Abstract: A method of forming a battery pack from a plurality of battery pouch cells, where each battery pouch cell has a pouch and a pair of electrically conductive connectors extending from a portion of a sealed edge of the pouch, includes forming a battery array using a set of battery pouch cells selected from among the plurality of battery pouch cells; and encasing, for each battery pouch cell in the battery array, at least the pouch of the battery pouch cell with a polyurethane foam formed using a non-conductive physical blowing agent.

Abstract: A battery system includes an array of cells and an insulating plate. The array of cells is arranged in first and second subsets of cells. The first and second subsets of cells define a space therebetween. The insulating plate has a central region disposed within the space. The insulating plate has first and second lateral regions disposed external to the space and extending beyond first and second opposing lateral ends of the array of cells, respectively. The central region has a first dimension extending in a first direction between the first and second subsets of cells. The first and second lateral regions have second and third dimensions, respectively, extending in a second direction. The second direction is substantially parallel to the first direction. The second and third dimensions are greater than the first dimension.

Abstract: A method for forming one or more layers of a lithium-ion battery includes a step of sequentially depositing a wet coating and a free-standing material layer onto a moving substrate to form a first bilayer on the substrate. The first bilayer including a wet coating-derived layer and the free-standing material layer. The first bilayer is heat roll pressed to form a second bilayer in which the wet coating-derived layer is at least partially dried and adhered to the free-standing material layer.

Abstract: A positive electrode active material may include a compound represented by formula 1 or formula 2: Li(1.333?0.667x?y)Mn(0.667?0.333x)NixA(y?a)MaO2 (1), Li(1.333?0.667x?z?a)Mn(0.667?0.333x?0.5y)Ni(x?0.5y+z)A(y+a?b)MbO2 (2). A is Co, Cr, or a combination thereof, M is W+6, Ta+5, V+5, or a combination thereof, 0<x<0.5, 0<y<0.333, 0<x<0.04, 0<x?0.5y+z<0.5, 0<y+a?b<0.333, and 0<b<0.04.

Abstract: Busbars are provided for electrically connecting battery cells within a traction battery pack. An exemplary busbar may include features for locating and positioning tab terminals of neighboring battery cells. For example, the busbar may include openings and ribs that separate adjacent openings. A first tab terminal of a first battery cell may be positioned for connection at a first side of the rib, and a second tab terminal of a second battery cell may be positioned for connection at a second side of the rib. The first and second tab terminals may each be secured (e.g., welded) to the rib.

Abstract: A positive electrode active material may include a compound represented by formula 1 or formula 2: Li1.10Mn0.52Ni(0.38-x)A(x-a)MaO2 (1), Li1.12Mn0.51Ni(0.37-x)A(x-a)MaO2 (2). A is Co, Cr, or a combination thereof, M is W+6, Ta+5, V+5, or a combination thereof, 0<x<0.1, 0<a<0.04, and 3.8<average oxidation state of Mn ion<4.0.

Abstract: A traction battery includes a battery array and a flexible printed circuit (FPC). The FPC including a hurdle-shaped flexible substrate that is planar and has opposing first and second planar surfaces and opposing first and second edges extending between the planar surfaces, the substrate having a straight middle portion, a first end portion that is joined to the middle portion by a first elbow portion, and a second end portion that is joined to the middle portion by a second elbow portion. The elbow portions are folded relative to the middle portion at first and second folds, respectively, such that the first planar surfaces of the first and second elbows face each other. A circuit is supported by the substrate and electrically connected between circuit boards supported on opposite sides of the battery array.

Abstract: A positive electrode active material includes a compound represented by formula 1: Li(1.1+a)Mn(0.51+c)Ni(0.37?x)MxO(2?b)Fb (1), wherein M is Co, Cr, or a combination thereof, 0?a?0.02, 0<b<0.01, 0?c?0.1, and 0<x<0.1. This positive electrode active material can be used within the context of a lithium-ion battery or a cell of a lithium-ion battery.

Abstract: A positive electrode active material includes a compound represented by formula 1: Li(1.333?0.667x?cz?ca)Mn(0.667?0.333x?0.5y)Ni(x?0.5y+cz)M(y+ca)O(2?b)Fb (1), wherein, 0<b<0.1, c=(0 or 1), 0.2<x<0.35, 0.04<y<0.09, 1<1.333?0.667x?cz?a<1.20, 0.5<0.667?0.333x?0.5y<0.667, 0.13<x?0.5y+cz<0.5, 0<y+ca<0.13, and M is Co, Cr, or a combination thereof. This positive electrode active material can be used within the context of a lithium-ion battery or a cell of a lithium-ion battery.

