Abstract: Multilayered electrodes according to aspects of the present disclosure may include a bottom layer comprising a first plurality of electrode particles adhered together by a first binder, and a top layer comprising a second plurality of electrode particles adhered together by a second binder, wherein the first binder is configured to crosslink or coalesce upon calendering. In some examples, the first binder is configured to constrict expansion of electrode particles included in the bottom layer. In some examples, the bottom layer is configured to spring back by a lesser degree than the top layer upon calendering.

Abstract: In general, a solid-state electrode includes an electrode composite layer comprising a plurality of active material particles mixed with a solid electrolyte buffer material comprising a first plurality of solid electrolyte particles layered onto and directly contacting a current collector foil, and an electrically non-conductive separator layer comprising a second plurality of solid electrolyte particles layered onto and directly contacting the electrode composite layer. In some examples, an interpenetrating boundary layer is disposed between the electrode composite layer and the electrically non-conductive separator layer. In some examples, the electrode composite layer includes one or more conductive additives intermixed with the plurality of active material particles, and the electrode composite layer is electrically conductive. In some examples, the electrode composite layer is adhered together by a binder.

Abstract: Methods are disclosed for manufacturing an electrode for use in a device such as a secondary battery. Electrodes may include a first layer having first active particles adhered together by a binder, a second layer having second active particles adhered together by a binder, and an interphase layer interposed between the first and second layers. In some examples, the interphase layer may include an interpenetration of the first and second particles, such that substantially discrete fingers of the first layer interlock with substantially discrete fingers of the second layer.

Abstract: Electrochemical cells of the present disclosure may include one or more multilayered electrodes. Each multilayered electrode may be configured such that active materials of the layer closest to the current collector have a lower energy to lithiate per mole, a higher energy to delithiate per mole, a different solid state diffusivity, and/or a different average particle size. This arrangement counteracts, for example, natural gradient fields and undesirable polarization found in standard lithium-ion batteries.

Abstract: A patterned multilayered electrode includes at least one electrode layer comprising an array of cavities, and at least one electrode layer comprising a plurality of protrusions interlocked with the array of cavities. In some examples, a patterned multilayered electrode includes a first active material layer, a second active material layer comprising an array of cavities, and a separator layer comprising a plurality of protrusions interlocked with the cavities of the second active material layer. In some examples, a patterned multilayered electrode includes a first active material layer comprising an array of cavities and a second active material layer comprising a plurality of protrusions interlocked with the cavities of the first active material layer.

Abstract: An electrochemical cell including a lithium metal anode and a multilayered cathode includes a lithium metal anode laminated, electroplated, or alloyed onto a first current collector, a multilayered cathode layered onto a second current collector, and a separator disposed between the lithium metal anode and the multilayered cathode. In some examples, the lithium metal anode is electroplated onto the first current collector when the electrochemical cell is charged and stored within the multilayered cathode when the electrochemical cell is discharged. In some examples, multilayered cathode further includes an integrated ceramic separator.

Abstract: An electrode including an integrated fibrous separator may include an active material layer layered onto a current collector substrate, and an integrated separator layer comprising a mixture of ceramic particles and fibers layered onto the active material layer. The fibers may be oriented substantially horizontally, and may be configured to increase a lateral strength of the electrode. In some examples, the electrode includes two or more active material layers disposed between the integrated separator layer and the current collector substrate. In some examples, the electrode includes an interlocking region disposed between the active material layer and the integrated separator layer.

Abstract: An electrode including a gradated integrated separator according to the present teachings includes a first layer comprising a first plurality of active material particles adhered together by a first binder, a second layer comprising a second plurality of active material particles mixed with a first plurality of inorganic separator particles and adhered together by a second binder, and a third layer comprising a second plurality of inorganic separator particles adhered together by a third binder. In some examples, the first and second layers are electrically conductive and the third layer is electrically non-conductive.

Abstract: An electrode including an integrated fibrous separator may include an active material layer layered onto a current collector substrate, and an integrated separator layer comprising a mixture of ceramic particles and fibers layered onto the active material layer. The fibers may be oriented substantially horizontally, and may be configured to increase a lateral strength of the electrode. In some examples, the electrode includes two or more active material layers disposed between the integrated separator layer and the current collector substrate. In some examples, the electrode includes an interlocking region disposed between the active material layer and the integrated separator layer.

Abstract: An electrode including an integrated separator for use in an electrochemical device may include one or more active material layers, and a separator layer comprising inorganic particles. An interlocking region may couple the separator layer to an adjacent active material layer. In some examples, the interlocking region may include interlocking fingers formed by an interpenetration of active material particles of the active material layers with ceramic particles of the separator.

Abstract: In general, a solid-state electrode includes an electrode composite layer comprising a plurality of active material particles mixed with a solid electrolyte buffer material comprising a first plurality of solid electrolyte particles layered onto and directly contacting a current collector foil, and an electrically non-conductive separator layer comprising a second plurality of solid electrolyte particles layered onto and directly contacting the electrode composite layer. In some examples, an interpenetrating boundary layer is disposed between the electrode composite layer and the electrically non-conductive separator layer. In some examples, the electrode composite layer includes one or more conductive additives intermixed with the plurality of active material particles, and the electrode composite layer is electrically conductive. In some examples, the electrode composite layer is adhered together by a binder.

