Abstract: A method of making an electrode includes the step of mixing active material particles, radiation curable resin precursors, and electrically conductive particles to create an electrode precursor mixture. The electrode precursor mixture is electrostatically sprayed onto a current collector to provide an electrode preform. The electrode preform is heated and calendered to melt the resin precursor such that the resin precursor surrounds the active particles and electrically conductive particles. Radiation is applied to the electrode preform sufficient to cure the radiation curable resin precursors into resin.

Abstract: A method of making an electrode includes the step of mixing active material particles, radiation curable resin precursors, and electrically conductive particles to create an electrode precursor mixture. The electrode precursor mixture is electrostatically sprayed onto a current collector to provide an electrode preform. The electrode preform is heated and calendered to melt the resin precursor such that the resin precursor surrounds the active particles and electrically conductive particles. Radiation is applied to the electrode preform sufficient to cure the radiation curable resin precursors into resin.

Abstract: A lithium-ion battery comprising: (a) an anode; (b) a cathode; and (c) an electrolyte composition comprising lithium bis(fluorosulfonyl)imide (LiFSI) dissolved in the following solvent system containing at least the following solvent components: (i) ethylene carbonate and/or propylene carbonate in an amount of 5-70 wt % by weight of the solvent system; and (ii) at least one additional solvent selected from acyclic carbonate, acyclic or cyclic ester, and acyclic or cyclic ether solvents having a molecular weight of no more than 110 g/mol, wherein said at least one additional solvent is in an amount of 30-70 wt % by weight of the solvent system; wherein the wt % amounts for solvent components (i) and (ii), or any additional solvent components (if present) sum to 100 wt %, and wherein LiFSI is present in the solvent system in a concentration of 1.2 M to about 2 M.

Abstract: A method for fast formation cycling for rechargeable batteries comprising the steps of: step 1 (First Partial Charge)—charge cell from open-circuit voltage (OVC) up to 80-90% of an upper cutoff voltage (UCV) of from 4-5 V at a C rate not less than 0.5 and not more than 1.5; step 2 (First Shallow Charge)—charge cell from 80-90% of UCV to 97-100% of UCV at a C rate of not less than 0.2 and not more than 0.5; step 3 (First Shallow Discharge)—discharge cell from 97-100% of UCV to 80-90% of UCV at a C rate of not less than 0.2 and not more than 0.5; and step 4 (Subsequent Charge/Discharge Cycles)—repeat steps 2-3 up to 2-10 times where the charging and discharging rates are progressively increased by 25-75%. A battery made according to the method of the invention is also disclosed.

Abstract: A method for fast formation cycling for rechargeable batteries comprising the steps of: step 1 (First Partial Charge)—charge cell from open-circuit voltage (OVC) up to 80-90% of an upper cutoff voltage (UCV) of from 4-5 V at a C rate not less than 0.5 and not more than 1.5; step 2 (First Shallow Charge)—charge cell from 80-90% of UCV to 97-100% of UCV at a C rate of not less than 0.2 and not more than 0.5; step 3 (First Shallow Discharge)—discharge cell from 97-100% of UCV to 80-90% of UCV at a C rate of not less than 0.2 and not more than 0.5; and step 4 (Subsequent Charge/Discharge Cycles)—repeat steps 2-3 up to 2-10 times where the charging and discharging rates are progressively increased by 25-75%. A battery made according to the method of the invention is also disclosed.

Abstract: Thermal methods and systems are described for the batch and/or continuous monitoring of films and/or membranes and/or electrodes produced in large-scale manufacturing lines. Some of the methods described include providing an energy input into a film, measuring a thermal response of the film, and correlating these to one or more physical properties and/or characteristics of the film.

Abstract: A method of making an electrode includes the step of dispersing an active electrode material and a conductive additive in a solvent to create a mixed dispersion. The solvent has a surface tension less than 40 mN/m and an ozone forming potential of no more than 1.5 lbs. ozone/lb. solvent. A surface of a current collector is treated to raise the surface energy of the surface to at least the surface tension of the solvent or the mixed dispersion. The dispersed active electrode material and conductive additive are deposited on the current collector. The coated surface is heated to remove solvent from the coating.

Abstract: A method for fast formation cycling for rechargeable batteries comprising the steps of: step 1 (First Partial Charge)—charge cell from open-circuit voltage (OVC) up to 80-90% of an upper cutoff voltage (UCV) of from 4-5 V at a C rate not less than 0.5 and not more than 1.5; step 2 (First Shallow Charge)—charge cell from 80-90% of UCV to 97-100% of UCV at a C rate of not less than 0.2 and not more than 0.5; step 3 (First Shallow Discharge)—discharge cell from 97-100% of UCV to 80-90% of UCV at a C rate of not less than 0.2 and not more than 0.5; and step 4 (Subsequent Charge/Discharge Cycles)—repeat steps 2-3 up to 2-10 times where the charging and discharging rates are progressively increased by 25-75%. A battery made according to the method of the invention is also disclosed.

