Abstract: Provided herein are methods for processing electrochemically active materials and resulting active material structures for use in rechargeable batteries. The resulting active materials structures include carbon containing coatings that partially or completely cover the surface of the active material structures. In a typical embodiment, the method includes providing a solution of carbon containing precursor in a solvent, dispersing electrochemically active material in the solution to form a mixture, removing the solvent from the mixture to form electrochemically active material coated with the carbon containing precursor, and heating the electrochemically active material coated with the carbon containing precursor in an inert atmosphere at a temperature sufficient to at least partially convert the carbon containing precursor into a carbon coating.

Abstract: Provided herein are methods for processing electrochemically active materials for use in rechargeable batteries. The methods may also be practiced on electrodes and batteries containing such electrochemically active materials. In a typical embodiment, a method of chemically modifying the surface of an electrochemically active component of a battery is provided, the method including receiving the electrochemically active material and exposing the electrochemically active material to a gaseous reactant under conditions that chemically modify surfaces of the electrochemically active material that are accessible to the gaseous reactant, and thereby produce a modified electrochemically active material having improved properties for use in the battery.

Abstract: Provided are electrochemical cell assemblies and methods of fabricating thereof. A cell assembly includes an anode containing lithium titanium oxide and a cathode forming a jellyroll together with the anode. Each of the electrodes is connected to a separate cap and electrically insulated from the case. As such, the case is electrochemically neutral and may be made from a larger selection of materials. For example, a case may be made from steel that would otherwise dissolve if exposed to the anode potential during cycling of the battery. Some of these case materials simplify processing and sealing characteristics. In certain embodiments, a case may be crimped around each of the caps and corresponding gaskets to provide sealing interfaces. The caps or at least their surfaces exposed to the electrolyte are made from materials that are electrochemically stable at corresponding potentials of the electrodes.

Abstract: The present invention provides a protection circuit disposed in a lithium-ion cell for protection of the lithium-ion cell. The protection circuit includes a first protection module, a second protection module, an integrated circuit module, a thermal sensor or thermocouple, a switch, a fuse and/or a resistor.