Abstract: The invention is directed to a process for forming a particle film on a substrate. Preferably, a series of corona guns, staggered to optimize film thickness uniformity, are oriented on both sides of a slowly translating grounded substrate (copper or aluminum for the anode or cathode, respectively). The substrate is preferably slightly heated to induce binder flow, and passed through a set of hot rollers that further induce melting and improve film uniformity. The sheeting is collected on a roll or can be combined in-situ and rolled into a single-cell battery. The invention is also directed to products formed by the processes of the invention and, in particular, batteries.

Abstract: Methods of forming encapsulated electrochemical and/or ionically conducting particles as their use in manufacturing electrochemical cells are described.

Abstract: Powderized solid-state electrolytes and electroactive materials as well as related methods of manufacturing and use are disclosed. In one embodiment, an ionically conductive powder comprises a plurality of ionically conductive particles. The ionically conductive particles may comprise an ionically conductive salt dissolved in a thermoplastic polymer, with optional components (e.g., electroactive and/or inorganic solid particles) dispersed within. Related methods of producing these ionically conductive powders are also disclosed including, but are not limited to, low-temperature milling, spray drying, and aerosol polymerization. Embodiments related to using the resultant ionically conductive powders in a spray deposition process are also described.

Abstract: Methods of forming encapsulated electrochemical and/or ionically conducting particles as well as their use in manufacturing electrochemical cells are described.

Abstract: A system for forming a particle layer on a substrate may include at least one sprayer and at least two masks configured to selectively mask a substrate in a first region and second region of the substrate. The at least one sprayer may be configured to spray particles at the substrate, where the at least two masks maintain the first region and second region substantially free of the deposited material. A heater may be employed to heat the substrate as the particles are sprayed by the at least one sprayer onto the substrate.

Abstract: Embodiments of a device and methods to operating the same are described that can provide high level status information about a battery having multiple modular battery packs which may be arranged in different numbers and/or electrical configurations depending on the specific application. In some embodiments, a smart hub is in communication with battery packs within the battery and configured to selectively query low level status information associated with individual battery packs based on a stored pack configuration that can be updated by a user. The device allows more efficient provision of battery information during flexible assembly and connection of the battery packs.

Abstract: A system for forming a particle layer on a substrate may include at least one sprayer and at least two masks configured to selectively mask a substrate in a first region and second region of the substrate. The at least one sprayer may be configured to spray particles at the substrate, where the at least two masks maintain the first region and second region substantially free of the deposited material. A heater may be employed to heat the substrate as the particles are sprayed by the at least one sprayer onto the substrate.

Abstract: Powderized solid-state electrolytes and electroactive materials as well as related methods of manufacturing and use are disclosed. In one embodiment, an ionically conductive powder comprises a plurality of ionically conductive particles. The ionically conductive particles may comprise an ionically conductive salt dissolved in a thermoplastic polymer, with optional components (e.g.,electroactive and/or inorganic solid particles) dispersed within. Related methods of producing these ionically conductive powders are also disclosed including, but are not limited to, low-temperature milling, spray drying, and aerosol polymerization. Embodiments related to using the resultant ionically conductive powders in a spray deposition process are also described.

Abstract: Methods of forming encapsulated electrochemical and/or ionically conducting particles as well as their use in manufacturing electrochemical cells are described.

Abstract: The invention is directed to a process for forming a particle film on a substrate. Preferably, a series of corona guns, staggered to optimize film thickness uniformity, are oriented on both sides of a slowly translating grounded substrate (copper or aluminum for the anode or cathode, respectively). The substrate is preferably slightly heated to induce binder flow, and passed through a set of hot rollers that further induce melting and improve film uniformity. The sheeting is collected on a roll or can be combined in-situ and rolled into a single-cell battery. The invention is also directed to products formed by the processes of the invention and, in particular, batteries.

