Abstract: Battery systems using doped conversion materials as the active material in battery cathodes are provided herein. Doped conversion material may include a defect-rich structure or an amorphous or glassy structure, including at least one or more of a metal material, one or more oxidizing species, a reducing cation species, and a dopant. Methods for fabricating batteries and battery systems with doped conversion material are also provided herein.

Abstract: The disclosure is related to battery systems. More specifically, embodiments of the disclosure provide a nanostructured conversion material for use as the active material in battery cathodes. In an implementation, a nanostructured conversion material is a glassy material and includes a metal material, one or more oxidizing species, and a reducing cation species mixed at a scale of less than 1 nm. The glassy conversion material is substantially homogeneous within a volume of 1000 nm3.

Abstract: The present invention provides an energy storage device comprising a cathode region or other element. The device has a major active region comprising a plurality of first active regions spatially disposed within the cathode region. The major active region expands or contracts from a first volume to a second volume during a period of a charge and discharge. The device has a catholyte material spatially confined within a spatial region of the cathode region and spatially disposed within spatial regions not occupied by the first active regions. The device has a protective material formed overlying exposed regions of the cathode material to substantially maintain the sulfur species within the catholyte material. Also included is a novel dopant configuration of the LiaMPbSc (LMPS) [M=Si, Ge, and/or Sn] containing material.

Abstract: Provided are methods and apparatus for forming electrode active materials for electrochemical cells. These materials include a metal (e.g., iron, cobalt), lithium, and fluorine and are produced using plasma synthesis or, more specifically, non-equilibrium plasma synthesis. A metal containing material, organometallic lithium containing material, and fluorine-containing material are provided into a flow reactor, mixed, and exposed to the electrical energy generating plasma. The plasma generation enhances reaction between the provided materials and forms nanoparticles of the electrode active materials. The nanoparticles may have a mean size of 1-30 nanometers and may have a core-shell structure. The core may be formed by metal, while the shell may include lithium fluoride. A carbon shell may be disposed over the lithium fluoride shell. The nanoparticles are collected and may be used to form an electrochemical cell.

Abstract: A method for manufacturing thin films for a battery device. The method includes vaporizing a precursor material from a liquid source to form droplets ranging from, for example, about 10 microns to about 20 microns. Thereafter, the method includes subjecting the droplets from about 10 to about 20 microns to a megasonic energy source to cause formation of a plurality of smaller droplets ranging from, for example, about 0.25 micron to about 5 microns which are then directed to a heated substrate, where through a heterogeneous reaction a film of material overlying the surface region is formed. The method includes irradiating (e.g., ultra-violet, infra-red, or plasma) the film of material using electromagnetic radiation to process the film to cause a recrystallization of the film to form larger sized crystalline materials. Optionally, the method includes sequentially performing the vaporizing, reacting/releasing, and irradiating to build up a thickness of the film of material.

Abstract: In an example, the present invention provides a solid state battery device, e.g., battery cell or device. The device has a current collector region and a lithium containing anode member overlying the current collector region. The device has a thickness of electrolyte material comprising a first garnet material overlying the lithium containing anode member. The thickness of electrolyte material has a density ranging from about 80 percent to 100 percent and a porous cathode material comprising a second garnet material overlying the thickness of electrolyte material. The porous cathode material has a porosity of greater than about 30 percent and less than about 95 percent and a carbon bearing material overlying a surface region of the porous cathode material. In an example, the carbon bearing material comprises substantially carbon material, although there can be variations.

Abstract: In an example, the present invention provides a solid state battery device, e.g., battery cell or device. The device has a current collector region and a lithium containing anode member overlying the current collector region. The device has a thickness of electrolyte material comprising a first garnet material overlying the lithium containing anode member. The thickness of electrolyte material has a density ranging from about 80 percent to 100 percent and a porous cathode material comprising a second garnet material overlying the thickness of electrolyte material. The porous cathode material has a porosity of greater than about 30 percent and less than about 95 percent and a carbon bearing material overlying a surface region of the porous cathode material. In an example, the carbon bearing material comprises substantially carbon material, although there can be variations.

