Abstract: Provided is anode active material for use in a lithium ion battery, wherein the anode active material is capable of reversibly storing lithium ions therein up to a maximum lithium storage capacity Cmax during a charge or discharge of the battery and the anode active material comprises an amount of solid-electrolyte interphase (SEI) on a surface or in an internal structure of the anode active material wherein the SEI is pre-formed prior to incorporating the anode active material in an anode electrode of the battery. Also provided is a method of producing the pre-formed SEI substances in the anode material; e.g. through repeated lithiation/delithiation procedures.

Abstract: A hybrid solid electrolyte particulate for use in a rechargeable lithium battery cell, wherein said particulate comprises one or more than one inorganic solid electrolyte particles encapsulated by a shell of conducting polymer electrolyte wherein (i) the hybrid solid electrolyte particulate has a lithium-ion conductivity from 10?6 S/cm to 5×10?2 S/cm and both the inorganic solid electrolyte and the conducting polymer electrolyte individually have a lithium-ion conductivity no less than 10?6 S/cm; (ii) the conducting polymer electrolyte has an electron conductivity no less than 10?6 S/cm; and (iii) the conducting polymer electrolyte-to-inorganic solid electrolyte ratio is from 1/100 to 100/1 or the conducting polymer electrolyte shell has a thickness from 1 nm to 10 ?m. Also provided is a lithium-ion or lithium metal cell containing multiple hybrid solid electrolyte particulates in the anode and/or the cathode. Processes for producing hybrid solid electrolyte particulates are also disclosed.

Abstract: A hybrid solid electrolyte particulate for use in a rechargeable lithium battery cell, wherein said particulate comprises one or more than one inorganic solid electrolyte particles encapsulated by a shell of elastic polymer electrolyte wherein (i) the hybrid solid electrolyte particulate has a lithium-ion conductivity from 10?6 S/cm to 5×10?2 S/cm and both the inorganic solid electrolyte and the elastic polymer electrolyte individually have a lithium-ion conductivity no less than 10?6 S/cm; (ii) the elastic polymer electrolyte-to-inorganic solid electrolyte ratio is from 1/100 to 100/1 or the elastic polymer electrolyte shell has a thickness from 1 nm to 10 ?m; and (iii) the elastic polymer electrolyte has a recoverable elastic tensile strain from 5% to 1,000%. Also provided is a lithium-ion or lithium metal cell containing multiple hybrid solid electrolyte particulates in the anode, cathode and/or the separator. Processes for producing hybrid solid electrolyte particulates are also disclosed.

Abstract: A hybrid solid electrolyte particulate (or multiple particulates) for use in a rechargeable lithium battery cell, wherein the particulate comprises one or more than one inorganic solid electrolyte particles encapsulated by a shell of polymer electrolyte wherein the hybrid solid electrolyte particulate has a lithium-ion conductivity from 10?6 S/cm to 5×10?2 S/cm and both the inorganic solid electrolyte and the polymer electrolyte individually have a lithium-ion conductivity no less than 1031 6 S/cm. Also provided is a lithium-ion or lithium metal cell containing multiple hybrid solid electrolyte particulates in the anode, cathode and/or the separator. Processes for producing hybrid solid electrolyte particulates are also disclosed.

Abstract: An electrochemical battery cell comprising an anode having a primary anode active material, a cathode, and an ion-conducting electrolyte, wherein the cell has an initial output voltage, Vi, measured at 10% depth of discharge (DoD), selected from a range from 0.3 volts to 0.8 volts, and a final output voltage Vf measured at a DoD no greater than 90%, wherein a voltage variation, (Vi?Vf)/Vi, is no greater than ±10% and the specific capacity between Vi and Vf is no less than 100 mAh/g or 200 mAh/cm3 based on the cathode active material weight or volume, and wherein the primary anode active material is selected from lithium (Li), sodium (Na), potassium (K), magnesium (Mg), aluminum (Al), zinc (Zn), titanium (Ti), manganese (Mn), iron (Fe), vanadium (V), cobalt (Co), nickel (Ni), a mixture thereof, an alloy thereof, or a combination thereof.

Abstract: Provided is a graphene-based aqueous coating suspension comprising multiple graphene sheets, particles of an anti-corrosive pigment or sacrificial metal, and a waterborne binder resin dissolved or dispersed in water, wherein the multiple graphene sheets contain single-layer or few-layer graphene sheets selected from a pristine graphene material having essentially zero % of non-carbon elements, or a non-pristine graphene material having 0.001% to 47% by weight of non-carbon elements wherein the non-pristine graphene is selected from graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, doped graphene, chemically functionalized graphene, or a combination thereof and wherein the coating suspension does not contain a silicate binder or microspheres dispersed therein. Also provided is an object or structure coated at least in part with such a coating.

