Abstract: In general, a solid-state electrode includes an electrode composite layer comprising a plurality of active material particles mixed with a solid electrolyte buffer material comprising a first plurality of solid electrolyte particles layered onto and directly contacting a current collector foil, and an electrically non-conductive separator layer comprising a second plurality of solid electrolyte particles layered onto and directly contacting the electrode composite layer. In some examples, an interpenetrating boundary layer is disposed between the electrode composite layer and the electrically non-conductive separator layer. In some examples, the electrode composite layer includes one or more conductive additives intermixed with the plurality of active material particles, and the electrode composite layer is electrically conductive. In some examples, the electrode composite layer is adhered together by a binder.

Abstract: Methods are disclosed for manufacturing an electrode for use in a device such as a secondary battery. Electrodes may include a first layer having first active particles adhered together by a binder, a second layer having second active particles adhered together by a binder, and an interphase layer interposed between the first and second layers. In some examples, the interphase layer may include an interpenetration of the first and second particles, such that substantially discrete fingers of the first layer interlock with substantially discrete fingers of the second layer.

Abstract: Electrochemical cells of the present disclosure may include one or more multilayered electrodes. Each multilayered electrode may be configured such that active materials of the layer closest to the current collector have a lower energy to lithiate per mole, a higher energy to delithiate per mole, a different solid state diffusivity, and/or a different average particle size. This arrangement counteracts, for example, natural gradient fields and undesirable polarization found in standard lithium-ion batteries.

Abstract: An electrode including an integrated fibrous separator may include an active material layer layered onto a current collector substrate, and an integrated separator layer comprising a mixture of ceramic particles and fibers layered onto the active material layer. The fibers may be oriented substantially horizontally, and may be configured to increase a lateral strength of the electrode. In some examples, the electrode includes two or more active material layers disposed between the integrated separator layer and the current collector substrate. In some examples, the electrode includes an interlocking region disposed between the active material layer and the integrated separator layer.

Abstract: An electrode including an integrated separator for use in an electrochemical device may include one or more active material layers, and a separator layer comprising inorganic particles. An interlocking region may couple the separator layer to an adjacent active material layer. In some examples, the interlocking region may include interlocking fingers formed by an interpenetration of active material particles of the active material layers with ceramic particles of the separator.

Abstract: A method for manufacturing a solventless multilayered electrode may include mixing electrode particles with binders to form dry electrode mixtures, compressing the dry electrode mixtures to form electrode films, stacking the electrode films, and compressing the stacked electrode films. Suitable electrode films may include active material particles, conductive particles, electrochemically inactive ceramic particles, and/or the like. In some examples, compressing the stacked electrode films may include compressing the electrode films between pairs of rollers having patterns disposed on one or more exterior surfaces, thereby increasing surface roughness of the electrode films. A system for manufacturing solventless multilayered electrodes may comprise a first plurality of rollers configured to compress dry electrode mixes into electrode films, and a second plurality of rollers configured to compress a stack of electrode films into a single electrode stack.

Abstract: Anodes having high top layer sphericity may include a first active material layer including a plurality of first active material particles having a first particle sphericity and a first particle size layered onto and directly contacting a current collector, and a second active material layer including a plurality of second active material particles having a second particle sphericity and a second particle size layered onto and directly contacting the first layer. The second particle sphericity is greater than the first particle sphericity. In some examples, the second particle size is greater than the first particle size.

Abstract: Electrochemical cells of the present disclosure may include one or more multilayered electrodes. One or both multilayered electrodes may be configured such that a second layer farther from the current collector has a higher resistance to densification than a first layer closer to the current collector. This may be achieved by including a plurality of non-active ceramic particles in the second layer. Accordingly, calendering of the electrode results in a greater compression of the first layer, and a beneficial porosity profile is created. This may improve the ionic conductivity of the electrode, as compared with known systems.

Abstract: Methods are disclosed for manufacturing an electrode for use in a device such as a secondary battery. Electrodes may include a first layer having first active particles adhered together by a binder, a second layer having second active particles adhered together by a binder, and an interphase layer interposed between the first and second layers. In some examples, the interphase layer may include an interpenetration of the first and second particles, such that substantially discrete fingers of the first layer interlock with substantially discrete fingers of the second layer.

Abstract: An electrochemical cell including a positive electrode (e.g., a cathode) and a negative electrode (e.g., an anode), at least one of which includes an integrated ceramic separator. An integrated ceramic separator may include a plurality of ceramic particles. In some examples, an interlocking region may be disposed between the integrated ceramic separator layer and a corresponding electrode layer, the region including a non-planar boundary between the two layers. In some examples, the electrochemical cell includes a polyolefin separator disposed between the positive electrode and the negative electrode. In some examples, both the positive electrode and the negative electrode include an integrated ceramic separator. In these examples, the positive electrode and the negative electrode may be calendered together such that the integrated separator layers merge and become indistinguishable from each other.

