Abstract: A free-standing electrode film may comprise an electrode active material and a composite binder comprising polytetrafluoroethylene (PTFE) and polyvinylpyrrolidone (PVP). An electrode for an energy storage device may comprise a current collector and a film on the current collector, the film including an electrode active material and a composite binder comprising PTFE and PVP. A method of manufacturing a free-standing electrode film may comprise preparing a mixture including an electrode active material and a composite binder, the composite binder comprising PTFE and one or more additional binders selected from the group consisting of PVP, polyvinylidene fluoride (PVDF), polyethylene oxide (PEO), and carboxymethylcellulose (CMC). The method may further comprise adding a solvent to the mixture, subjecting the mixture to a shear force, and, after the solvent has been added and the mixture has been subjected to the shear force, pressing the mixture into a free-standing film.

Abstract: A method of manufacturing a free-standing electrode film includes preparing a mixture including an electrode active material, a binder, and an additive solution or conductive paste, the additive solution or conductive paste being in an amount less than 5% by weight of the mixture and including a polymer additive and a liquid carrier, as well as a conductive material in the case of a conductive paste. The mixture may have total solid contents greater than 95% by weight. Preparing the mixture may include mixing the additive solution or conductive paste with the electrode active material to lubricate the electrode active material and subsequently adding and mixing in the binder. The method may further include subjecting the mixture to a shear force and, after the mixture has been subjected to the shear force, pressing the mixture into a free-standing film.

Abstract: A method of manufacturing an electrode block for a solid-state battery includes providing an electrode film with a current collector on a first side of the electrode film, coating a layer of dry electrolyte powder on a second side of the electrode film opposite the first side, and pressing the dry electrolyte powder coated on the electrode film to produce a solid electrolyte layer on the electrode film. A method of manufacturing an electrolyte film for a solid-state battery includes preparing a powder mixture including at least one type of fibrillizable binder and at least one type of dry electrolyte powder, the at least one type of dry electrolyte powder being 80-97% of the powder mixture by weight, fibrillizing the at least one type of fibrillizable binder in the powder mixture by subjecting the powder mixture to a shear force, and pressing the powder mixture into a free-standing film.

Abstract: A free-standing electrode film may comprise an electrode active material and a composite binder comprising polytetrafluoroethylene (PTFE) and polyvinylpyrrolidone (PVP). An electrode for an energy storage device may comprise a current collector and a film on the current collector, the film including an electrode active material and a composite binder comprising PTFE and PVP. A method of manufacturing a free-standing electrode film may comprise preparing a mixture including an electrode active material and a composite binder, the composite binder comprising PTFE and one or more additional binders selected from the group consisting of PVP, polyvinylidene fluoride (PVDF), polyethylene oxide (PEO), and carboxymethylcellulose (CMC). The method may further comprise adding a solvent to the mixture, subjecting the mixture to a shear force, and, after the solvent has been added and the mixture has been subjected to the shear force, pressing the mixture into a free-standing film.

Abstract: A method for lithiation of an electrode includes providing an electrode to be lithiated, providing a piece of lithium metal with predetermined weight attached to a conductive material, attaching the conductive material to a current collector of the electrode to be lithiated or to a metal tab connected to or from the electrode to be lithiated, placing the electrode to be lithiated, the piece of lithium, and the conductive material in a container, and filling the container with an electrolyte containing a lithium salt.

Abstract: A method of manufacturing a free-standing electrode film includes preparing a mixture including an electrode active material, a conductive material, and a binder, heating the mixture to 70° C. or higher, subjecting the mixture to a shear force, and, after the mixture has been subjected to the shear force, pressing the mixture into a free-standing film. The method may further include adding a solvent to the mixture. A resulting free-standing electrode film may include an amount of binder less than 4% by weight.

Abstract: A method of manufacturing a free-standing electrode film includes preparing a mixture including an electrode active material, a binder, and an additive solution or conductive paste, the additive solution or conductive paste being in an amount less than 5% by weight of the mixture and including a polymer additive and a liquid carrier, as well as a conductive material in the case of a conductive paste. The mixture may have total solid contents greater than 95% by weight. Preparing the mixture may include mixing the additive solution or conductive paste with the electrode active material to lubricate the electrode active material and subsequently adding and mixing in the binder. The method may further include subjecting the mixture to a shear force and, after the mixture has been subjected to the shear force, pressing the mixture into a free-standing film.

Abstract: A manufacturing method for the formation of lithium, potassium, and/or calcium intercalation compounds on a negative electrode for a battery or capacitor cell is disclosed. The battery or capacitor cell is constructed with a negative electrode that may contain graphitic carbon, silicon, metal oxide, and/or complex metal oxides and a lithium, potassium, and/or calcium ion source supplemental electrode. After construction of the cell, a method of controlled electrical contact is applied between the positive electrode and negative electrode to accelerate and regulate a process of ion exchange between the supplemental metal ion source electrode and the negative electrode which results in the formation of intercalation compounds within the negative electrode, and produces a battery or capacitor with a higher working voltage, high cycle life, and long DC life.

Abstract: A method for lithiation of an electrode includes providing an electrode to be lithiated, providing a piece of lithium metal with predetermined weight attached to a conductive material, attaching the conductive material to a current collector of the electrode to be lithiated or to a metal tab connected to or from the electrode to be lithiated, placing the electrode to be lithiated, the piece of lithium, and the conductive material in a container, and filling the container with an electrolyte containing a lithium salt.

Abstract: A method for fabricating an electrode, includes: determining a thickness of an active layer; selecting a lithium (Li) foil having a specified thickness; determining a Li layer pattern for the Li foil based on a portion of a surface of the active layer to be covered by the Li foil; and pressing the Li layer pattern into the surface of the active layer.

Abstract: A method for fabricating an electrode includes: determining a thickness of an active layer; selecting lithium (Li) foil having a specified thickness; determining widths of one or more Li strips based on an active layer to Li layer weight ratio or volume ratio; laminating the active layer onto a conductive substrate; forming one or more grooves in the active layer exposing a bare surface of the conductive substrate; and pressing the one or more Li strips into the one or more grooves, wherein widths of the one or more grooves are slightly larger than the widths of the Li strips.

Abstract: A method for producing an electrode for an energy storage device includes: forming a current collector from a conductive material; forming a primer layer on the current collector; injecting dry powder electrode materials into the primer layer, wherein the dry powder electrode materials injected into the primer layer form an electrode film in electrical contact with the current collector.