Abstract: Composite cathode-separator laminations (CSL) include a current collector with sulfur-based host material applied thereto, a coated separator comprising an electrolyte membrane separator with a carbonaceous coating, and a porous, polymer-based interfacial layer (PBIL) forming a binding interface between the carbonaceous coating and the host material. The host material includes less than about 6% polymeric binder, and less than about 40% electrically conductive carbon, with the balance comprising one or more sulfur compounds. The PBIL can have a thickness of less than about 5 ?m and a porosity of about 5% to about 40%. The host material can comprise less than about 40% conductive carbon (e.g., graphene) and have a porosity of less than about 40%. The carbonaceous coating (e.g., graphene) can have a thickness of about 1 ?m to about 5 ?m. The CSL can be disposed with an anode within an electrolyte to form a lithium-sulfur battery cell.

Abstract: A lithium ion battery pouch cell is disclosed that includes a copper-free negative terminal tab in which at least a joining region of an exterior portion of the negative terminal tab is aluminum or nickel-coated aluminum. In this way, the negative terminal tab of the lithium ion battery pouch cell may be welded to a common aluminum bus bar along with a positive terminal tab of another lithium ion battery pouch cell, or the negative terminal tab and the positive terminal tab of the two lithium ion battery pouch cells may be directly welded together in the absence of a common bus bar. Because the negative terminal tab does not include copper, the difficulties inherent in welding aluminum and copper, such as the formation of brittle Al—Cu intermetallic compounds, can be avoided. Lithium ion battery packs that include the disclosed lithium ion battery pouch cell are also disclosed.

Abstract: In a method of manufacturing an electrochemical cell, a porous or non-porous electrically conductive metal substrate may be provided. A conformal metal chalcogenide layer may be formed on a surface of the metal substrate. The metal substrate with the conformal metal chalcogenide layer may be immersed in a nonaqueous liquid electrolyte solution comprising a lithium salt dissolved in a polar aprotic organic solvent. An electrical potential may be established between the metal substrate and a counter electrode immersed in the nonaqueous liquid electrolyte solution such that lithium ions in the electrolyte solution are reduced to metallic lithium and deposited on the surface of the metal substrate over the metal chalcogenide layer to form a conformal lithium metal layer on the surface of the metal substrate over the metal chalcogenide layer.

Abstract: A method of manufacturing an electrochemical cell may comprise exposing a surface of a metal substrate to a chalcogen in gas phase such that a metal chalcogenide layer forms on the surface of the metal substrate. A lithium metal foil may be laminated onto the metal chalcogenide layer on the surface of the metal substrate such that a surface of the lithium metal foil physically and chemically bonds to the metal chalcogenide layer on the surface of the metal substrate.

Abstract: A method of making a metal organic framework (MOF)-polymer composite material includes forming a homogeneous solution comprising a solvent, a metal salt, a polymer which is soluble in the solvent, and a reactant which can be synthesized to provide an organic linker during formation of a MOF structure, synthesizing the homogeneous solution to crystallize a MOF structure in the homogenous solution to yield the MOF structure distributed in a remainder solution, applying an antisolvent to the remainder solution with the MOF structure distributed in the remainder solution to form a polymer-rich phase, where the MOF structure is integrated into the polymer matrix during forming of the polymer matrix to produce a MOF-polymer composite material. The MOF-polymer composite material can be formed on a substrate to produce a MOF structured object, which can be a membrane, film, or other object.

Abstract: Electrochemical cells that cycle lithium ions are provided. The electrochemical cells have an electrode that includes a silicon-containing electroactive material that undergoes volumetric expansion and contraction during the cycling of the electrochemical cell; and an electrolyte system that promotes passive formation of a flexible protective layer comprising a lithium fluoride-polymer composite on one or more exposed surface regions of the silicon-containing electroactive material. The electrolyte system includes a lithium salt, at least one cyclic carbonate, and two or more linear carbonates. At least one of the two or more linear carbonate-containing co-solvents is a fluorinated carbonate-containing co-solvent. The electrolyte system accommodates the volumetric expansion and contraction of the silicon-containing electroactive material to promote long term cycling stability.

