Abstract: A method of making the sulfide-impregnated solid-state battery is provided. The method comprises providing a cell core that is constructed by cell unit. The cell core is partially sealed into the packaging such as the Al laminated film and metal can. The method further comprises introducing a sulfide solid-state electrolyte (S-SSE) precursor solution in the cell core, the S-SSE precursor solution comprises a sulfide solid electrolyte and a solvent. The method further comprises evaporating the solvent from the cell core to dry the cell core to solidify the sulfide-based solid-state electrolyte within the cell core and pressurizing the cell core to densify the solid sulfide-base electrolyte within the cell core. The cell core is then fully sealed.

Abstract: A sulfide-impregnated solid-state battery is provided. The battery comprises a cell core constructed by basic cell units. Each unit comprises a positive electrode comprising a cathode layer and a positive meshed current collector comprising a conductive material which is further coated by oxide-based solid-state electrolyte. The cell unit further comprises a negative electrode comprising an anode layer and a negative meshed current collector comprising a conductive material which is further coated by oxide-based solid-state electrolyte. The positive and negative electrodes are stacked together to form the cell unit. The two coated oxide-based solid electrolyte layers are disposed between the positive and negative electrode as dual separators. Such a cell unit may be repeated or connected in parallel or bipolar stacking to form the cell core to achieve a desired battery voltage, power and energy. The cell core comprises a sulfide-based solid-state electrolyte dispersed in the pore structures of cell core.

Abstract: An electrode including micro-sized secondary particle (MSSP) with enhanced ionic conductivity for solid-state battery is provided. The MSSP comprises a cathode particle and a solid-state electrolyte. The cathode particle is at least partially coated by solid-state electrolyte. The lithium ion transport inside the micro-sized secondary particles is increased by the incorporation of solid-state electrolyte. The electrode can be prepared by casting the slurry comprising MSSP, another electrolyte, binders, and conductive additives on the current collector. The current collector is comprised of a conductive material. The current collector has a first side and a second side. The electrode active material layer is disposed on one of the first and second sides of the current collector.

Abstract: A solid-state battery cell having a capacitor interlayer is disclosed. The solid-state battery includes an anode, a cathode spaced from the anode, a solid-state electrolyte layer disposed between the anode and the cathode, and a capacitor assisted interlayer sandwiched between at least one of (i) the anode and solid-state electrolyte layer, and (ii) the cathode and the solid-state electrolyte layer. The capacitor assisted interlayer comprise at least one of a polymer-based material, an inorganic material, and a polymer-inorganic hybrid material; and a capacitor anode active material or a capacitor cathode active material. The polymer-based material includes at least one of a poly(ethylene glycol) methylether acrylate with Al2O3 and LiTFSI, a polyethylene oxide (PEO) with LiTFSI, and a poly(vinylidene fluoride) copolymer with hexafluoropropylene (PVDF-HFP)-based gel electrolyte. The inorganic material includes a 70% Li2S-29% P2S5-1% P2O5.

Abstract: Electrodes are formed with a porous layer of particulate electrode material bonded to each of the two major sides of a compatible metal current collector. In one embodiment, opposing electrodes are formed with like lithium-ion battery anode materials or like cathode materials or capacitor materials on both sides of the current collector. In another embodiment, a battery electrode material is applied to one side of a current collector and capacitor material is applied to the other side. In general, the electrodes are formed by combining a suitable grouping of capacitor layers with un-equal numbers of anode and cathode battery layers. One or more pairs of opposing electrodes are assembled to provide a combination of battery and capacitor energy and power properties in a hybrid electrochemical cell. The cells may be formed by stacking or winding rolls of the opposing electrodes with interposed separators.

Abstract: Lithium-based and sodium-based batteries and capacitors using metal foil current collectors, coated with porous layers of particles of active electrode materials for producing an electric current, may adapted to produce heat for enhancing output when the cells are required to periodically operate during low ambient temperatures. A self-heating cell may be placed in heat transfer contact with a working cell that is temporarily in a cold environment. Or one or both of the anode current collector and cathode current collectors of a heating cell may be formed with shaped extended portions, uncoated with electrode materials, through which cell current may be passed for resistance heating of the extended current collector areas. These extended current collector areas may be used to heat the working area of the cell in which they are incorporated, or to contact and heat an adjacent working cell.

