Abstract: Methods for manufacturing intermittently coated dry electrodes for energy storage devices and energy storage devices including the intermittently coated dry electrodes are disclosed. In one embodiment, the method includes providing a metal layer and providing an electrochemically active free-standing film formed of a dry active material. The method also includes combining the electrochemically active free-standing film and the metal layer to form a combined layer. The method further includes removing a portion of the electrochemically active free-standing film from the combined layer so that the electrochemically active free-standing film is intermittently formed on the metal layer in a longitudinal direction of the metal layer.

Abstract: Methods for manufacturing intermittently coated dry electrodes for energy storage devices and energy storage devices including the intermittently coated dry electrodes are disclosed. In one embodiment, the method includes providing a metal layer and providing an electrochemically active free-standing film formed of a dry active material. The method also includes combining the electrochemically active free-standing film and the metal layer to form a combined layer. The method further includes removing a portion of the electrochemically active free-standing film from the combined layer so that the electrochemically active free-standing film is intermittently formed on the metal layer in a longitudinal direction of the metal layer.

Abstract: An energy storage device can include a cathode, an anode, and a separator between the cathode and the anode. At least one of the electrodes can include an electrode film prepared by a dry process. The electrode film, the electrode and/or the separator can comprise a salt, improved porosity, increased density, be prelithiated, and/or a foam. Process and apparatuses used for fabricating the electrode and/or electrode film are also described.

Abstract: Dry process electrode films, and energy storage devices incorporating the same are described, including a silicon active material. The films may be free standing anode electrode films. Also provided are methods for fabricating such anode electrode films.

Abstract: Materials and methods for preparing electrode film mixtures and electrode films including reduced damage bulk active materials are provided. In a first aspect, a method for preparing an electrode film mixture for an energy storage device is provided, comprising providing an initial binder mixture comprising a first binder and a first active material, processing the initial binder mixture under high shear to form a secondary binder mixture, and nondestructively mixing the secondary binder mixture with a second portion of active materials to form an electrode film mixture.

Abstract: Materials and methods for preparing dry cathode electrode film including reduced binder content are described. The cathode electrode film may be a self-supporting film including a single binder. The binder loading may be 3 weight % or less. In a first aspect, a method for preparing a dry free standing electrode film for an energy storage device is provided, comprising nondestructively mixing a cathode active material, a porous carbon, and optionally a conductive carbon to form an active material mixture, adding a single fibrillizable binder to the active material mixture, nondestructively mixing to form an electrode film mixture, and calendering the electrode film mixture to form a free standing electrode film.

Abstract: An energy storage device can include a first electrode, a second electrode and a separator between the first electrode and the second electrode wherein the first electrode includes an electrochemically active material and a porous carbon material, and the second electrode includes elemental lithium metal and carbon particles. A method for fabricating an energy storage device can include forming a first electrode and a second electrode, and inserting a separator between the first electrode and the second electrode, where forming the first electrode includes combining an electrochemically active material and a porous carbon material, and forming the second electrode includes combining elemental lithium metal and a plurality of carbon particles.

Abstract: An energy storage device can include a first electrode, a second electrode and a separator between the first electrode and the second electrode wherein the first electrode includes an electrochemically active material and a porous carbon material, and the second electrode includes elemental lithium metal and carbon particles. A method for fabricating an energy storage device can include forming a first electrode and a second electrode, and inserting a separator between the first electrode and the second electrode, where forming the first electrode includes combining an electrochemically active material and a porous carbon material, and forming the second electrode includes combining elemental lithium metal and a plurality of carbon particles.

Abstract: An energy storage device can include a cathode and an anode, where at least one of the cathode and the anode are made of a polytetrafluoroethylene (PTFE) composite binder material including PTFE and at least one of polyvinylidene fluoride (PVDF), a PVDF co-polymer, and poly(ethylene oxide) (PEO). The energy storage device can be a lithium ion battery, a lithium ion capacitor, and/or any other lithium based energy storage device. The PTFE composite binder material can have a ratio of about 1:1 of PTFE to a non-PTFE component, such a PVDF, PVDF co-polymer and/or PEO.

