Patents by Inventor Keith D. Kepler

Keith D. Kepler has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 10693131
    Abstract: A composite for the cathode of Li-ion battery is disclosed and comprises: a base active material represented by Li1+a(N1?b?cCobMnc)O2 wherein 0?a?0.5, 0?b?0.4, 0?c?0.6, with b+c<1; and a coating on the base active material comprising a phase containing the components B2O3 or SnBxO2+3x/2?y/2Fy; wherein 0?x?5, 0<y<4+3x; wherein relative to the total amount of the base active material, the weight percentage of B element is not more than 2 wt %, the weight percentage of Sn element is not more than 5 wt %. A method for making a composite is disclosed and includes: mixing the base active material with the phase components and/or a precursor for the phase components; and firing the mixture obtained. The application provides a high capacity, long cycle life cathode material that is stabilized at high voltages.
    Type: Grant
    Filed: February 13, 2018
    Date of Patent: June 23, 2020
    Assignee: FARASIS ENERGY (GANZHOU) CO. LTD.
    Inventors: Hongjian Liu, Keith D Kepler, Robbert M. Vermeulen, Floris Tsang, Phillip Hailey, Michael Slater
  • Patent number: 10573885
    Abstract: The present invention relates to Li-ion cells area, particularly relates to lithium source material and preparation method thereof and use in Li-ion cells. Wherein the lithium source material which is represented by a formula LiyFe1-xMxO4Rz, wherein M represents one or more of transition metal elements, R represents halogen element, 0?x?0.9, 0<z?0.2, 3.5<y?[5(1?x)+6x]. The lithium source material of the present invention which is lithium deficient relative to its stoichiometric lithium formulation, is a lithium source additive material to the cathode material for Li-ion cells, and exhibits high capacity and high stability.
    Type: Grant
    Filed: January 23, 2018
    Date of Patent: February 25, 2020
    Assignee: Farasis Energy (Ganzhou) Co., Ltd.
    Inventors: Keith D. Kepler, Hongjian Liu, Robbert M. Vermeulen
  • Patent number: 10079413
    Abstract: The present invention provides a Li-ion pouch cell wherein the Li-ion pouch cells comprise a sealed enclosure, electrode stack and thermally conductive elements, wherein the electrode stack and the thermally conductive elements are in the sealed enclosure, the thermally conductive elements include extensions which extend beyond the electrode stack, the sealed enclosure has thermal conductivity, the thermally conductive elements provide a thermally conductive pathway connecting the electrode stack and the sealed enclosure by way of the extension. The present invention also provides a cell module comprising the Li-ion pouch cells. The Li-ion pouch cell and the cell module according to the present application could minimize differences in cell temperature, monitor internal cell temperature, cool the cell rapidly, increase cell and module safety, allowing for minimal impact on cell energy density, performance or life and difficulty of manufacturing.
    Type: Grant
    Filed: January 24, 2014
    Date of Patent: September 18, 2018
    Assignee: Farasis Energy, Inc.
    Inventors: Keith D. Kepler, Robbert Vermeulen, Phillip Hailey, Andrew Larson
  • Publication number: 20180248180
    Abstract: A composite for the cathode of Li-ion battery is disclosed and comprises: a base active material represented by Li1+a(N1-b-cCobMnc)O2 wherein 0?a?0.5, 0?b?0.4, 0?c?0.6, with b+c<1; and a coating on the base active material comprising a phase containing the components B2O3 or SnBxO2+3x/2-y/2Fy; wherein 0?x?5, 0<y<4+3x; wherein relative to the total amount of the base active material, the weight percentage of B element is not more than 2 wt %, the weight percentage of Sn element is not more than 5 wt %. A method for making a composite is disclosed and includes: mixing the base active material with the phase components and/or a precursor for the phase components; and firing the mixture obtained. The application provides a high capacity, long cycle life cathode material that is stabilized at high voltages.
    Type: Application
    Filed: February 13, 2018
    Publication date: August 30, 2018
    Inventors: Hongjian Liu, Keith D. Kepler, Robbert M. Vermeulen, Floris Tsang, Phillip Hailey, Michael Slater
  • Publication number: 20180212231
    Abstract: The present invention relates to Li-ion cells area, particularly relates to lithium source material and preparation method thereof and use in Li-ion cells. Wherein the lithium source material which is represented by a formula LiyFe1-xMxO4Rz, wherein M represents one or more of transition metal elements, R represents halogen element, 0?x?0.9, 0<z?0.2, 3.5<y?[5(1?x)+6x]. The lithium source material of the present invention which is lithium deficient relative to its stoichiometric lithium formulation, is a lithium source additive material to the cathode material for Li-ion cells, and exhibits high capacity and high stability.
