Abstract: A method of manufacturing a calendered cathode structure for a hybrid lithium metal cell includes depositing a first cathode coating layer without ionic liquid onto a cathode current collector, depositing a second cathode coating layer with ionic liquid onto the first coating layer, and depositing a third cathode coating layer without ionic liquid onto the second coating layer. A calendaring process is then performed on the cathode structure comprising the cathode current collector with the first, second, and third coating layers thereon such that a predetermined thickness and porosity for the cathode structure is achieved while at the same time the ionic liquid is spread throughout the cathode electrode without reaching the cathode current collector.

Abstract: A lithium cell for a lithium metal battery includes an electrolyte material, a cathode structure arranged on one side of the electrolyte material, the cathode structure including a cathode electrode and a cathode current collector, and an anode structure arranged on an opposite side of the electrolyte material from the cathode structure. The anode structure includes an anode current collector, a lithium metal anode arranged on a side of the anode current collector arranged facing the electrolyte material, a nanoceramic protective coating deposited on a surface of the lithium metal anode arranged facing the electrolyte material. The nanoceramic protective coating includes a nanoceramic material, a base polymer material, a binder material including a UV curable polymer, and one or more lithium salts.

Abstract: A lithium cell for a lithium metal battery includes: an electrolyte material; a cathode structure arranged on one side of the electrolyte material, the cathode structure including a cathode electrode and a cathode current collector; and an anode structure arranged on an opposite side of the electrolyte material from the cathode structure. The anode structure includes: an anode current collector; a lithium metal anode arranged on a side of the anode current collector arranged facing the electrolyte material; and a protective coating deposited on a surface of the lithium metal anode and arranged facing the electrolyte material, wherein the protective coating extends beyond the lithium metal anode and onto the anode current collector so as to seal both a surface and edge regions of the lithium metal anode from contact with a liquid electrolyte of the electrolyte material.

Abstract: Provided herein is a high-volume continuous roll-to-roll method for manufacturing dimensionally stable, large format, high performance solid batteries using high lithium-ion conducting polymer matrix electrolyte (PME). The batteries can include a cathode layer sandwich with a thin contiguous PME layer across the anode and a high conducting PME in both the anode and cathode structures. The batteries can also retain a thin PME layer that functions as solid-state electrolyte between the cathode and anode thus maintaining continuity among the layers, resulting in minimal interface resistance and stronger structural integrity.

Abstract: An active anode (10) is provided that includes a framework (11) of a first anodic material which contains large cavities (12) that include particles (13) of a second anodic material. The cavities have to be large enough so that a fully lithiated particles of the second anodic material fits into the cavity that contains it and does not apply stress to the framework. The first anodic material has a lower lithiation/delithiation potential than the second anodic material. To produce the anode cavities the second anodic material is coated with an organic coating which is then removed once the anodic layer is produced from a mixture of the first and second anodic materials.

Abstract: An active anode (10) is provided that includes a framework (11) of a first anodic material which contains large cavities (12) that include particles (13) of a second anodic material. The cavities have to be large enough so that a fully lithiated particles of the second anodic material fits into the cavity that contains it and does not apply stress to the framework. The first anodic material has a lower lithium intercalation potential than the second anodic material. To produce the anode cavities the second anodic material is coated with an organic coating which is then removed once the anodic layer is produced from a mixture of the first and second anodic materials.

Abstract: A solid composite electrolyte membrane for use in a lithium battery is provided which exhibits a conductivity ranging from about 10?4 S cm?1 to about 10?3 S cm?1 at ambient temperature. The membrane is formed by providing a glass or glass-ceramic powder formed from a mixture of lithium carbonate, alumina, titanium dioxide, and ammonium dihydrogen phosphate. The powder is mixed with a conditioning agent and at least one solvent, followed by the addition of a binder and one or more plasticizers. The resulting slurry is cast into a tape which is then subjected to a binder burn-off and sintering process to form the membrane. The resulting membrane may be a glass-ceramic composite having a porosity ranging from 0 to 50%, or the membrane may be further infiltrated with a polymer to form a water-impermeable polymeric-ceramic composite membrane.