Abstract: Electrodes are formed with a porous layer of particulate electrode material bonded to each of the two major sides of a compatible metal current collector. In one embodiment, opposing electrodes are formed with like lithium-ion battery anode materials or like cathode materials or capacitor materials on both sides of the current collector. In another embodiment, a battery electrode material is applied to one side of a current collector and capacitor material is applied to the other side. In general, the electrodes are formed by combining a suitable grouping of capacitor layers with un-equal numbers of anode and cathode battery layers. One or more pairs of opposing electrodes are assembled to provide a combination of battery and capacitor energy and power properties in a hybrid electrochemical cell. The cells may be formed by stacking or winding rolls of the opposing electrodes with interposed separators.

Abstract: A copper foil, intended for use as a current collector in a lithium-containing electrode for a lithium-based electrochemical cell, is subjected to a series of chemical oxidation and reduction processing steps to form a field of integral copper wires extending outwardly from the surfaces of the current collector (and from the copper content of the foil) to be coated with a resin-bonded porous layer of particles of active electrode material. The copper wires serve to anchor thicker layers of porous electrode material and enhance liquid electrolyte contact with the electrode particles and the current collector to improve the energy output of the cell and its useful life.

Abstract: Lithium-utilizing electrochemical cells, providing battery and hybrid-capacitor activity, are formed of one or more lithium battery anodes, one or more lithium battery cathodes, and one or more positive-charge or negative-charge hybrid capacitor electrodes which are formed of a combination of capacitor particles with one of anode or cathode particles. The anode and cathodes are formed of porous layers of particles of anode or cathode material, bonded to each side of a current collector foil. The hybrid capacitor electrodes are formed of porous layers of capacitor particles, mixed or layered with anode or capacitor particles, bonded to each side of a current collector foil. The compositions of the hybrid capacitors are determined to balance the capacities of the electrodes in the lithium-ion electrochemical cell to intercalate or adsorb lithium cations and corresponding anions in the electrolyte infiltrating the pores of the electrode materials.

Abstract: A copper foil, intended for use as a current collector in a lithium-containing electrode for a lithium-based electrochemical cell, is subjected to a series of chemical oxidation and reduction processing steps to form a field of integral copper wires extending outwardly from the surfaces of the current collector (and from the copper content of the foil) to be coated with a resin-bonded porous layer of particles of active electrode material. The copper wires serve to anchor thicker layers of porous electrode material and enhance liquid electrolyte contact with the electrode particles and the current collector to improve the energy output of the cell and its useful life.

Abstract: A hybrid lithium-ion battery/capacitor cell comprising at least a pair of graphite anodes assembled with a lithium compound cathode and an activated carbon capacitor electrode can provide useful power performance properties and low temperature properties required for many power utilizing applications. The graphite anodes are formed of porous layers of graphite particles bonded to at least one side of current collector foils which face opposite sides of the activated carbon capacitor. The porous graphite particles are pre-lithiated to form a solid electrolyte interface on the anode particles before the anodes are assembled in the hybrid cell. The pre-lithiation step is conducted to circumvent the irreversible reactions in the formation of a solid electrolyte interface (SEI) and preserve the lithium content of the electrolyte and lithium cathode during formation cycling of the assembled hybrid cell. The pre-lithiation step is also applicable to other anode materials that benefit from such pre-lithiation.

Abstract: Lithium-utilizing electrochemical cells, providing hybrid battery and capacitor activity, are formed of one or more lithium battery anodes, one or more lithium battery cathodes, and with at least one capacitor electrode in the cell, with an equal number of electrodes with opposing charges. The respective electrodes are formed of porous layers of one of lithium anode material particles, lithium cathode material particles, or compatible capacitor material particles, formed on both sides of a compatible current collector foil. The capacity and durability of the hybrid cell is enhanced when through-holes are formed through selected electrodes, or through the current collector foils of selected electrodes, to enhance the flow of a non-aqueous liquid electrolyte solution, with its lithium cations and associated anions, to reach both sides of the closely spaced, separated, electrodes in an assembled and operating lithium battery/capacitor hybrid cell.

Abstract: A method for laser welding a plurality of battery foils to a battery tab that does not include ultrasonic welding and includes clamping the plurality of battery foils and the battery tab together. Each of the plurality of battery foils has a thickness that is between 0.004 millimeters and 0.03 millimeters. The battery tab has a thickness that is between 0.1 millimeters and 0.5 millimeters. The method further includes laser welding the plurality of battery foils to the battery tab.