Abstract: A method of making an electrode includes the step of mixing active material particles, radiation curable resin precursors, and electrically conductive particles to create an electrode precursor mixture. The electrode precursor mixture is electrostatically sprayed onto a current collector to provide an electrode preform. The electrode preform is heated and calendered to melt the resin precursor such that the resin precursor surrounds the active particles and electrically conductive particles. Radiation is applied to the electrode preform sufficient to cure the radiation curable resin precursors into resin.

Abstract: A method of making an electrode includes the step of dispersing an active electrode material and a conductive additive in a solvent to create a mixed dispersion. The solvent has a surface tension less than 40 mN/m and an ozone forming potential of no more than 1.5 lbs. ozone/lb. solvent. A surface of a current collector is treated to raise the surface energy of the surface to at least the surface tension of the solvent or the mixed dispersion. The dispersed active electrode material and conductive additive are deposited on the current collector. The coated surface is heated to remove solvent from the coating.

Abstract: Thermal methods and systems are described for the batch and/or continuous monitoring of films and/or membranes and/or electrodes produced in large-scale manufacturing lines. Some of the methods described include providing an energy input into a film, measuring a thermal response of the film, and correlating these to one or more physical properties and/or characteristics of the film.

Abstract: A system and a method for characterizing a dielectric material are provided. The system and method generally include applying an excitation signal to electrodes on opposing sides of the dielectric material to evaluate a property of the dielectric material. The method can further include measuring the capacitive impedance across the dielectric material, and determining a variation in the capacitive impedance with respect to either or both of a time domain and a frequency domain. The measured property can include pore size and surface imperfections. The method can still further include modifying a processing parameter as the dielectric material is formed in response to the detected variations in the capacitive impedance, which can correspond to a non-uniformity in the dielectric material.

Abstract: A method of making a battery electrode includes the steps of dispersing an active electrode material and a conductive additive in water with at least one dispersant to create a mixed dispersion; treating a surface of a current collector to raise the surface energy of the surface to at least the surface tension of the mixed dispersion; depositing the dispersed active electrode material and conductive additive on a current collector; and heating the coated surface to remove water from the coating.

Abstract: A system and a method for characterizing a dielectric material are provided. The system and method generally include applying an excitation signal to electrodes on opposing sides of the dielectric material to evaluate a property of the dielectric material. The method can further include measuring the capacitive impedance across the dielectric material, and determining a variation in the capacitive impedance with respect to either or both of a time domain and a frequency domain. The measured property can include pore size and surface imperfections. The method can still further include modifying a processing parameter as the dielectric material is formed in response to the detected variations in the capacitive impedance, which can correspond to a non-uniformity in the dielectric material.

Abstract: A method of drying casted slurries that includes calculating drying conditions from an experimental model for a cast slurry and forming a cast film. An infrared heating probe is positioned on one side of the casted slurry and a thermal probe is positioned on an opposing side of the casted slurry. The infrared heating probe may control the temperature of the casted slurry during drying. The casted slurry may be observed with an optical microscope, while applying the drying conditions from the experimental model. Observing the casted slurry includes detecting the incidence of micro-structural changes in the casted slurry during drying to determine if the drying conditions from the experimental model are optimal.

Abstract: A method of making a battery electrode includes the steps of dispersing an active electrode material and a conductive additive in water with at least one dispersant to create a mixed dispersion; treating a surface of a current collector to raise the surface energy of the surface to at least the surface tension of the mixed dispersion; depositing the dispersed active electrode material and conductive additive on a current collector; and heating the coated surface to remove water from the coating.

Abstract: A method of making a battery electrode includes the steps of dispersing an active electrode material and a conductive additive in water with at least one dispersant to create a mixed dispersion; treating a surface of a current collector to raise the surface energy of the surface to at least the surface tension of the mixed dispersion; depositing the dispersed active electrode material and conductive additive on a current collector; and heating the coated surface to remove water from the coating.

Abstract: The invention provides a method of making a battery anode in which a quantity of graphite powder is provided. The temperature of the graphite powder is raised from a starting temperature to a first temperature between 1000 and 2000° C. during a first heating period. The graphite powder is then cooled to a final temperature during a cool down period. The graphite powder is contacted with a forming gas during at least one of the first heating period and the cool down period. The forming gas includes H2 and an inert gas.

Abstract: The invention provides a method of making a battery anode in which a quantity of graphite powder is provided. The temperature of the graphite powder is raised from a starting temperature to a first temperature between 1000 and 2000° C. during a first heating period. The graphite powder is then cooled to a final temperature during a cool down period. The graphite powder is contacted with a forming gas during at least one of the first heating period and the cool down period. The forming gas includes H2 and an inert gas.

Abstract: A fuel cell system with a proton exchange membrane. There is a cathode catalyst layer overlying the first face of the proton exchange membrane, and a cathode diffusion layer overlying the cathode catalyst layer. There is an anode catalyst layer overlying the second face of the proton exchange membrane, and an anode diffusion layer overlying the anode catalyst layer. The cathode diffusion layer has a water vapor permeance of less than about 3×10?4 g/(Pa s m2) at 80° C. and 1 atmosphere. The invention also relates to cathode diffusion layers for fuel cell systems.