Abstract: A positive electrode active material includes a compound represented by formula 1: wherein: M is Co or Cr; 2<average oxidation state of Ni ion<2.27; and 0<x<0.1.

Abstract: A positive electrode active material includes a compound represented by formula 1: wherein: (Li+/[M3+ & Ni2+] substitution for Mn3+·M3+=Co3+ or Cr3+) 1 < 1.333 - 0.667 x - z - a < 1.333 0 < x - 0.5 y + z < 0.5 0 < y + a < 0.

Abstract: A positive electrode active material includes a compound represented by formula 1: Li 1.1 ? Mn 0.52 ? Ni 0 . 3 ? 8 - x ? M x ? O 2 ( 1 ) wherein: M is Co or Cr; 2<average oxidation state of Ni ion<2.15; and 0<x<0.06.

Abstract: A coating system for a solid-state battery includes a feeder for a first substrate foil, and an electrolyte dispenser between two electrode dispensers. The first electrode dispenser has a first mixture of a first solid active material and a first solid electrolyte therein, and deposits a first electrode layer on the foil. The electrolyte dispenser deposits an electrolyte layer on the first electrode layer. The second electrode dispenser has a second mixture of second solid active material and a second solid electrolyte, and deposits a second electrode layer on the electrolyte layer. A roller provides a second substrate foil downstream of the second electrode dispenser on the second electrode layer to form a layered structure. The system also includes drums for press rolling the layered structure to form a solid-state battery, with the layers being continuously deposited.

Abstract: A positive electrode material includes a plurality of particles composed of a positive electrode active material and a passivating layer disposed over each particle of the plurality of particles. The passivating layer is thermally insulating and lithium-ion conducting wherein the passivating layer is composed of a carbonate-phosphate composite.

Abstract: A method for forming a solid electrolyte interface on a lithium-ion battery electrode is provided. The method includes a step of introducing a first quantity of a first electrolyte composition into a container. The container includes at least one lithium-ion battery cell and the first electrolyte composition including ethylene carbonate. The lithium-ion battery cell is cycled for at least one charging cycle such that one or more solid electrolyte interfaces are formed. A second electrolyte composition is introduced into the container to form a final electrolyte composition, the second electrolyte composition including propylene carbonate.

Abstract: A positive electrode for a lithium-ion battery includes a current collector a positive electrode active layer disposed over the current collector. The positive electrode active layer is composed of a positive electrode composition includes a first positive electrode active material that has been aged for a first predetermined time period.

Abstract: A method for forming one or more layers of a lithium-ion battery includes a step of sequentially depositing a wet coating and a free-standing material layer onto a moving substrate to form a first bilayer on the substrate. The first bilayer including a wet coating-derived layer and the free-standing material layer. The first bilayer is heat roll pressed to form a second bilayer in which the wet coating-derived layer is at least partially dried and adhered to the free-standing material layer.

Abstract: Electrochemical cell arrays such as battery packs having cells of different sizes and/or thicknesses is disclosed. For example, the cells in an array may progressively increase or decrease in size or thickness from a first end to a second end such that a gradient in thickness is created. Alternatively, the gradient may be from the center to the outside. In a variation, the first and second endplates may be of different sizes or thicknesses.

Abstract: A positive electrode active material includes a compound represented by formula 1: Li(1.333-0.667x-y)Mn(0.667-0.333x)NixMyO2 or Li(4/3-2/3x-y)Mn(2/3-1/3x)NixMyO2??(1) wherein, M is Co, Cr, or a combination thereof, 0.13<x<0.5; and 0<y<0.333.

Abstract: Electrochemical stacks such as lithium-ion battery stacks and methods of assembling the same are disclosed. The stacks may include various electrochemical cells having different attributes. In one variation, the outer electrochemical cells may be different than the inner electrochemical cells. For example, the electrodes of the outer cells and inner cells may have different compositions, loading levels, and/or thicknesses. In a refinement, the separators of the outer cells and inner cells may have different thicknesses or porosities.