Abstract: The electrical performance and structural integrity of lithium battery electrodes, formed of particles of active electrode materials, are improved by mixing electrically conductive wires (metal wires, carbon fibers, and/or the like, including chemically-reduced metal oxide particles) with the particles of active electrode material. For example, copper wires may be intimately mixed with anode particles in porous anode layers which are resin-bonded to sides of a copper current collector foil. And aluminum wires may be mixed with cathode particles in porous cathode layers resin bonded to an aluminum current collector. The wires may be used to increase both the conductivity of electrons and lithium ions and the flexibility of the electrode layer when the electrodes are infiltrated with a solution of a lithium salt electrolyte. The workable thickness of each electrode layer can thus be increased and its performance enhanced to produce a lower cost and better forming battery.

Abstract: Lithium battery cells, and battery packs comprising the same, include an electrolyte, and an anode and a cathode, each of which include a current collector having a length, the length defining a first end and a second end, a width, a host or active material disposed on the current collector between the first end and the second end, a first tab extending from the first end, and a second tab extending from the second end. A plurality of cells can be stacked in a planar configuration, and a plurality of anode first tabs, a plurality of anode second tabs, a plurality of cathode first tabs, and a plurality of cathode second tabs can each be electrically connected via a respective busbar. The anode and cathode can have a length:width ratio of at least three, or 2.5 to 10. The battery cell can be a power source for an electric/hybrid vehicle.

Abstract: The present disclosure provides an electrochemical device that may include a stack having at least one electrochemical cell having a first electrode, a second electrode, a porous separator, and an electrolyte liquid disposed in the porous separator and optionally disposed in the first electrode, the second electrode, or both the first electrode and the second electrode. The stack has a first volume of electrolyte liquid. The electrochemical device also has an integrated storage region that stores a second volume of electrolyte liquid and is in fluid communication with the plurality of electrochemical cells and is configured to transfer the electrolyte liquid into the plurality of electrochemical cells, wherein the second volume of electrolyte liquid is at least about 3% of the first volume. Methods of increasing lifetime of the electrochemical device are also provided.

Abstract: Some lithium-ion batteries are assembled using a plurality of electrically interconnected battery pouches to obtain the electrical potential and power requirements of the battery application. Such battery pouches may be prepared to contain a stacked grouping, or a wound grouping, of inter-layered and interconnected anodes, cathodes, and separators, each wetted with a liquid electrolyte. A reference electrode, an optional auxiliary reference electrode, and adjacent enclosing modified working electrodes are combined in a specific arrangement and inserted within the stack structure, or the wound structure, of other cell members to enable accurate assessment of both anode group and cathode group performance, and to validate and regenerate reference electrode capability.

Abstract: Lithium battery cells, and battery packs comprising the same, include an electrolyte, and an anode and a cathode, each of which include a current collector having a length, the length defining a first end and a second end, a width, a host or active material disposed on the current collector between the first end and the second end, a first tab extending from the first end, and a second tab extending from the second end. A plurality of cells can be stacked in a planar configuration, and a plurality of anode first tabs, a plurality of anode second tabs, a plurality of cathode first tabs, and a plurality of cathode second tabs can each be electrically connected via a respective busbar. The anode and cathode can have a length:width ratio of at least three, or 2.5 to 10. The battery cell can be a power source for an electric/hybrid vehicle.

Abstract: A method of making a patterned electrode material is provided. The method includes disposing a first mask having a first pattern on a first surface of an electrode material, disposing a second mask having a second pattern on an opposing second surface of the electrode material, applying pressure through both the first mask and the second mask towards the electrode material, wherein the first pattern of the first mask is engraved into the first surface of the electrode material and the second pattern of the second mask is engraved into the second surface of the electrode material, and removing the first mask and the second mask form the electrode material to from the patterned electrode material.

Abstract: A lithium ion battery is provided that includes: a positive electrode; a negative electrode; and a polymer separator soaked in an electrolyte solution, the polymer separator being disposed between the positive electrode and the negative electrode. The positive electrode includes an active material of lithium manganese oxide, lithium nickel manganese cobalt oxide, or combinations thereof. The negative electrode includes lithium titanate. A method of making the lithium ion battery is also provided.