Abstract: Provided herein are dry process electrode films, and energy storage devices incorporating the same, including an elastic polymer binder. In some embodiments, the dry process electrode films are PTFE-free or comprise an insubstantial amount of PTFE. The electrode films exhibit improved mechanical and processing characteristics. Also provided are methods for processing such elastic polymer binders, and for incorporating the elastic polymer binders in electrode films.

Abstract: Provided herein are energy storage device electrode films comprising a hybrid electrode film, and methods of forming such multilayer hybrid electrode films and energy storage devices comprising multilayer hybrid electrode films. Each hybrid electrode film may comprise a self-supporting dry coated active layer and a wet cast active layer, wherein each active layer comprises a binder and an active material. The binder and/or active material may be the same or different as any other active layer. The hybrid multilayer electrode film may further comprise at least one additional layer, and the hybrid multilayer electrode film may be laminated with a current collector to form an electrode.

Abstract: Provided herein are multilayer dry films for electrode film fabrication, and electrode films, electrodes, and energy storage devices that implement the multilayer dry films. The multilayer dry film for electrode film fabrication comprises a dry free-standing active layer comprising a first dry active material and a first dry binder, and a dry prelithiating layer comprising lithium, such that the first dry free-standing active layer and the dry prelithiating layer are laminated to each other to form a free-standing multilayer dry film.

Abstract: An energy storage device can include a cathode and an anode, where at least one of the cathode and the anode are made of a polytetrafluoroethylene (PTFE) composite binder material including PTFE and at least one of polyvinylidene fluoride (PVDF), a PVDF co-polymer, and poly(ethylene oxide) (PEO). The energy storage device can be a lithium ion battery, a lithium ion capacitor, and/or any other lithium based energy storage device. The PTFE composite binder material can have a ratio of about 1:1 of PTFE to a non-PTFE component, such a PVDF, PVDF co-polymer and/or PEO.

Abstract: An energy storage device can include a cathode, an anode, and a separator between the cathode and the anode. At least one of the electrodes can include an electrode film prepared by a dry process. The electrode film and/or the electrode can comprise a prelithiating material. Processes and apparatuses used for fabricating the electrode and/or electrode film are also described.

Abstract: An energy storage device can include a first electrode, a second electrode and a separator between the first electrode and the second electrode wherein the first electrode or the second electrode includes elemental lithium metal and carbon particles. A method for fabricating an energy storage device can include forming a first electrode and a second electrode, and inserting a separator between the first electrode and the second electrode, where forming the first electrode or the second electrode can include combining elemental lithium metal and a plurality of carbon particles.

Abstract: Methods for manufacturing intermittently coated dry electrodes for energy storage devices and energy storage devices including the intermittently coated dry electrodes are disclosed. In one embodiment, the method includes providing a metal layer and providing an electrochemically active free-standing film formed of a dry active material. The method also includes combining the electrochemically active free-standing film and the metal layer to form a combined layer. The method further includes removing a portion of the electrochemically active free-standing film from the combined layer so that the electrochemically active free-standing film is intermittently formed on the metal layer in a longitudinal direction of the metal layer.

Abstract: An energy storage device can include a first electrode, a second electrode and a separator between the first electrode and the second electrode wherein the first electrode or the second electrode includes elemental lithium metal and carbon particles. A method for fabricating an energy storage device can include forming a first electrode and a second electrode, and inserting a separator between the first electrode and the second electrode, where forming the first electrode or the second electrode can include combining elemental lithium metal and a plurality of carbon particles.

Abstract: Provided herein are dry process electrode films, and energy storage devices incorporating the same, including a microparticulate non-fibrillizable binder having certain particle sizes. The electrode films exhibit improved mechanical and processing characteristics. Also provided are methods for processing such microparticulate non-fibrillizable electrode film binders, and for incorporating the microparticulate non-fibrillizable binders in electrode films.

Abstract: Provided herein are energy storage devices comprising at least one dry process, self-supporting electrode film having improved performance. The improved performance may be realized as improved electrode material loading, improved active material loading, improved active material density, improved areal capacity, improved specific capacity, improved areal energy density, improved energy density, improved specific energy density, or improved Coulombic efficiency.

Abstract: Provided herein are improved electrolyte formulations. The improved performance may be realized as improved discharge rate cycling, improved capacity, improved Coulombic efficiency, or improved capacity upon cycling.