Abstract: Solid state energy storage systems and devices are provided. A solid state energy storage devices can include an active layer disposed between conductive electrodes, the active layer having one or more quantum confinement species (QCS), such as quantum dots, quantum particles, quantum wells, nanoparticles, nanostructures, nanowires and nanofibers. The solid state energy storage device can have a charge rate of at least about 500 V/s and an energy storage density of at least about 150 Whr/kg.

Abstract: The present invention is directed to processing techniques and systems of metal fluoride based material, including but not limited to nickel difluoride, copper difluoride, manganese fluoride, chromium fluoride, bismuth fluoride, iron trifluoride, iron difluoride, iron oxyfluoride, metal doped iron fluorides, e.g., FexM1-xFy (M=metals, which can be Co, Ni, Cu, Cr, Mn, Bi and Ti) materials. An exemplary implementation involves mixing a first compound comprising a metal material, nitrogen, and oxygen to a second compound comprising hydrogen fluoride. The mixed compound is milled to form metal fluoride precursor and a certain byproduct. The byproduct is removed, and the metal fluoride precursor is treated to form iron trifluoride product. There are other embodiments as well.

Abstract: Provided herein are energy storage device cathodes with high capacity electrochemically active material including compounds that include iron, fluorine, sulfur, and optionally oxygen. Batteries with active materials including a compound of the formula FeFaSbOc exhibit high capacity, high specific energy, high average discharge voltage, and low hysteresis, even when discharged at high rates. Iron, fluorine, and sulfur-containing compounds may be ionically and electronically conductive.

Abstract: A method for manufacturing thin films for a battery device. The method includes vaporizing a precursor material from a liquid source to form droplets ranging from, for example, about 10 microns to about 20 microns. Thereafter, the method includes subjecting the droplets from about 10 to about 20 microns to a megasonic energy source to cause formation of a plurality of smaller droplets ranging from, for example, about 0.25 micron to about 5 microns which are then directed to a heated substrate, where through a heterogeneous reaction a film of material overlying the surface region is formed. The method includes irradiating (e.g., ultra-violet, infra-red, or plasma) the film of material using electromagnetic radiation to process the film to cause a recrystallization of the film to form larger sized crystalline materials. Optionally, the method includes sequentially performing the vaporizing, reacting/releasing, and irradiating to build up a thickness of the film of material.

Abstract: Battery systems using coated conversion materials as the active material in battery cathodes are provided herein. Protective coatings may be an oxide, phosphate, or fluoride, and may be lithiated. The coating may selectively isolate the conversion material from the electrolyte. Methods for fabricating batteries and battery systems with coated conversion material are also provided herein.

Abstract: The present invention is related to formation and processing of antiperovskite material. In various embodiments, a thin film of aluminum doped antiperovskite is deposited on a substrate, which can be an electrolyte material of a lithium-based electrochemical storage device.

Abstract: Various embodiments herein relate to the design of battery stacks, batteries and battery packs that are able to accommodate volumetric expansion in the battery materials. These designs may be especially useful in connection with batteries having negative electrodes made of lithium metal and/or positive electrodes made of an electrochemically active conversion material. These batteries may expand on the order of 10-40% during cycling. The battery designs disclosed herein include compressible regions that span a wide variety of different designs and implementations.

Abstract: Various embodiments herein provide methods and apparatus for conditioning a battery. The conditioning may be undertaken to restore charge capacity or power capability, especially when practiced on a battery having a lithium negative electrode and/or a positive electrode having a conversion material. In one embodiment, the conditioning method includes applying a substantially constant current or power until a conditioning voltage is reached, where the conditioning voltage is higher than the maximum voltage used during normal cycling. The method further includes continuing to charge the battery at the conditioning voltage until a maximum conditioning charge is reached. Next, the method includes discharging the battery to about the maximum charge voltage prior to using the battery in an end use. Also provided is a conditioning apparatus that is configured to perform the conditioning method.

Abstract: Described in this patent application are devices for energy storage and methods of making and using such devices. In various embodiments, blocking layers are provided between dielectric material and the electrodes of an energy storage device. The block layers are characterized by higher dielectric constant than the dielectric material. There are other embodiments as well.