Abstract: In general, a solid-state electrode includes an electrode composite layer comprising a plurality of active material particles mixed with a solid electrolyte buffer material comprising a first plurality of solid electrolyte particles layered onto and directly contacting a current collector foil, and an electrically non-conductive separator layer comprising a second plurality of solid electrolyte particles layered onto and directly contacting the electrode composite layer. In some examples, an interpenetrating boundary layer is disposed between the electrode composite layer and the electrically non-conductive separator layer. In some examples, the electrode composite layer includes one or more conductive additives intermixed with the plurality of active material particles, and the electrode composite layer is electrically conductive. In some examples, the electrode composite layer is adhered together by a binder.

Abstract: An electrochemical cell including one or more multilayered electrodes may include electrodes configured to have tailored polarization profiles. In some examples, an electrode may include a first layer having a first solid state diffusivity and a second layer having a second solid state diffusivity. In some examples, an electrode may include a first layer having active particles with a first particle size and a second layer having active particles with a second particle size. These configurations of layers may be selected to achieve desired lithiation patterns so as to improve cell charge or discharge rates.

Abstract: A method for manufacturing a solventless multilayered electrode may include mixing electrode particles with binders to form dry electrode mixtures, compressing the dry electrode mixtures to form electrode films, stacking the electrode films, and compressing the stacked electrode films. Suitable electrode films may include active material particles, conductive particles, electrochemically inactive ceramic particles, and/or the like. In some examples, compressing the stacked electrode films may include compressing the electrode films between pairs of rollers having patterns disposed on one or more exterior surfaces, thereby increasing surface roughness of the electrode films. A system for manufacturing solventless multilayered electrodes may comprise a first plurality of rollers configured to compress dry electrode mixes into electrode films, and a second plurality of rollers configured to compress a stack of electrode films into a single electrode stack.

Abstract: A method for manufacturing a solventless multilayered electrode may include mixing electrode particles with binders to form dry electrode mixtures, compressing the dry electrode mixtures to form electrode films, stacking the electrode films, and compressing the stacked electrode films. Suitable electrode films may include active material particles, conductive particles, electrochemically inactive ceramic particles, and/or the like. In some examples, compressing the stacked electrode films may include compressing the electrode films between pairs of rollers having patterns disposed on one or more exterior surfaces, thereby increasing surface roughness of the electrode films. A system for manufacturing solventless multilayered electrodes may comprise a first plurality of rollers configured to compress dry electrode mixes into electrode films, and a second plurality of rollers configured to compress a stack of electrode films into a single electrode stack.

Abstract: An electrode including an integrated separator for use in an electrochemical device may include one or more active material layers, and a separator layer comprising inorganic particles. An interlocking region may couple the separator layer to an adjacent active material layer. In some examples, the interlocking region may include interlocking fingers formed by an interpenetration of active material particles of the active material layers with ceramic particles of the separator.

Abstract: Anodes having high top layer sphericity may include a first active material layer including a plurality of first active material particles having a first particle sphericity and a first particle size layered onto and directly contacting a current collector, and a second active material layer including a plurality of second active material particles having a second particle sphericity and a second particle size layered onto and directly contacting the first layer. The second particle sphericity is greater than the first particle sphericity. In some examples, the second particle size is greater than the first particle size.

Abstract: Methods are disclosed for manufacturing an electrode for use in a device such as a secondary battery. Electrodes may include a first layer having first active particles adhered together by a binder, a second layer having second active particles adhered together by a binder, and an interphase layer interposed between the first and second layers. In some examples, the interphase layer may include an interpenetration of the first and second particles, such that substantially discrete fingers of the first layer interlock with substantially discrete fingers of the second layer.

Abstract: A method for manufacturing a solventless multilayered electrode may include mixing electrode particles with binders to form dry electrode mixtures, compressing the dry electrode mixtures to form electrode films, stacking the electrode films, and compressing the stacked electrode films. Suitable electrode films may include active material particles, conductive particles, electrochemically inactive ceramic particles, and/or the like. In some examples, compressing the stacked electrode films may include compressing the electrode films between pairs of rollers having patterns disposed on one or more exterior surfaces, thereby increasing surface roughness of the electrode films. A system for manufacturing solventless multilayered electrodes may comprise a first plurality of rollers configured to compress dry electrode mixes into electrode films, and a second plurality of rollers configured to compress a stack of electrode films into a single electrode stack.

Abstract: Anodes having high top layer sphericity may include a first active material layer including a plurality of first active material particles having a first particle sphericity and a first particle size layered onto and directly contacting a current collector, and a second active material layer including a plurality of second active material particles having a second particle sphericity and a second particle size layered onto and directly contacting the first layer. The second particle sphericity is greater than the first particle sphericity. In some examples, the second particle size is greater than the first particle size.