    Type: Application
    Filed: January 23, 2018
    Publication date: July 26, 2018
    Applicant: Farasis Energy (Ganzhou) Co., Ltd.
    Inventors: Keith D. Kepler, Hongjian Liu, Robbert M. Vermeulen
  • Patent number: 10026957
    Abstract: Li-ion cathode materials with improved performance characteristics and precursors to prepare such materials are disclosed. The precursors consist of complex, mixed alkali transition metal oxides of the formula LixAy(MnaNibMc)O2+d, where M represents one or more selected from transition metal elements beside Ni and Mn, and the groups IIA and IIIA elements of the periodic table, x is between 1 and 1.4, y is between 0.1 and 0.5, and x+y is between 1.1 and 1.5, a+b+c=1, the value of d depends on the proportions and average oxidation states of the cation elements Li, A, Mn, Ni and M such that the combined positive charge of the cation elements is balanced by the number of oxygen anions, A represents one or more elements selected from Na, K and Cs. The Li-ion cathode materials are produced by exchange of element(s) A for Li under mild conditions to limit the degree of structural reorganization that occurs during the reaction.
    Type: Grant
    Filed: April 24, 2015
    Date of Patent: July 17, 2018
    Assignee: Farasis Energy (Ganzhou) Co., Ltd.
    Inventors: Keith D. Kepler, Hongjian Liu, Floris Tsang, Robbert Vermeulen, Phillip Hailey, Michael Slater
  • Patent number: 10008702
    Abstract: The present invention relates to the field of battery cells, particularly to a pouch cell comprising a packaging seal, a heating element and a fault switch, wherein the fault switch will activate the heating element to generate heat to make the packaging seal delaminate when the inner space of the pouch cell reaches a predetermined pressure, such that the pouch cell vents. The mechanism and components of these venting concepts can be designed to be fully compatible with existing manufacturing methods and typical cell handling situations. The most favorable configuration has both vent device components outside the cell, with nothing passing through or even into the seal. Such a configuration has the advantage of having no impact on the seal integrity relative to a conventional pouch cell, is easy to manufacture, and has improved safety.
    Type: Grant
    Filed: May 20, 2016
    Date of Patent: June 26, 2018
    Assignee: Farasis Energy, Inc.
    Inventors: Keith D. Kepler, Andrew W. Larson
  • Patent number: 9614261
    Abstract: Herein is disclosed a process for recycling electrode material from lithium-ion batteries, comprising harvesting a mixture of anode and cathode electrode materials from waste lithium-ion batteries, and separating the anode electrode material from the cathode electrode material by means of dense liquid separation. The mixed anode and cathode material is suspended in a liquid that has a density between those of the anode material and cathode material, such that the anode material rises to the top of the dense liquid and the cathode material sinks to the bottom of the dense liquid. The thus separated materials can easily be collected and further purified and regenerated for reuse in new lithium-ion batteries, providing an efficient and low-cost method for recycling electrode active materials from waste lithium-ion batteries.
    Type: Grant
    Filed: August 13, 2015
    Date of Patent: April 4, 2017
    Assignee: Farasis Energy, Inc.
    Inventors: Keith D. Kepler, Floris Tsang, Robbert Vermeulen, Phillip Hailey
  • Publication number: 20160344004
    Abstract: The present invention relates to the field of battery cells, particularly to a pouch cell comprising a packaging seal, a heating element and a fault switch, wherein the fault switch will activate the heating element to generate heat to make the packaging seal delaminate when the inner space of the pouch cell reaches a predetermined pressure, such that the pouch cell vents. The mechanism and components of these venting concepts can be designed to be fully compatible with existing manufacturing methods and typical cell handling situations. The most favorable configuration has both vent device components outside the cell, with nothing passing through or even into the seal. Such a configuration has the advantage of having no impact on the seal integrity relative to a conventional pouch cell, is easy to manufacture, and has improved safety.
    Type: Application
    Filed: May 20, 2016
    Publication date: November 24, 2016
    Inventors: Keith D. KEPLER, Andrew W. LARSON
  • Publication number: 20160072162
    Abstract: Herein is disclosed a process for recycling electrode material from lithium-ion batteries, comprising harvesting a mixture of anode and cathode electrode materials from waste lithium-ion batteries, and separating the anode electrode material from the cathode electrode material by means of dense liquid separation. The mixed anode and cathode material is suspended in a liquid that has a density between those of the anode material and cathode material, such that the anode material rises to the top of the dense liquid and the cathode material sinks to the bottom of the dense liquid. The thus separated materials can easily be collected and further purified and regenerated for reuse in new lithium-ion batteries, providing an efficient and low-cost method for recycling electrode active materials from waste lithium-ion batteries.
