaining cells of the battery continue to operate. Each cell has solid-state thin film layers concentrically nucleated and grown over a length of the wire substrate as it is drawn through the successive deposition sections, including at least a first electrochemical active material layer, ion-exchange material layer, a second electrochemical active material layer, which is followed by deposition of a conductive layer forming an outer current collector and hermetic seal for the cell. The active material layers form electrodes (cathode and anode), wherein the anode may be formed as a multi-layer composite with stress-absorbing compliant layers.

Abstract: A reserve activated lithium ion battery is provided with a number of safety features designed to prevent a thermal run-away condition. The reserve activated battery may include a non-flammable electrolyte, a phosphate-based cathode, an anode with a non-fluorinated binder, and/or a solid electrolyte interface on the anode.

Abstract: Methods of fabricating porous silicon by electrochemical etching and subsequent coating with a passivating agent process are provided. The coated porous silicon can be used to make anodes and batteries. It is capable of alloying with large amounts of lithium ions, has a capacity of at least 1000 mAh/g and retains this ability through at least 60 charge/discharge cycles. A particular pSi formulation provides very high capacity (3000 mAh/g) for at least 60 cycles, which is 80% of theoretical value of silicon. The Coulombic efficiency after the third cycle is between 95-99%. The very best capacity exceeds 3400 mAh/g and the very best cycle life exceeds 240 cycles, and the capacity and cycle life can be varied as needed for the application.

Abstract: Nanostructured anodes for high capacity rechargeable batteries are provided according to various aspects of the disclosure. The nanostructure anodes may comprise silicon nanoparticles for the active material of the anodes to increase the storage capacity of the batteries. The silicon nanoparticles are able to move relative to one another to accommodate volume expansion during lithium intercalation, and therefore mitigate active material degradation due to volume expansion. The anodes may also comprise elastomeric binders that bind the silicon nanoparticles together and prevent capacity loss due to separation and electrical isolation of the silicon nanoparticles.

Abstract: A reserve activated lithium ion battery is provided with a number of safety features designed to prevent a thermal run-away condition. The reserve activated battery may include a non-flammable electrolyte, a phosphate-based cathode, an anode with a non-fluorinated binder, and/or a solid electrolyte interface on the anode.

Abstract: A modular vehicle system for a vehicle includes one or more elongated modular members adapted to be coupled to an interior portion of a vehicle. One or more removable articles are configured for attachment to one or more of the members and a utility system provides utilities to the articles. One or more holders are positioned to align with the members and are coupled to the articles for attaching them to one or more of the members. The articles are interchangeable across multiple different vehicles, including different vehicle models and makes.

Abstract: In making a laminar assembly for use in the battery, a layer of battery electrode material is deposited onto a substrate surface and the battery electrode material is caused to have an uneven surface. Then an electrolyte layer is deposited onto the uneven surface of the battery electrode material. Where the method calls for first depositing the electrolyte material, then electrolyte material is deposited onto the substrate layer where the electrolyte layer is caused to have an uneven surface. Thereafter, the battery electrode material is deposited onto the uneven surface of the electrolyte material. In both cases, slippage between the battery electrode material and electrolyte material is reduced during cutting, folding and other handling process in making a laminar battery, thereby reducing the probability of shorts in the battery.

Abstract: This invention is directed to a solid electrolyte containing a polymeric matrix, a salt, a solvent and a viscosifying agent containing a reactive group as well as electrolytic cells prepared from such solid electrolytes.