Abstract: In certain aspects, electrolytic deposition and electroless displacement deposition methods are provided to form bimetallic structures that may be used as a bipolar current collector in a battery or a substrate for forming graphene sheets. In other aspects, bipolar current collectors for lithium-ion based electrochemical cells are provided. The bimetallic current collector may have an aluminum-containing surface and a continuous copper coating. In other aspects, a flexible substrate may be coated with one or more conductive materials, like nickel, copper, graphene, aluminum, alloys, and combinations thereof. The flexible substrate is folded to form a bipolar current collector. New stack assemblies for lithium-ion based batteries incorporating such bipolar current collectors are also provided that can have cells with a tab-free and/or weld-free design.

Abstract: A highly-concentrated electrolyte system for an electrochemical cell is provided, along with methods of making the electrolyte system. The electrolyte system includes a bound moiety having an ionization potential greater than an electron affinity and comprising one or more salts selected from the group consisting of: lithium bis(fluorosulfonyl)imide, sodium bis(fluorosulfonyl)imide, potassium bis(fluorosulfonyl)imide, and combinations thereof bound to a solvent comprising one or more solvents selected from the group consisting of: dimethyl carbonate, dimethyl dicarbonate, and combinations thereof. The salts have a concentration in the electrolyte system of greater than or equal to about 4 M. A molar ratio of the salts to the dimethyl carbonate is about 0.5. A molar ratio of the salts to the dimethyl dicarbonate is about 1.

Abstract: Methods for manufacturing sulfur electrodes include providing an electrode, wherein the electrode includes a current collector having a first surface, and a sulfur-based host material applied to the first surface of the current collector, wherein the sulfur-based host material comprises one or more sulfur compounds, one or more electrically conductive carbon materials, and one or more binders. The methods further include forming a plurality of channels within the sulfur-based host material using a laser or electron beam, wherein the plurality of channels define a plurality of host material columns, each column having one or more exterior surfaces contiguous which one or more of the channels which extend outward from the first surface of the current collector. Each of the one or more exterior surfaces can define a heat affected zone comprising a higher concentration of sulfur than the host material column prior to forming the plurality of channels.

Abstract: Disclosed are methods for manufacturing a pouch-type battery cells, and include disposing an anode and a cathode, and optionally a reference electrode, between a first pouch layer and a second pouch layer, and applying heat to the outer corrosion resistant polymer layer of the first pouch layer or the second pouch layer via a laser along a peripheral seal path forming a peripheral seal joining the first pouch layer and the second pouch layer to form a pouch encasing the anode and the cathode, and optionally the reference electrode. Each pouch layer includes an inner heat-activated polymer adhesive layer, a middle aluminum layer, and an outer corrosion resistant polymer layer. The outer corrosion resistant polymer layer of the first pouch layer and/or the second pouch layer can have a laser absorptivity of less than about 10%. The laser can have a wavelength of about 800 nanometers to about 2,000 nanometers.

Abstract: To make a pouch format cell, an outermost stack (including a negative electrode and separators positioned on opposed surfaces thereof) is formed. An inner stack is formed, including a positive electrode and a sub-stack (i.e., another negative electrode with separators positioned on opposed surfaces thereof and another positive electrode). The inner stack is positioned on the outermost stack to form a core stack, such that i) one inner stack end substantially aligns with one outermost stack end, ii) another end and a portion of the outermost stack remain exposed, and iii) the inner stack positive electrode is adjacent to one of the outermost stack separators. The outermost stack exposed portion is folded around another inner stack end and to cover a portion of an outer layer of the inner stack. This forms an initial overlay. The core stack is folded around at least a portion of the initial overlay.

Abstract: A lithium-based electrode assembly and methods of formation relating thereto are provided. The lithium-based electrode assembly comprises a metal current collector, an electrode comprising lithium metal, and an intermediate layer disposed therebetween. The intermediate layer comprising an intermetallic compound comprising the lithium metal of the electrode and a metal selected from the group consisting of: aluminum, silver, gold, barium, bismuth, boron, calcium, cadmium, carbon, gallium, germanium, mercury, indium, iridium, lead, palladium, platinum, rhodium, antimony, selenium, silicon, tin, strontium, sulfur, tellurium, zinc, and combinations thereof.

Abstract: An electrochemical cell comprising a lithium metal negative electrode layer physically and chemically bonded to a surface of a negative electrode current collector via an intermediate metal chalcogenide layer. The intermediate metal chalcogenide layer may comprise a metal oxide, a metal sulfide, a metal selenide, or a combination thereof. The intermediate metal chalcogenide layer may be formed on the surface of the negative electrode current collector by exposing the surface to a chalcogen in gas phase. Then, the lithium metal negative electrode layer may be formed on the surface of the negative electrode current collector over the intermediate metal chalcogenide layer by contacting at least a portion of the metal chalcogenide layer with a source of lithium such that the lithium actively wets the metal chalcogenide layer and forms a conformal lithium metal layer on the surface of the negative electrode current collector over the metal chalcogenide layer.