Abstract: An electrochemical cell including a positive electrode (e.g., a cathode) and a negative electrode (e.g., an anode), at least one of which includes an integrated ceramic separator. An integrated ceramic separator may include a plurality of ceramic particles. In some examples, an interlocking region may be disposed between the integrated ceramic separator layer and a corresponding electrode layer, the region including a non-planar boundary between the two layers. In some examples, the electrochemical cell includes a polyolefin separator disposed between the positive electrode and the negative electrode. In some examples, both the positive electrode and the negative electrode include an integrated ceramic separator. In these examples, the positive electrode and the negative electrode may be calendered together such that the integrated separator layers merge and become indistinguishable from each other.

Abstract: An electrochemical cell including a positive electrode (e.g., a cathode) and a negative electrode (e.g., an anode), at least one of which includes an integrated ceramic separator. An integrated ceramic separator may include a plurality of ceramic particles. In some examples, an interlocking region may be disposed between the integrated ceramic separator layer and a corresponding electrode layer, the region including a non-planar boundary between the two layers. In some examples, the electrochemical cell includes a polyolefin separator disposed between the positive electrode and the negative electrode. In some examples, both the positive electrode and the negative electrode include an integrated ceramic separator. In these examples, the positive electrode and the negative electrode may be calendered together such that the integrated separator layers merge and become indistinguishable from each other.

Abstract: Electrochemical cells of the present disclosure may include one or more multilayered electrodes. Each multilayered electrode may be configured such that active materials of the layer closest to the current collector have a lower energy to lithiate per mole, a higher energy to delithiate per mole, a different solid state diffusivity, and/or a different average particle size. This arrangement counteracts, for example, natural gradient fields and undesirable polarization found in standard lithium-ion batteries.

Abstract: An electrode including conduction channels includes at least one electrode layer layered onto a current collector, the electrode layer including a plurality of active material particles and a plurality of high aspect ratio components. The high aspect ratio components are configured to provide ion conduction channels through the electrode layer. In some examples, the electrode may include two or more electrode layers, at least one of which includes high aspect ratio components. In some examples, the high aspect ratio components may be oriented transverse to the current collector to provide ion transport through a first electrode layer to a second electrode layer.

Abstract: Electrochemical cells of the present disclosure may include one or more multilayered electrodes. One or both multilayered electrodes may be configured such that a second layer farther from the current collector has a higher resistance to densification than a first layer closer to the current collector. This may be achieved by including a plurality of non-active ceramic particles in the second layer. Accordingly, calendering of the electrode results in a greater compression of the first layer, and a beneficial porosity profile is created. This may improve the ionic conductivity of the electrode, as compared with known systems.

Abstract: An electrode including an integrated separator for use in an electrochemical device may include one or more active material layers, and a separator layer comprising inorganic particles. An interlocking region may couple the separator layer to an adjacent active material layer. In some examples, the interlocking region may include interlocking fingers formed by an interpenetration of active material particles of the active material layers with ceramic particles of the separator.

Abstract: Electrochemical cells of the present disclosure may include one or more multilayered electrodes. One or both multilayered electrodes may be configured such that a second layer farther from the current collector has a higher resistance to densification than a first layer closer to the current collector. This may be achieved by including a plurality of non-active ceramic particles in the second layer. Accordingly, calendering of the electrode results in a greater compression of the first layer, and a beneficial porosity profile is created. This may improve the ionic conductivity of the electrode, as compared with known systems.

Abstract: Methods are disclosed for manufacturing an electrode for use in a device such as a secondary battery. Electrodes may include a first layer having first active particles adhered together by a binder, a second layer having second active particles adhered together by a binder, and an interphase layer interposed between the first and second layers. In some examples, the interphase layer may include an interpenetration of the first and second particles, such that substantially discrete fingers of the first layer interlock with substantially discrete fingers of the second layer.

Abstract: Systems and methods of the present disclosure include applying a mask to a substrate before coating the substrate with a multilayer composite to form an electrode. The mask may be removed to produce desired gaps in the coating for further manufacturing of wound battery cell designs and the like. In some examples, the mask comprises a single-sided thermal-release tape.

Abstract: A multilayered electrode having a high discharge rate includes a current collector, a first electrode layer adjacent the current collector, and a second electrode layer adjacent the first electrode layer. Active material particles included in the first electrode layer and the second electrode layer have tailored electrochemical properties, which achieve a “backfill” lithiation profile. Active material particles in the first electrode layer have a greater average voltage potential with respect to lithium than active material particles in the second electrode layer. This configuration causes the first electrode layer to lithiate before the second electrode layer during discharge of an electrochemical cell including the electrode.