Abstract: Provided is a rechargeable battery system comprising at least a battery cell and an external cooling means, wherein the battery cell comprises an anode, a cathode, an electrolyte disposed between the anode and the cathode, a protective housing that at least partially encloses the anode, the cathode and the electrolyte, and at least one heat-spreader element disposed partially or entirely inside the protective housing and wherein the external cooling means is in thermal contact with the heat spreader element configured to enable transporting internal heat of the battery through the heat spreader element to the external cooling means. Also provided is a method of operating a rechargeable battery system, the method comprising implementing a heat spreader element in one or each of a plurality of battery cells and bringing the heat spreader element in thermal contact with one or a plurality of external cooling means.

Abstract: A lithium secondary battery comprising a cathode, an anode, and an elastic polymer protective layer disposed between the cathode and the anode, and a working electrolyte, wherein the elastic polymer protective layer comprises a high-elasticity polymer having a thickness from 50 nm to 100 ?m, a lithium ion conductivity from 10?8 S/cm to 5×10?2 S/cm at room temperature, and a fully recoverable tensile elastic strain from 2% to 1,000% when measured without any additive or filler dispersed therein and wherein the high-elasticity polymer comprises a crosslinked polymer network of chains derived from at least one multi-functional monomer or oligomer selected from an acrylate, polyether, polyurethane acrylate, tetraethylene glycol diacrylate, triethylene glycol dimethacrylate, or di(trimethylolpropane) tetraacrylate, wherein a multi-functional monomer or oligomer comprises at least three reactive functional groups.

Abstract: An anode active material layer for a lithium battery, the layer comprising multiple anode active material particles and a conductive additive that are protected by (embedded in and bonded by) a matrix resin comprising an ion-conducting elastomer or rubber having a recoverable tensile strain from 5% to 700% when measured without an additive or reinforcement in the polymer and a lithium ion conductivity no less than 10?6 S/cm at room temperature. The amount of conductive additive is preferably sufficient to form a 3D network of electron-conducing pathways that are in electrical contact with the anode material particles. Such an elastomeric or rubbery matrix also acts to maintain the structural integrity of the anode electrode, preventing interruption of the electron- and lithium ion-conducting pathways when the anode active material particles repeatedly expand and shrink in volume during battery cycling.

Abstract: Provided is a lithium metal secondary battery comprising a cathode, an anode, an electrolyte-separator assembly disposed between the cathode and the anode, wherein the anode comprises: (a) an anode active material layer containing a layer of lithium or lithium alloy optionally supported by an anode current collector; and (b) an anode-protecting layer in physical contact with the anode active material layer and in ionic contact with the electrolyte-separator assembly, having a thickness from 10 nm to 500 ?m and comprising an electrically and ionically conducting network of cross-linked conjugated polymer chains having a lithium ion conductivity from 10?8 to 5×10?2 S/cm and an electron conductivity from 10?8 to 103 S/cm.

Abstract: A method of producing a powder mass for a lithium battery, the method comprising: (a) providing a solution containing a sulfonated elastomer dissolved in a solvent or a precursor in a liquid form or dissolved in a solvent; (b) dispersing a plurality of particles of a cathode active material in the solution to form a slurry; and (c) dispensing the slurry and removing the solvent and/or polymerizing/curing the precursor to form the powder mass, wherein the powder mass comprises multiple particulates and at least a particulate comprises one or a plurality of particles of a cathode active material being encapsulated by a thin layer of sulfonated elastomer having a thickness from 1 nm to 10 ?m, a fully recoverable tensile strain from 2% to 800%, and a lithium ion conductivity from 10?7 S/cm to 5×10?2 S/cm at room temperature.

Abstract: A process for producing a graphene/Si nanowire hybrid material, comprising: (a) dispersing catalyst metal-coated Si particles, graphene sheets, and an optional blowing agent in a liquid medium to form a graphene/Si dispersion; (b) dispensing and depositing the dispersion onto a supporting substrate to form a wet layer and removing the liquid medium from the wet layer to form a dried layer of graphene/Si mixture material; (c) exposing the dried layer to a high temperature environment, from 300° C. to 2,000° C., to induce volatile gas molecules from graphene sheets or to activate the blowing agent for producing the graphene foam and to enable a catalyst metal-catalyzed growth of multiple Si nanowires emanated from Si particles as a feed material in pores of the foam to form a layer of the hybrid material; and (d) operating a mechanical breaking means to produce the Si nanowire/graphene hybrid material in a powder mass form.

Abstract: Provided is a lithium secondary battery comprising a cathode, an anode, and an electrolyte or separator-electrolyte assembly disposed between the cathode and the anode, wherein the anode comprises: (a) An anode current collector, initially having no lithium or lithium alloy as an anode active material when the battery is made and prior to a charge or discharge operation; and (b) a thin layer of a high-elasticity polymer in ionic contact with the electrolyte and having a recoverable tensile strain from 2% to 700%, a lithium ion conductivity no less than 10?8 S/cm, and a thickness from 0.5 nm to 100 ?m. Preferably, the high-elasticity polymer contains a cross-linked network of polymer chains having an ether linkage, nitrile-derived linkage, benzo peroxide-derived linkage, ethylene oxide linkage, propylene oxide linkage, vinyl alcohol linkage, cyano-resin linkage, triacrylate monomer-derived linkage, tetraacrylate monomer-derived linkage, or a combination thereof in the cross-linked network of polymer chains.

