Abstract: A method for validating non-destructive, electromagnetic methods in atmospheric conditions of a battery cell intended to include a lithium metal layer includes selecting a lithium mimic metal layer to replace the lithium metal layer; and creating a mock-up sample including one or more layers of the battery cell. One or more layers comprise the lithium mimic metal layer. The method includes performing electromagnetic testing of the mock-up sample.

Abstract: The present disclosure provides electrode assemblies for safe nondestructive testing in ambient conditions. In certain variations, the electrode assembly includes a current collector and a non-reactive lithium mimic material disposed on or near one or more surfaces of the current collector or embedded in the current collector. In other variations, the electrode assembly includes include a current collector, a lithium metal material disposed on or near one or more surfaces of the current collector or embedded in the current collector to form an electrode assembly, and a non-conductive pouch holding the electrode assembly.

Abstract: In various aspects, the present disclosure provides a method of manufacturing an electrode for an electrochemical cell. The method includes contacting a solid electrode material and a substrate at an interface. The method further includes preparing a liquid electrode material at the interface by heating at least a portion of the solid electrode material to a first temperature. The first temperature is greater than or equal to a melting point of the solid electrode material. The method further includes creating a layer of the liquid electrode material on the substrate by moving at least one of the solid electrode material and the substrate with respect to the other of the solid electrode material and the substrate. The method further includes forming the electrode by cooling the liquid electrode material to a second temperature. The second temperature is less than or equal to the melting point.

Abstract: In various aspects, the present disclosure provides a method of manufacturing an electrode for an electrochemical cell. The method includes contacting a solid electrode material and a substrate at an interface. The method further includes preparing a liquid electrode material at the interface by heating at least a portion of the solid electrode material to a first temperature. The first temperature is greater than or equal to a melting point of the solid electrode material. The method further includes creating a layer of the liquid electrode material on the substrate by moving at least one of the solid electrode material and the substrate with respect to the other of the solid electrode material and the substrate. The method further includes forming the electrode by cooling the liquid electrode material to a second temperature. The second temperature is less than or equal to the melting point.

Abstract: A battery cell comprises a battery cell enclosure made of a non-metallic material. First battery terminals arranged in the battery cell enclosure. Second battery terminals arranged in the battery cell enclosure. Electrolyte is located between the first battery terminals and the second battery terminals. C conductive portions are arranged adjacent to an outer surface of the battery cell enclosure, where C is an integer greater than zero.

Abstract: A quality control system in a battery manufacturing process includes two or more capacitive measurement apparatuses to obtain a capacitance measurement from two or more intermediate products generated during the battery manufacturing process. The system also includes processing circuitry to obtain the capacitive measurement from the two or more capacitive measurement apparatuses, to determine a characteristic of the corresponding intermediate product, and to control at least one process of the battery manufacturing process that produced at least one of the two or more intermediate products based on the characteristic.

Abstract: A device for simulating a battery condition includes a plurality of electrically conductive plates, the plurality of electrically conductive plates including a set of opposing plates having a first plate and a second plate. The device also includes an electrically conductive material extending between the first plate and the second plate, the electrically conductive material in electrical contact with the first plate and the second plate and defining at least part of an electrical path from the first plate to the second plate, the electrically conductive material having a resistance selected to simulate the battery condition in response to activating the device.

Abstract: A system for testing a battery cell includes a test fixture configured to enclose the battery cell, a battery cycler configured to alternately charge and discharge the battery cell, an antenna mounted on a surface of the test fixture, the antenna configured to detect an electromagnetic signature of the battery cell and generate a signal indicative of the electromagnetic signature, and a detection module configured to receive the signal and detect characteristics of the battery cell based on the signal.

Abstract: A system for testing a battery cell includes a test fixture configured to enclose the battery cell, a battery cycler configured to alternately charge and discharge the battery cell, an antenna mounted on a surface of the test fixture, the antenna configured to detect an electromagnetic signature of the battery cell and generate a signal indicative of the electromagnetic signature, and a detection module configured to receive the signal and detect characteristics of the battery cell based on the signal.

Abstract: Aspects of the disclosure include an electrode coating having a spatially varied porosity and a method of forming the same by using a porous current collector. An exemplary method can include forming a porous current collector having a bulk material and a plurality of voids. The porous current collector can be coated, infused, or otherwise saturated with an electrode coating having an active electrode material. The porous current collector and the electrode coating can be compressed in a calendering process to define the electrode film. The distribution of the plurality of voids in the porous current collector provides for regions of different calendering pressures during the calendering process. The regions of different calendering pressures leads to regions of higher and lower porosity in the resultant electrode film. In other words, an electrode film having a spatially varied porosity.