Abstract: Porous separators for use in electrochemical cells and methods of their manufacture are provided. The separators are porous structures comprising an electroactive material and an electronically insulating structural material, wherein the electroactive material forms a percolating path in the separator.

Abstract: Systems and methods for assessing voltage threshold detection circuitry of individual battery cells within a battery pack supplying power to a vehicle are disclosed. One example system comprises, a plurality of battery cells within a battery pack, a plurality of voltage threshold detecting circuits detecting voltage of the plurality of battery cells, a voltage of a first battery cell of the plurality of battery cells coupled to a first voltage threshold detecting circuit of the plurality of voltage threshold detecting circuits, and a network that selectively couples a second battery cell to the first voltage detecting circuit while the first battery cell is coupled to the first voltage detecting circuit.

Abstract: Systems and methods for a scalable battery controller are disclosed. In one example, a circuit board coupled to a battery cell stack is designed to be configurable to monitor and balance battery cells of battery cell stacks that may vary depending on battery pack requirements. Further, the battery pack control module may configure software instructions in response to a voltage at a battery cell stack.

Abstract: An electrode/separator assembly for use in an electrochemical cell includes a current collector; a porous composite electrode layer adhered to the current collector, said electrode layer comprising at least electroactive particles and a binder; and a porous composite separator layer comprising inorganic particles substantially uniformly distributed in a polymer matrix to form nanopores and having a pore volume fraction of at least 25%, wherein the separator layer is secured to the electrode layer by a solvent weld at the interface between the two layers, said weld comprising a mixture of the binder and the polymer. Methods of making and using the assembly are also described.

Abstract: A material suitable for use in an electrode, preferably an anode, and processes of its formation are provided. The material includes an electrode base material and an organic artificial solid electrolyte interface material including a water soluble organic polymer coating the electrode base material. The polymer is polymerized with a crosslinker to form the organic artificial solid electrolyte interface material. The resulting artificial SEI coated electrode material demonstrates superior discharge rate capacity and cycle stability.

Abstract: An LFP electrode material is provided which has improved impedance, power during cold cranking, rate capacity retention, charge transfer resistance over the current LFP based cathode materials. The electrode material comprises crystalline primary particles and secondary particles, where the primary particle is formed from a plate-shaped single-phase spheniscidite precursor and a lithium source. The LFP includes an LFP phase behavior where the LFP phase behavior includes an extended solid-solution range.

Abstract: Systems and methods for balancing charge of battery cells of a battery pack are disclosed. In one example, battery cell balancing may be improved by balancing battery cells of a battery cell stack simultaneously. The system and method may be particularly useful battery packs that may be constructed with battery cell stacks that vary in a number of series battery cells.

Abstract: Systems and methods for verifying a reference voltage within a battery pack are disclosed. In one example, an assessment of a reference voltage is made via a band-gap voltage of a microcontroller. The system and method may be particularly useful determining whether or not the reference voltage has drifted from a desired voltage.

Abstract: A lithium-ion battery is provided that has a fast charge and discharge rate capability and low rate of capacity fade during high rate cycling. The battery can exhibit low impedance growth and other properties allowing for its use in hybrid electric vehicle applications and other applications where high power and long battery life are important features.

Abstract: Electroactive compositions are disclosed for use in lithium ion battery electrodes. The compositions, such as multifunctional mixed metal olivines, provide an electrochemical cell having a plurality of open circuit voltages at different states of charge. The compositions afford improved state-of-charge monitoring, overcharge protection and/or overdischarge protection for lithium ion batteries.

Abstract: A battery pack includes at least one voltaic cell module. A substrate is mechanically coupled to the module and configured to receive excess heat therefrom. A section of an electrically insulating thermal gap pad is arranged between the module and the substrate. The pad includes a dielectric sheet supporting a deformable layer.

Abstract: Systems and methods for balancing battery cells of a battery pack are disclosed. In one example, a charge imbalance is determined while battery cells operate in a high charge resolution voltage range. The charge imbalance determined during operation in the high charge resolution voltage range may be removed when the battery cells are operated in a low charge resolution voltage range. The system and method may be particularly useful for balancing battery cells that operate in the low charge resolution voltage range for a large portion of their operating time.