Abstract: The invention is directed to a process for forming a particle film on a substrate. Preferably, a series of corona guns, staggered to optimize film thickness uniformity, are oriented on both sides of a slowly translating grounded substrate (copper or aluminum for the anode or cathode, respectively). The substrate is preferably slightly heated to induce binder flow, and passed through a set of hot rollers that further induce melting and improve film uniformity. The sheeting is collected on a roll or can be combined in-situ and rolled into a single-cell battery. The invention is also directed to products formed by the processes of the invention and, in particular, batteries.

Abstract: A system for forming a particle layer on a substrate may include at least one sprayer and at least two masks configured to selectively mask a substrate in a first region and second region of the substrate. The at least one sprayer may be configured to spray particles at the substrate, where the at least two masks maintain the first region and second region substantially free of the deposited material. A heater may be employed to heat the substrate as the particles are sprayed by the at least one sprayer onto the substrate.

Abstract: Methods of forming encapsulated electrochemical and/or ionically conducting particles as their use in manufacturing electrochemical cells are described.

Abstract: The invention is directed to a process for forming a particle film on a substrate. Preferably, a series of corona guns, staggered to optimize film thickness uniformity, are oriented on both sides of a slowly translating grounded substrate (copper or aluminum for the anode or cathode, respectively). The substrate is preferably slightly heated to induce binder flow, and passed through a set of hot rollers that further induce melting and improve film uniformity. The sheeting is collected on a roll or can be combined in-situ and rolled into a single-cell battery. The invention is also directed to products formed by the processes of the invention and, in particular, batteries.

Abstract: The invention is directed to a process for forming a particle film on a substrate. Preferably, a series of corona guns, staggered to optimize film thickness uniformity, are oriented on both sides of a slowly translating grounded substrate (copper or aluminum for the anode or cathode, respectively). The substrate is preferably slightly heated to induce binder flow, and passed through a set of hot rollers that further induce melting and improve film uniformity. The sheeting is collected on a roll or can be combined in-situ and rolled into a single-cell battery. The invention is also directed to products formed by the processes of the invention and, in particular, batteries.

Abstract: Multicomponent nanoparticles materials and apparatuses and processes therefor are disclosed. In one aspect of the disclosure, separate particles generated from solution or suspension or by flame synthesis or flame spray pyrolysis, and the resultant particles are mixed in chamber prior to collection or deposition. In another aspect of the disclosure, nanoparticles are synthesized in stagnation or Bunsen flames and allowed to deposit by theirnophoresis on a moving substrate. These techniques are scalable allowing mass production of multicomponent nanoparticles materials and films. The foregoing techniques can be used to prepare composites and component devices comprising one ore more lithium based particles intimately mixed with carbon particles.

Abstract: Multicomponent nanoparticles materials and apparatuses and processes therefor are disclosed. In one aspect of the disclosure, separate particles generated from solution or suspension or by flame synthesis or flame spray pyrolysis, and the resultant particles are mixed in chamber prior to collection or deposition. In another aspect of the disclosure, nanoparticles are synthesized in stagnation or Bunsen flames and allowed to deposit by thermophoresis on a moving substrate. These techniques are scalable allowing mass production of multicomponent nanoparticles materials and films. The foregoing techniques can be used to prepare composites and component devices comprising one or more lithium based particles intimately mixed with carbon particles.

Abstract: Processes for depositing conductive materials on substrates are disclosed which include the steps of combusting a premixed fuel and oxidant to form a stagnation flame against a moving surface which stabilizes the stagnation flame and introducing at least one precursor to the flame to form a conducting material onto the substrate.

Abstract: Multicomponent nanoparticles materials and apparatuses and processes therefor are disclosed. In one aspect of the disclosure, separate particles generated from solution or suspension or by flame synthesis or flame spray pyrolysis, and the resultant particles are mixed in chamber prior to collection or deposition. In another aspect of the disclosure, nanoparticles are synthesized in stagnation or Bunsen flames and allowed to deposit by thermophoresis on a moving substrate. These techniques are scalable allowing mass production of multicomponent nanoparticles materials and films. The foregoing techniques can be used to prepare composites and component devices comprising one or more lithium based particles intimately mixed with carbon particles.