Abstract: Systems and methods for use of silicon with impurities in silicon-dominant anode cells may include a cathode, an electrolyte, and an anode including an active material, where the anode active material includes silicon, and where an impurity level of the silicon may be more than 400 ppm. The impurity level of the silicon is more than 600 ppm. The impurity level may be for elements with an atomic number between 2 and 42. The silicon may have a purity of 99.90% or less. A resistance of the silicon when pressed into a 4 mm thick and 15 mm diameter pellet may be 25 k? or less. The active material may include silicon, carbon, and a pyrolyzed polymer on a metal current collector. The metal current collector may include a copper or nickel foil in electrical contact with the active material. The active material may include more than 50% silicon.

Abstract: This disclosure describes a battery device with at least two battery cells and a stainless-steel foil pouch located between the battery cells. The stainless-steel foil pouch holds fire retardant materials that prevent and/or delay thermal propagation.

Abstract: Systems and methods utilizing aqueous-based polymer binders for silicon-dominant anodes containing pyrolyzed carbon may include an electrode coating layer on a current collector, where the electrode coating layer is formed from silicon and a water soluble polymer and may comprise one or more additional materials. The electrode coating layer may include more than 70% silicon and the anode may be in a lithium ion battery.

Abstract: Systems and methods utilizing aqueous-based polymer binders for silicon-based anodes may include an electrode coating layer on a current collector, where the electrode coating layer is formed from a silicon carbon composite or SiOx-based or Si-Carbon-SiOx-based powder and a water soluble polymer and may comprise one or more additional materials. The anode may be in a lithium ion battery.

Abstract: Systems and methods for anisotropic expansion of silicon-dominant anodes may include forming an anode by pyrolyzing an active material layer comprising a binder and silicon particles in a temperature range of 600 to 800° C.; and forming a battery cell comprising a cathode, an electrolyte, and the anode, where the anode comprises the pyrolyzed active material layer on a current collector. A lateral expansion of the anode during operation may be less than 2%, less than 1%, or less than 0.6%. The active material layer may be pyrolyzed on the current collector or may be pyrolyzed on a substrate before laminating on the current collector. The anode active material layer may be pyrolyzed using a 1 hour dwell time or less or using a 2 hour dwell time or less. The active material layer may be pyrolyzed in a temperature range of 650 to 800° C.

Abstract: A method and system for carbon-coated silicon in a pyrolyzed carbon binder electrode on copper current collectors may include providing a metal current collector; forming a non-porous carbon coating on the metal current collector; coating silicon particles with carbon; forming an active material layer on the metal current collector, where the active material layer comprises at least 50% silicon particles by weight and a carbon source; and pyrolyzing the active material layer on the metal current collector, with no silicon particles in contact with metal from the metal current collector. The metal current collector may include copper. The battery anode may include no copper-silicon eutectic. The silicon particles may range in size from 2 to 50 ?m. The active material layer may include aluminum carbide. A source for the pyrolyzed carbon may include polyimide and/or polyamide-imide. The current collector may be coated with the non-porous carbon coating using physical vapor deposition.

Abstract: Systems and methods utilizing aqueous-based polymer binders for silicon-dominant anodes containing pyrolyzed carbon may include an electrode coating layer on a current collector, where the electrode coating layer is formed from silicon and a water soluble polymer and may comprise one or more additional materials. The electrode coating layer may include more than 70% silicon and the anode may be in a lithium ion battery.

Abstract: A method of managing battery performance may include obtaining, via a measurement device, measurements of one or more parameters relating to one or more cells; generating or updating, based on the measurements, a machine learning model; and generating, using the machine learning model, cell performance prediction data for use in managing at least one cell. Each cell includes a cathode, a separator, and a silicon-dominant anode. The measurements of the one or more parameters correspond to a plurality of different types of data. The measurements include one or more of: measurements of cells or cell components before formation or cycling, measurements from formation cycles for one or more cells, measurements from a number of cycles after formation for one or more cells, and measurements of characteristics of cell components prior to cell assembly.

Abstract: Systems and methods for silicon dominant lithium-ion cells with controlled lithiation of silicon may include a cathode, an electrolyte, and an anode. The anode may include silicon lithiated at a level after discharge that is configured to be above a minimum threshold level, where the minimum threshold lithiation is 3% silicon lithiation. The lithiation level of the silicon after charging the battery may range between 30% and 95% silicon lithiation, between 30% and 75% silicon lithiation, between 30% and 65% silicon lithiation, or between 30% and 50% silicon lithiation. The lithiation level of the silicon after discharging the battery may range between 3% and 50% silicon lithiation, between 3% and 30% silicon lithiation, or between 3% and 10% silicon lithiation. The minimum threshold level may be a lithiation level below which a cycle life of the battery degrades. The electrolyte may include a liquid, solid, or gel.

Abstract: Systems and methods are provided for control of furnace atmosphere for improving capacity retention of silicon-dominant anode cells. Furnace atmosphere may be controlled during processing of a silicon-dominated electrode in a furnace, with the processing including pyrolysis of the silicon-dominated electrode, and the controlling including setting or adjusting one or more of pressure of the furnace atmosphere, and composition of the furnace atmosphere. The controlling of the furnace atmosphere may be configured based on at least one environment condition. The at least one environment condition may be an oxygen-free environment.