Abstract: This disclosure relates to compositions and methods of manufacture of electrodes for batteries, including rechargeable lithium batteries, wherein at least one electrode comprises an electroactive material and a malleable metal. The electrode may be substantially free of other conductive additives and organic binders. Manufacture of the electrode may be performed without solvent or sintering.

Abstract: Disclosed herein are lithium or lithium-ion batteries that employ an aluminum or aluminum alloy current collector protected by conductive coating in combination with electrolyte containing aluminum corrosion inhibitor and a fluorinated lithium imide or methide electrolyte which exhibit surprisingly long cycle life at high temperature.

Abstract: Provided are methods of passivating active materials for use in electrochemical cells as well as active materials and cell components prepared using such methods. Active material particles may be combined with passivating material particles, and this combination may be mixed together using high shear mixing. The mixed combination may not include any solvents or binders. As such, drying mixing may be performed on this combination of the active material particles and passivating material particles. A passivating layer is formed on the active material particles during mixing. This passivating layer later prevents direct contact between the active material particles and the electrolyte while still allowing ionic exchange. Furthermore, the passivating layer may increase electronic conductivity between active material particles in an electrode. The passivating layer may be mechanically bonded to the surface of the active material particles rather than chemically bonded.

Abstract: One aspect of the present disclosure relates to a wound electromechanical storage device assembly including a negative electrode sheet, a plurality of negative electrode tabs which are integral to and extend from the negative electrode sheet, a positive electrode sheet, a plurality of positive electrode tabs which are integral to and extend from the positive electrode sheet, and a separator sheet disposed between the negative and positive electrode sheets, wherein the negative electrode sheet, positive electrode sheet, and separator sheet are wound around a common axis to form a plurality of windings, and wherein each winding includes one negative electrode tab and one positive electrode tab.

Abstract: Subassemblies for use in an electrochemical device are provided, as are processes for preparing the subassemblies and electrochemical cells incorporating the subassemblies. In some embodiments, the subassemblies include (a) a first electrode and (b) a separator or a first current collector or both. The first electrode is bonded to the separator or the first current collector or both. In some embodiments, the subassemblies further include a second electrode and a second current collector. In some embodiments, the electrodes or separators are sintered. Bipolar cells are also provided, including a plurality of stacked electrochemical cells that are joined in series. The positive electrode and the negative electrode of each stack include a sintered electrode.

Abstract: Disclosed herein are lithium or lithium-ion batteries that employ an aluminum or aluminum alloy current collector protected by conductive coating in combination with electrolyte containing aluminum corrosion inhibitor and a fluorinated lithium imide or methide electrolyte which exhibit surprisingly long cycle life at high temperature.

Abstract: Provided herein are methods of processing electrode active material structures for use in electrochemical cells or, more specifically, methods of forming surface layers on these structures. The structures are combined with a liquid to form a mixture. The mixture includes a surface reagent that chemically reacts and forms a surface layer covalently bound to the structures. The surface reagent may be a part of the initial liquid or added to the mixture after the liquid is combined with the structures. In some embodiments, the mixture may be processed to form a powder containing the structures with the surface layer thereon. Alternatively, the mixture may be deposited onto a current collecting substrate and dried to form an electrode layer. Furthermore, the liquid may be an electrolyte containing the surface reagent and a salt. The liquid soaks the previously arranged electrodes in order to contact the structures with the surface reagent.

Abstract: Provided are electrochemical cells and electrolytes used to build such cells. The electrolytes include imide salts and/or methide salts as well as fluorinated solvents capable of maintaining single phase solutions at between about ?30° C. to about 80° C. The fluorinated solvents, such as fluorinated carbonates, fluorinated esters, and fluorinated esters, are less flammable than their non-fluorinated counterparts and improve safety characteristics of cells containing these solvents. The amount of fluorinated solvents in electrolytes may be between about 30% and 80% by weight not accounting weight of the salts. Linear and cyclic imide salts, such as LiN(SO2CF2CF3)2, and LiN(SO2CF3)2, as well as methide salts, such as LiC(SO2CF3)3 and LiC(SO2CF2CF3)3, may be used in these electrolytes. Fluorinated alkyl groups enhance solubility of these salts in the fluorinated solvents. In some embodiments, the electrolyte may also include a flame retardant, such as a phosphazene, and/or one or more ionic liquids.