Abstract: A lithium secondary battery comprising a cathode, an anode, and an elastic polymer protective layer disposed between the cathode and the anode, and a working electrolyte in ionic communication with the anode and the cathode, wherein the elastic polymer protective layer comprises a high-elasticity polymer having a thickness from 2 nm to 200 ?m, a lithium ion conductivity from 10?8 S/cm to 5×10?2 S/cm at room temperature, and a fully recoverable tensile elastic strain of at least 5% when measured without any additive or filler dispersed therein and wherein the high-elasticity polymer comprises a crosslinked polymer network of chains derived from a phosphazene compound and wherein the crosslinked polymer network of chains is impregnated with from 0% to 90% by weight of a liquid electrolyte.

Abstract: Provided is a metal matrix nanocomposite comprising: (a) a metal or metal alloy as a matrix material; and (b) multiple graphene sheets that are dispersed in said matrix material, wherein said multiple graphene sheets are substantially aligned to be parallel to one another and are in an amount from 0.1% to 95% by volume based on the total nanocomposite volume; wherein the multiple graphene sheets contain single-layer or few-layer graphene sheets selected from pristine graphene, graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, doped graphene, chemically functionalized graphene, or a combination thereof and wherein the chemically functionalized graphene is not graphene oxide. The metal matrix exhibits a combination of exceptional tensile strength, modulus, thermal conductivity, and/or electrical conductivity.

Abstract: Disclosed herein is a composite particulate comprising a plurality of active material particles; and a single graphene sheet or a plurality of graphene sheets surrounds the plurality of active material particles and a surface of the composite particulate, wherein a single graphene sheet or a plurality of graphene sheets provides an electron-conducting path.

Abstract: A lithium-ion battery comprising an anode, a cathode, a separator that electrically separates the anode from the cathode, wherein the anode comprises (i) multiple particles of an anode active material selected from the group consisting of silicon (Si), germanium (Ge), phosphorus (P), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (Co), cadmium (Cd), alloys thereof, oxides thereof, alloys thereof with lithium (Li), and combinations thereof; (ii) from 0.1% to 15% by weight of an ion-conducting protective polymer that is in physical contact with multiple particles of the anode active material to protect the particles, wherein the protective polymer has a lithium-ion conductivity no less than 10?6 S/cm; (iii) from 0% to 10% by weight of a conductive additive; (iv) from 0% to 10% by weight of a binder resin; and (v) 5%-80% by volume of pores in the anode.

Abstract: A lithium-ion battery comprising an anode, a cathode, a lithium-ion permeable and electrically insulating separator that electrically separates the anode from the cathode, and an artificial solid-electrolyte interface (SEI) layer disposed between the anode and the separator wherein (a) the artificial SEI layer has a lithium-ion conductivity greater than 10?6 S/cm and (b) the anode comprises (i) multiple particles of an anode active material selected from the group consisting of silicon (Si), germanium (Ge), phosphorus (P), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (Co), cadmium (Cd), alloys thereof, alloys thereof with lithium (Li), and combinations thereof; (ii) 0-10% (preferably 0.1%-5%) by weight of a conductive additive; and (iii) 0-10% (preferably 0-5%) by weight of a binder resin. Also provided is a method of producing such a battery.

Abstract: A rechargeable lithium battery comprising an anode, a cathode, and a hybrid electrolyte in ionic communication with the anode and the cathode, wherein: (a) the hybrid electrolyte comprises a mixture of a polymer and particles of an inorganic solid electrolyte; (b) the polymer is a polymerization or crosslinking product of a reactive additive, wherein the reactive additive comprises (i) a first liquid solvent that is polymerizable, (ii) an initiator or curing agent, and (iii) a lithium salt; (c) the polymer is present in the anode, the cathode, the separator, between the anode and the separator, or between the cathode and the separator; and (d) the hybrid electrolyte forms a contiguous phase in the cathode or in the anode, and occupies from 3% to 40% by volume of the cathode or from 3% to 40% by volume of the anode. Also provided is a process for producing the lithium cell.

Abstract: A lithium-ion battery comprising an anode, a cathode, and a separator, wherein the anode comprises (i) multiple particles of an anode active material, (ii) 0.1%-25% by weight of a first lithium ion-transporting medium, and (iii) from 10% to 80% by volume of pores in the anode, wherein (a) the first lithium ion-transporting medium and particles of the anode active material are combined to form an anode active material composite layer optionally supported by an anode current collector; (b) the anode active material occupies from 75% to 99.9% by weight of the anode, not counting the anode current collector weight; and (c) the first lithium ion-transporting medium comprises an ion-conducting and/or electron-conducting material selected from graphite, graphene, carbon, a sulfonated conducting polymer, a phthalocyanine compound, an organic or organometallic cathode or anode active material, or a combination thereof.