Abstract: Methods for making high-purity LiFSI salts and intermediate products using one, the other, or both of a reactive-solvent removal/replacement method and an LiFSI purification method. In some embodiments, the reactive-solvent removal/replacement method includes using non-reactive anhydrous organic solvents to remove and/or replace one or more reactive solvents in a crude LiFSI. In some embodiments, the LiFSI purification method includes using anhydrous organic solvents to remove impurities, such as synthesis impurities, from a crude LiFSI. In some embodiments, crude LiFSI can be made using an aqueous-based neutralization process. LiFSI salts and products made using methods of the disclosure are also described, as are uses of such salts and products and electrochemical devices that include such salts and products.

Abstract: Battery core packs employing minimum cell-face pressure containment devices and methods are disclosed for minimizing dendrite growth and increasing cycle life of metal and metal-ion battery cells.

Abstract: Processes for producing a N,N-dialkyl perfluoroalkyl-sulfonamide product of the formula Rf—S(O)2—NRaRb (I) in which Rf represents fully or partially fluorinated alkyl groups with carbon 1 to 12 and Ra and Rb represents linear or branched or cyclic alkyl, alkene or alkyne groups with carbon 1 to 12, wherein Ra=Rb or Ra?Rb. In some embodiments, a reaction proceeds by contacting a perfluoroalkylsulfonyl halide of the formula: X—S(O)2—Rf, (II), in which X represents F, Cl, Br or I, with dialkylamine of the formula HNRaRb, under conditions sufficient to produce the desired N,N-dialkyl perfluoroalkylsulfonamide product of Formula I. In some embodiments, the reaction is carried out using a solvent of Formula I.

Abstract: Alkali metal secondary batteries that include anodes constructed from alkali metal foil applied to only one side of a porous current collector metal foil. Openings in the porous current collectors permit alkali metal accessibility on both sides of the anode structure. Such anode constructions enable the utilization of lower-cost and more commonly available alkali metal foil thickness, while still achieving high cell cycle life at a significantly reduced cost. Aspects of the present disclosure also include batteries with porous current collectors having increased volumetric and gravimetric energy densities, and methods of manufacturing anodes with porous current collectors.

Abstract: Alkali metal secondary batteries that include anodes constructed from alkali metal foil applied to only one side of a porous current collector metal foil. Openings in the porous current collectors permit alkali metal accessibility on both sides of the anode structure. Such anode constructions enable the utilization of lower-cost and more commonly available alkali metal foil thickness, while still achieving high cell cycle life at a significantly reduced cost. Aspects of the present disclosure also include batteries with porous current collectors having increased volumetric and gravimetric energy densities, and methods of manufacturing anodes with porous current collectors.

Abstract: A method of forming anodes for electrochemical devices by laminating a metal foil to a current collector and creating anode-active-material patches, composed of the metal foil, that are spaced from one another by inter-patch regions, wherein each inter-patch region provides a location for forming one or more electrical tabs of the finished anodes. The method can further include applying conductive-coating patches to the current collector prior to laminating the metal foil to the current collector, wherein each conductive-coating patch corresponds to one of the anode-active-material patches. In some embodiments, the conductive-coating patches can assist with forming the anode-active-material patches and/or can improve the cycling performance of an electrochemical device made using anodes made therewith. Anodes containing anode-active material and conductive coatings applied to current collectors are also disclosed.

Abstract: A high energy density, high power lithium metal anode rechargeable battery having volumetric energy density of >1000 Wh/L and/or a gravimetric energy density of >350 Wh/kg, that is capable of >1 C discharge at room temperature. In some embodiments, a high power lithium metal anode rechargeable battery of the present disclosure includes a lithium metal anode having a thickness of less than 20 ?m and a ratio of anode capacity (n) to cathode capacity (p) in a discharged state, i.e., n/p, in a range of 0.8 to less than or equal to 1 or in a range of 0.9 to less than or equal to 1. In some embodiments, a high power lithium metal anode rechargeable battery of the present disclosure further includes a high-voltage cathode and a hybrid separator.

Abstract: Localized high-salt-concentration electrolytes each containing a salt, a glyme as a solvent, and a fluorinated diluent. In some embodiments, the glyme has a chemical formula R1—(O—CH2—CH2)n—O—R2, wherein n=1 to 4 and at least one of R1 and R2 is a hydrocarbon sidechain having at least 2 carbon atoms and wherein the salt is soluble in the glyme. In some embodiments, the fluorinated diluent is selected from the group consisting of a fluorinated glyme and a fluorinated ether. In some embodiments, the salt includes an alkali-metal salt. In some embodiments, the salt includes an alkali-earth-metal salt. The salt may include a perfluorinated sulfonimide salt. Electrochemical devices that include localized high-salt-concentration electrolytes of the present disclosure are also disclosed.

Abstract: A battery structure with a cathode, an electrolyte, and a lithium metal anode is coated with a composite coating including a mixture of a polymer and a reinforcing fiber. The cathode and the lithium metal are held apart by a porous separator soaked with the electrolyte. The reinforcing fiber is dispersed in the polymer matrix. The composite coating is porous or non-porous. The composite coating conducts lithium ions. The reinforcing fiber is chemically functionalized.

