Abstract: A lithium-ion battery including an electrodeposited anode material having a micron-scale, three-dimensional porous foam structure separated from interpenetrating cathode material that fills the void space of the porous foam structure by a thin solid-state electrolyte which has been reductively polymerized onto the anode material in a uniform and pinhole free manner, which will significantly reduce the distance which the Li-ions are required to traverse upon the charge/discharge of the battery cell over other types of Li-ion cell designs, and a procedure for fabricating the battery are described. The interpenetrating three-dimensional structure of the cell will also provide larger energy densities than conventional solid-state Li-ion cells based on thin-film technologies. The electrodeposited anode may include an intermetallic composition effective for reversibly intercalating Li-ions.

Abstract: Electrochemical methods for probing solid polymer electrolyte surface coatings on electrically conducting, active, three-dimensional electrode materials for use in lithium-ion batteries, to quantitatively determine the conformity, uniformity, and the presence of pinholes, and/or other defects in coatings, without requiring the detachment of the coating from the electrode or otherwise inducing damage to the coating, are described. Coated electrodes are submersed in an electrolyte solution containing a redox-active probe species which does not induce electrochemical damage to either the working electrode or the solid polymer electrolyte surface coating. For coated Cu2Sb working electrodes, molecules including a water-soluble redox active viologen moiety have been found to be effective.

Abstract: Methods are described for forming insulating hybrid organic-inorganic solid electrolytes on conducting electrodes that are active materials in Li-ion batteries by electrochemical deposition, and for forming second conducting electrodes on the solid electrolytes using aqueous slurries, whereby Li-ion battery cells having solid electrolytes are generated. X-ray photoelectron spectroscopy is utilized for determining that the solid electrolytes are defect and pinhole free.

Abstract: Methods for reductively polymerizing vinylic based monomers from a solution thereof onto the surface of an electrode material, resulting in thin, electrically insulating solid-polymer electrolyte coatings strongly bound to the surface of the electrode material, are described. The strong bond permits a second electrode to be coated directly onto the solid-polymer electrolyte, thereby incorporating the required components for a Li-ion battery cell. At least one initiator species, which is readily reduced by accepting an electron from the electrode material, is included in electropolymerization deposition solution for permitting the polymerization of vinylic species that would otherwise not electrochemically polymerize without damage to either the electrode material or to the solvents employed.

Abstract: A lithium-ion battery including an electrodeposited anode material having a micron-scale, three-dimensional porous foam structure separated from interpenetrating cathode material that fills the void space of the porous foam structure by a thin solid-state electrolyte which has been reductively polymerized onto the anode material in a uniform and pinhole free manner, which will significantly reduce the distance which the Li-ions are required to traverse upon the charge/discharge of the battery cell over other types of Li-ion cell designs, and a procedure for fabricating the battery are described. The interpenetrating three-dimensional structure of the cell will also provide larger energy densities than conventional solid-state Li-ion cells based on thin-film technologies. The electrodeposited anode may include an intermetallic composition effective for reversibly intercalating Li-ions.