Abstract: Systems and methods for high speed formation of cells for configuring anisotropic expansion of silicon-dominant anodes may include a cathode, an electrolyte, and an anode, where the anode may include a current collector and an active material on the current collector. An expansion of the anode may be configured by a charge rate during formation of the battery. The expansion of the anode may be less than 1.5% in lateral dimensions of the anode for higher charge rates during formation with the active material being more than 50% silicon, where the higher charge rate may be 1 C or higher, and perpendicular expansion may be higher for charge rates below 1 C during formation. The expansion of the anode may be lower in lateral dimensions for thicker current collectors, which may be 10 ?m or thicker, and may be lower in lateral dimensions for more rigid materials for the current collector.

Abstract: Systems and methods for batteries comprising a cathode, an electrolyte, and an anode, wherein sacrificial salts and prelithiation reagents are added to the cathode as functional additives for electrochemical prelithiation.

Abstract: Systems and methods are provided for managing anisotropic expansion of silicon-dominant anodes. An example battery may include a cathode, an electrolyte, and an anode, with the anode including a current collector and an active material on a surface of the current collector. One or more characteristics of the current collector may ensure meeting particular expansion criteria. The expansion criteria may include expanding less in one of x-y directions and z-direction while expanding more in other one of the x-y directions and the z-direction, the x-y directions being parallel to the surface of the current collector and perpendicular to a thickness of the active material. The one or more characteristics include at least material of the current collector.

Abstract: Systems and methods for silicon dominant lithium-ion cells with controlled lithiation of silicon may include a cathode, an electrolyte, and an anode. The anode may include silicon lithiated at a level after discharge that is configured to be above a minimum threshold level, where the minimum threshold lithiation is 3% silicon lithiation. The lithiation level of the silicon after charging the battery may range between 30% and 95% silicon lithiation, between 30% and 75% silicon lithiation, between 30% and 65% silicon lithiation, or between 30% and 50% silicon lithiation. The lithiation level of the silicon after discharging the battery may range between 3% and 50% silicon lithiation, between 3% and 30% silicon lithiation, or between 3% and 10% silicon lithiation. The minimum threshold level may be a lithiation level below which a cycle life of the battery degrades. The electrolyte may include a liquid, solid, or gel.

Abstract: Electrolytes and electrolyte additives for energy storage devices comprising a carboxylic ether, a carboxylic acid based salt, or an acrylate electrolyte are disclosed. The energy storage device comprises a first electrode and a second electrode, wherein at least one of the first electrode and the second electrode is a Si-based electrode, a separator between the first electrode and the second electrode, an electrolyte, and at least one electrolyte additive selected from carboxylic ethers, carboxylic acid based salts, and acrylates.

Abstract: Methods and systems are provided for key predictors and machine learning for configuring cell performance. One or more parameters relating to operation of a cell may be measured, via a measurement apparatus, with the cell including a cathode, a separator, and a silicon-dominant anode, and cell performance may be managed, based on the one or more parameters, with the managing including assessing the cell performance using a machine learning model. The cell may be within a battery pack that includes a plurality of cells, each of which including a cathode, a separator, and a silicon-dominant anode. One or more of the plurality of cells from the battery pack in response to a determination, based on the assessing, of a different performance of the one or more of the plurality of cells. The battery pack may be in an electric vehicle.

Abstract: Methods and systems are provided for key predictors and machine learning for configuring cell performance. One or more parameters relating to the cell may be measured, via a measurement apparatus, with the cell including a cathode, a separator, and a silicon-dominant anode, and the cell may be managed, based on the one or more parameters, with the managing including predetermining cycle life of the cell based on the one or more parameters using a machine learning model. The cell may be within a battery pack that includes a plurality of cells. The battery pack may be in an electric vehicle. At least one parameter may be measured before a formation process of the cell. At least one parameter may be measured during the formation process. At least one parameter may be measured during cycling of the cell.

Abstract: Systems and methods for batteries comprising a cathode, an electrolyte, and an anode, wherein sacrificial salts and prelithiation reagents are added to the cathode as functional additives for electrochemical prelithiation.

Abstract: Systems and methods for anisotropic expansion of silicon-dominant anodes may include a cathode, an electrolyte, and an anode, where the anode may include a current collector and an active material on the current collector. An expansion of the anode during operation may be configured by a roughness and/or thickness of the current collector, a metal used for the current collector, and/or a lamination process that adheres the active material to the current collector. The expansion of the anode may be more anisotropic for thicker current collectors. A thicker current collector may be 10 ?m thick or greater. The expansion of the anode may be more anisotropic for more rigid materials used for the current collector. A more rigid current collector may include nickel and a less rigid current collector may include copper. The expansion of the anode may be more anisotropic for a rougher surface current collector.

Abstract: Systems and methods are provided for control of thermal transfer during electrode pyrolysis based processing. An apparatus for processing battery electrodes may include a core configured for use in forming an electrode roll and a thermal rod. The core is configured to engage a sheet including electrode material applied on a current collector, specifically by rolling the sheet on the core to create concentric alternating layers of electrode material and current collector around an internal space formed by the core. The thermal rod is configured for engaging the electrode roll via the internal space of the core such that, once engaged, at least a portion of the thermal rod is disposed within the concentric alternating layers of electrode material and current collector. The thermal rod is configured to provide thermal transfer into the electrode roll via the core during processing of the electrode roll, with the processing including applying pyrolysis.