Abstract: Methods for making high-purity LiFSI salts and intermediate products using one, the other, or both of a reactive-solvent removal/replacement method and an LiFSI purification method. In some embodiments, the reactive-solvent removal/replacement method includes using non-reactive anhydrous organic solvents to remove and/or replace one or more reactive solvents in a crude LiFSI. In some embodiments, the LiFSI purification method includes using anhydrous organic solvents to remove impurities, such as synthesis impurities, from a crude LiFSI. In some embodiments, crude LiFSI can be made using an aqueous-based neutralization process. LiFSI salts and products made using methods of the disclosure are also described, as are uses of such salts and products and electrochemical devices that include such salts and products.

Abstract: Methods of removing target impurities from a crude lithium bis(fluorosulfonyl)imide (LiFSI) to make a purified LiFSI product. In some embodiments, a purification method includes contacting crude LiFSI with a first anhydrous organic solvent to create a solution containing LiFSI and the target impurity(ies), wherein the LiFSI is soluble and the impurity(ies) is/are substantially insoluble. In some embodiments, a second anhydrous organic solvent is added to the solution to precipitate the target impurity(ies), which is then filtered to obtain a filtrate. In some embodiments, solvent is removed from the filtrate to obtain a solid mass containing LiFSI, which may then be contacted with a third anhydrous organic solvent in which the LiFSI is insoluble. The LiFSI may then be isolated from the third anhydrous organic solvent to obtain the purified LiFSI product. Also disclosed are purified LiFSI products and electrochemical devices utilizing purified LiFSI products, among other things.

Abstract: Free-solvent-free lithium sulfonimide salt compositions that are liquid at room temperature, and methods of making free-solvent-free liquid lithium sulfonimide salt compositions. In an embodiment, the methods include mixing one or more lithium sulfonimide salts with one or more ether-based solvents and then removing the free solvent(s) under suitable vacuum, temperature, and time conditions so as to obtain a free-solvent-free liquid lithium sulfonimide salt composition that is liquid at room temperature. In an embodiment, the only solvent molecules that remain in the liquid lithium sulfonimide salt composition are adducted with lithium sulfonimide salt molecules. An example automated processing system for making free-solvent-free liquid lithium sulfonimide salts is also disclosed.

Abstract: Localized high-salt-concentration electrolytes each containing a salt, a glyme as a solvent, and a fluorinated diluent. In some embodiments, the glyme has a chemical formula R1—(O—CH2—CH2)n—O—R2, wherein n=1 to 4 and at least one of R1 and R2 is a hydrocarbon sidechain having at least 2 carbon atoms and wherein the salt is soluble in the glyme. In some embodiments, the fluorinated diluent is selected from the group consisting of a fluorinated glyme and a fluorinated ether. In some embodiments, the salt includes an alkali-metal salt. In some embodiments, the salt includes an alkali-earth-metal salt. The salt may include a perfluorinated sulfonimide salt. Electrochemical devices that include localized high-salt-concentration electrolytes of the present disclosure are also disclosed.

Abstract: The present invention provides a single-phase or homogeneous solution comprising a high concentration of a salt, in particular a lithium salt, in an organic solvent. Such a high salt content in organic solvent is useful in a variety of applications including, but not limited to, in electrical energy storage devices as well as other devices that can benefit from a low-volatility liquid electrolyte.

Abstract: A method of removing one or more target impurities from crude hydrogen bis(fluorosulfonyl)imide (HFSI) using a crystallization technique. In some embodiments, the method includes contacting the crude HFSI with at least one anhydrous solvent to create a solution. The solution is caused to have a temperature sufficient to cause HFSI in the solution to crystalize while the one or more impurities remain dissolved in the mother liquor of the solution. The crystalized HFSI and the mother liquor containing the one or more impurities are separated to obtained a purified HFSI product. Purified HFSI products are also disclosed, as are systems, such as secondary batteries, incorporating purified HFSI products.

Abstract: Aspects of the present disclosure include control systems for controlling secondary lithium metal batteries and for controlling electric devices powered, at least in part, thereby, that enable access to reserve energy stored in the lithium metal battery that is not typically available during normal operation. In some examples, the control systems provide access to the reserve energy in response to an emergency, such as requiring excess energy to power an electric device to a safe location.

Abstract: Aspects of the present disclosure include methods of charging secondary lithium metal batteries that include selectively and intentionally overcharging the battery to activate redox shuttling additives in order to reactivate dead lithium. Aspects of the present disclosure also include control systems for determining when to initiate a lithium reactivation charging process and for determining one or more parameters of a lithium reactivation charging protocol.

Abstract: A secondary high energy density lithium ion cell includes a cathode comprising a high voltage cathode active material, a lithium metal anode, and a non-aqueous electrolyte, wherein the non-aqueous electrolyte comprises an imide salt with a fluorosulfonyl group and a perchlorate salt, wherein the electrolyte is electrochemically stable at operating voltages greater than 4.2V.

Abstract: Binary and ternary eutectic mixtures and corresponding electrolytes are disclosed. In some embodiments, binary eutectic mixtures and electrolytes each include a first salt, X1+Y1?, and a second salt, X2+Y2?, wherein each of X1+ and X2+ is an alkali metal cation and X1+ is different from X2+; and each of Y1? and Y2? is a sulfonimide anion and Y1? is different from Y2?. In ternary eutectic mixtures and electrolytes further include a third salt, X3+Y3?, wherein X3+ is different from each of X1+ and X2+. In some embodiments, the eutectic mixtures and electrolytes have melting points in a range of about 5° C. to about 70° C. Electrochemical devices containing such eutectic-mixture electrolytes are also disclosed.