    Type: Application
    Filed: August 13, 2015
    Publication date: March 10, 2016
    Inventors: Keith D. Kepler, Floris Tsang, Robbert Vermeulen, Phillip Hailey
  • Publication number: 20160049701
    Abstract: Herein is disclosed a process for preparing a cathode active material for lithium-ion batteries, comprising preparing a slurry by mixing a lithium-deficient cathode active material for lithium-ion batteries with a solution containing lithium-ions; and applying a direct current in the slurry using a working electrode and a counter electrode. A method for recycling the cathode active material from lithium-ion batteries is also provided. The process of the invention can be used to recycle the cathode active material from used or waste lithium-ion batteries efficiently and at low cost, and the recycled cathode active material can be used to prepare new lithium-ion batteries.
    Type: Application
    Filed: August 13, 2015
    Publication date: February 18, 2016
    Inventors: Keith D. KEPLER, Floris TSANG, Robbert VERMEULEN, Phillip HAILEY
  • Publication number: 20150311514
    Abstract: Li-ion cathode materials with improved performance characteristics and precursors to prepare such materials are disclosed. The precursors consist of complex, mixed alkali transition metal oxides of the formula LixAy(MnaNibMc)O2+d, where M represents one or more selected from transition metal elements beside Ni and Mn, and the groups IIA and IIIA elements of the periodic table, x is between 1 and 1.4, y is between 0.1 and 0.5, and x+y is between 1.1 and 1.5, a+b+c=1, the value of d depends on the proportions and average oxidation states of the cation elements Li, A, Mn, Ni and M such that the combined positive charge of the cation elements is balanced by the number of oxygen anions, A represents one or more elements selected from Na, K and Cs. The Li-ion cathode materials are produced by exchange of element(s) A for Li under mild conditions to limit the degree of structural reorganization that occurs during the reaction.
    Type: Application
    Filed: April 24, 2015
    Publication date: October 29, 2015
    Inventors: Keith D. KEPLER, Hongjian LIU, Floris TSANG, Robbert VERMEULEN, Phillip HAILEY, Michael SLATER
  • Publication number: 20140205882
    Abstract: The present invention provides a Li-ion pouch cell wherein the Li-ion pouch cells comprise a sealed enclosure, electrode stack and thermally conductive elements, wherein the electrode stack and the thermally conductive elements are in the sealed enclosure, the thermally conductive elements include extensions which extend beyond the electrode stack, the sealed enclosure has thermal conductivity, the thermally conductive elements provide a thermally conductive pathway connecting the electrode stack and the sealed enclosure by way of the extension. The present invention also provides a cell module comprising the Li-ion pouch cells. The Li-ion pouch cell and the cell module according to the present application could minimize differences in cell temperature, monitor internal cell temperature, cool the cell rapidly, increase cell and module safety, allowing for minimal impact on cell energy density, performance or life and difficulty of manufacturing.
    Type: Application
    Filed: January 24, 2014
    Publication date: July 24, 2014
    Inventors: Keith D. KEPLER, Robbert VERMEULEN, Phillip HAILEY, Andrew LARSON
  • Patent number: 8609284
    Abstract: Disclosed herein is a composite for the cathode of Li-ion battery comprising: a base active material represented by Li1+y(Nia—COb—Mnc—Yd)O2 wherein Y is at least one selected from Mg, Zn, Al, Ga, Cu, B, Zr, and Ti, y is 0 to 0.5, a is 0.1 to 0.6, b is 0.05 to 0.5, c is 0.25 to 0.8, d is 0 to 0.02, and the sum of a, b, c and d is 1; and a coating on the base active material comprised of a glassy phase containing the components Li2O, B2O3 and LiX in which LiX is at least one of Li2F2, Li2Cl2 and Li2SO4, relative to the total amount of the glassy phase, the mole percent of Li2O is 43% to 75%, the mole percent of B2O3 is 25% to 57%, the mole percent of LiX is from more than 0% to 20%, and the sum of the mole percents of Li2O, B2O3 and LiX is 100%.
    Type: Grant
    Filed: October 27, 2010
    Date of Patent: December 17, 2013
    Assignee: Farasis Energy, Inc.
