Abstract: Systems and methods are provided for high volume roll-to-roll transfer lamination of electrodes for silicon-dominant anode cells.

Abstract: Methods of forming a composite material film can include providing a mixture comprising a carbon precursor and silicon particles. The methods can also include pyrolysing the carbon precursor to convert the precursor into one or more types of carbon phases to form the composite material film such that the precursor has a char yield of greater than about 0% to about 60% and the composite material film comprises the silicon particles at about 90% to about 99% by weight.

Abstract: Systems and methods for multiple carbon precursors for enhanced battery electrode robustness may include an electrode having an active material on a current collector, the active material including two or more carbon precursor materials, and an additive, wherein the carbon precursor materials have different pyrolysis temperatures. A battery may include the electrode. The carbon precursor materials may include polyimide (PI) and polyamide-imide (PAI). The active material may be pyrolyzed at a temperature such that a first carbon precursor material is partially pyrolyzed and a second carbon precursor material is completely pyrolyzed. The carbon precursor materials may include two or more of PI, PAI, carboxymethyl cellulose (CMC), styrene-butadiene rubber (SBR), polyacrylonitrile (PAN), and sodium alginate. The active material may include silicon constituting at least 50% of weight of a formed anode after pyrolysis.

Abstract: In some embodiments, an electrode can include a first and second conductive layer. At least one of the first and second conductive layers can include porosity configured to allow electrolyte to flow therethrough. The electrode can also include an electrochemically active layer having electrochemically active material sandwiched between the first and second conductive layers. The electrochemically active layer can be in electrical communication with the first and second conductive layers.

Abstract: In some embodiments, an electrode can include a first and second conductive layer. At least one of the first and second conductive layers can include porosity configured to allow electrolyte to flow therethrough. The electrode can also include an electrochemically active layer having electrochemically active material sandwiched between the first and second conductive layers. The electrochemically active layer can be in electrical communication with the first and second conductive layers.

Abstract: Systems and methods for thermal gradient during electrode pyrolysis may include fabricating the battery electrode by pyrolyzing an active material on a metal current collector, wherein the active material comprises silicon particles in a binder material, the binder material being pyrolyzed more than 75% at an outer surface and less than 50% at an inner surface in contact with the current collector. The active material may be pyrolyzed by electromagnetic radiation, which may be provided by one or more lasers, which may include one or more CO2 lasers. The electromagnetic radiation may be provided by one or more infrared lamps. An outer edge of the current collector may be gripped using a thermal transfer block that removes heat from the current collector during pyrolysis of the active material and subsequent cool down. Heat transfer plates may be placed on or adjacent to the active material during pyrolysis.

Abstract: In some embodiments, an electrode can include a first and second conductive layer. At least one of the first and second conductive layers can include porosity configured to allow electrolyte to flow therethrough. The electrode can also include an electrochemically active layer having electrochemically active material sandwiched between the first and second conductive layers. The electrochemically active layer can be in electrical communication with the first and second conductive layers.

Abstract: In various embodiments, a method of forming an electrode includes providing a current collector, providing a substantially solid layer of electrode attachment substance on a side of the current collector, providing electrochemically active material adjacent the substantially solid layer of the electrode attachment substance, and adhering the electrochemically active material to the side of the current collector via the electrode attachment substance. In some examples, the electrochemically active material is provided in powder form. In some examples, the electrochemically active material is provided between the substantially solid layer of electrode attachment substance and the current collector.

Abstract: An electrospinning method includes providing a nozzle fluidically coupled to a source of polymer ink and providing a substrate adjacent to the nozzle. A first voltage is applied to the nozzle to initiate electrospinning of the polymer ink onto the substrate, wherein the first voltage is within the range of about 400V to about 1000V. The voltage is then reduced to a second, lower voltage wherein the voltage is within the range of about 600V to about 150V.

Abstract: An electrospinning method includes providing a nozzle fluidically coupled to a source of polymer ink and providing a substrate adjacent to the nozzle. A first voltage is applied to the nozzle to initiate electrospinning of the polymer ink onto the substrate, wherein the first voltage is within the range of about 400V to about 1000V. The voltage is then reduced to a second, lower voltage wherein the voltage is within the range of about 600V to about 150V.