Abstract: An electrochemical cell includes a negative electrode that contains lithium and an electrolyte system. In one variation, the electrolyte system includes a first liquid electrolyte, a solid-dendrite-blocking layer, and an interface layer. The solid dendrite-blocking layer is ionically conducting and electrically insulating. The dendrite-blocking layer includes a first component and a distinct second component. The dendrite-blocking layer has a shear modulus of greater than or equal to about 7.5 GPa at 23° C. The interface layer is configured to interface with a negative electrode including lithium metal on a first side and the dendrite blocking layer on a second opposite side. The interface layer includes a second liquid electrolyte, a gel polymer electrolyte, or a solid-state electrolyte. The dendrite-blocking layer is disposed between the first liquid electrolyte and the interface layer.

Abstract: An example electrolyte includes a solvent, a lithium salt, and an additive selected from the group consisting of a mercaptosilane, a mercaptosiloxane, and combinations thereof. The electrolyte may be used in a method for making a solid electrolyte interface (SEI) layer on a surface of an electrode. A negative electrode structure may be formed from the method.

Abstract: Systems and methods are provided for thermal control using vascular channels. Vascular channels are incorporated in a network within a component. The component is a part of a manufactured environment configured for occupants. A fluid circuit is connected with the vascular channels and circulates a fluid through the component to alter a thermal state of the component.

Abstract: The present disclosure provides a battery pack component including a self-healing coating. The self-healing coating is disposed on at least a portion of a surface of the battery pack component. The self-healing coating includes a first precursor including a cyclic ether capable of reacting in a self-healing cationic ring-opening polymerization reaction. The self-healing coating further includes an initiator including an alkali metal salt. The self-healing cationic ring-opening polymerization reaction occurs when a defect is present in the self-healing coating. In certain aspects, the cyclic ether may include 1,3-dioxolane (C3H6O2) and the initiator may include lithium bis(fluorosulfonyl)imide (F2NaNO4S2). In other aspects, the self-healing coating may include a second precursor that is capable of copolymerizing with the first precursor. In still other aspects, the present disclosure provides a method of making a self-healing coating for a battery pack component.

Abstract: Systems and methods of providing self-healing gel-type electrolyte composites for metal batteries are disclosed. According to aspects of the disclosure, a method includes preparing a ternary mixture including an electrolyte portion, a matrix precursor portion, and a self-healing portion, forming a self-healing gel-electrolyte membrane by initiating polymerization of the gel-forming precursor and the gel-forming initiator to thereby form a polymer matrix, and disposing the self-healing gel-electrolyte membrane between an anode and a cathode. The self-healing portion includes a self-healing precursor that is flowable and a self-healing initiator. The matrix precursor portion includes a gel-forming precursor and a gel-forming initiator. The electrolyte portion and the self-healing portion are disposed substantially throughout the polymer matrix and the polymer matrix includes a plurality of gel-forming active sites.

Abstract: A negative electrode for an electrochemical cell of a lithium metal battery may be manufactured by joining together a metallic current collector piece and a lithium metal piece. The metallic current collector piece may be positioned adjacent the lithium metal piece in an at least partially lapped configuration at a weld site. A laser beam may be directed at an upper surface of the metallic current collector piece at the weld site to melt a portion of the lithium metal piece adjacent the metallic current collector piece and produce a lithium metal molten weld pool. The second laser beam may be terminated to solidify the lithium metal molten weld pool into a solid weld joint that physically bonds the lithium metal piece and the metallic current collector piece together at the weld site.

Abstract: A porous carbon material includes a hierarchical porous structure including a primary microporous structure and at least one of a secondary mesoporous structure and a secondary macroporous structure. The porous carbon material is formed by combining a halogenated-hydrocarbon, an aprotic hydrocarbon solvent, and a reductant to initiate a reaction that forms intermediate particles having a microporous framework; and subjecting the intermediate particles to a heat treatment at a heat treatment temperature ranging from about 300° C. to less than 1,500° C. for a heat treatment time period ranging from about 20 minutes to about 10 hours to thereby form the porous carbon material. The aprotic hydrocarbon solvent is selected from the group consisting of toluene, hexane, cyclohexane, and combinations thereof.