    Inventors: Keith D. Kepler, Yu Wang, Hongjian Liu, Floris Tsang
  • Patent number: 8585935
    Abstract: Disclosed herein is a composite for Li-ion cells, comprising an active material particle for Li-ion cells and an electronically conductive elastic material bound or attached to the active material particle. According to the present invention, the electronically conductive elastic material bound or attached to the active material particle allows the particle to maintain electronic contact with the electrode laminate matrix despite ongoing movement or expansion and contraction of the active material particles, such that the cycling efficiency and reversible capacity of the Li-ion cells prepared from the composite of the present invention is improved.
    Type: Grant
    Filed: June 3, 2010
    Date of Patent: November 19, 2013
    Assignee: Farasis Energy, Inc.
    Inventors: Keith D. Kepler, Yu Wang
  • Publication number: 20130270485
    Abstract: Disclosed herein is a composite for Li-ion cells, comprising an active material particle for Li-ion cells and an electronically conductive elastic material bound or attached to the active material particle. According to the present invention, the electronically conductive elastic material bound or attached to the active material particle allows the particle to maintain electronic contact with the electrode laminate matrix despite ongoing movement or expansion and contraction of the active material particles, such that the cycling efficiency and reversible capacity of the Li-ion cells prepared from the composite of the present invention is improved.
    Type: Application
    Filed: March 29, 2013
    Publication date: October 17, 2013
    Inventors: Keith D. KEPLER, Yu Wang
  • Patent number: 8551653
    Abstract: Disclosed herein is a composite material for use as an anode for Li-ion batteries and its preparation method and use. The composite material comprises the components represented by the following formula: Ma1-Xa2—Sed1—Zd2—Cc, in which, M represents one or more selected from Sn, Al, Pb, Sb, Si and Bi; X represents one or more selected from Cu, V, Co, Ti, Mo, Mg, W and Zn; Z represents Si and/or Ge; and a1, a2, d1, d2 and c represent the weight ratio of M, X, Se, Z and C to the total amount of M, X, Se, Z and C, respectively, wherein a1+a2 is equal to 0.4-0.7, d1+d2 is equal to 0.05-0.6, c is equal to 0.01-0.25, d2/d1 ranges from 0 to 1/1.4, and a2/a1 ranges from 0 to 1/1.5.
    Type: Grant
    Filed: December 4, 2008
    Date of Patent: October 8, 2013
    Assignee: Farasis Energy, Inc.
    Inventors: Keith D. Kepler, Hongjian Liu
  • Publication number: 20110123865
    Abstract: Disclosed herein is a composite for the cathode of Li-ion battery comprising: a base active material represented by Li1+y(Nia—COb—Mnc—Yd)O2 wherein Y is at least one selected from Mg, Zn, Al, Ga, Cu, B, Zr, and Ti, y is 0 to 0.5, a is 0.1 to 0.6, b is 0.05 to 0.5, c is 0.25 to 0.8, d is 0 to 0.02, and the sum of a, b, c and d is 1; and a coating on the base active material comprised of a glassy phase containing the components Li2O, B2O3 and LiX in which LiX is at least one of Li2F2, Li2Cl2 and Li2SO4, relative to the total amount of the glassy phase, the mole percent of Li2O is 43% to 75%, the mole percent of B2O3 is 25% to 57%, the mole percent of LiX is from more than 0% to 20%, and the sum of the mole percents of Li2O, B2O3 and LiX is 100%.
    Type: Application
    Filed: October 27, 2010
    Publication date: May 26, 2011
    Inventors: Keith D. Kepler, Yu Wang, Hongjian Liu, Floris Tsang
  • Publication number: 20110086272
    Abstract: Disclosed herein is a Li-ion cell comprising a cathode, an anode, and a separator disposed between the cathode and the anode, wherein the cathode comprises Li-ion cathode active material, and the anode comprises Li-ion anode active material and an additive which has an energy density greater than that of the Li-ion anode active material and which is capable of reacting irreversibly with Li-ions.
    Type: Application
    Filed: October 13, 2010
    Publication date: April 14, 2011
    Inventors: Keith D. KEPLER, Hongjian Liu
  • Publication number: 20100308278
    Abstract: Disclosed herein is a composite for Li-ion cells, comprising an active material particle for Li-ion cells and an electronically conductive elastic material bound or attached to the active material particle. According to the present invention, the electronically conductive elastic material bound or attached to the active material particle allows the particle to maintain electronic contact with the electrode laminate matrix despite ongoing movement or expansion and contraction of the active material particles, such that the cycling efficiency and reversible capacity of the Li-ion cells prepared from the composite of the present invention is improved.
    Type: Application
    Filed: June 3, 2010
    Publication date: December 9, 2010
    Inventors: Keith D. KEPLER, Yu Wang