Abstract: An electrode including an electrode active material and a ceramic hydrofluoric acid (HF) scavenger is provided. The ceramic hydrofluoric acid (HF) scavenger includes M2SiO3, MAlO2, M2O—Al2O3—SiO2, or combinations thereof, where M is lithium (Li), sodium (Na), or combinations thereof. Methods of making the electrode are also provided.

Abstract: A system for pump assist to maximize fuel consumption in a natural gas powertrain includes a fuel delivery system including a natural gas storage tank supplying a first natural gas flow, a pressure sensor disposed to provide data regarding a natural gas pressure within the storage tank, and a natural gas pump operable to selectively boost the first natural gas flow to create a second natural gas flow with increased pressure. The system further includes an engine operable to utilize one of the natural gas flows to provide an output torque and including a fuel injector and a computerized fuel system controller programmed to monitor the data regarding the natural gas pressure within the storage tank, compare the data regarding the natural gas pressure within the storage tank to a threshold cut-off pressure for the fuel injector, and command activation of the natural gas pump based upon the comparing.

Abstract: A porous separator for a lithium-containing electrochemical cell is provided herein. The porous separator includes a porous substrate and an active layer comprising lithium ion-exchanged zeolite particles. Methods of manufacturing the porous separator and lithium-containing electrochemical cells including the porous separator are also provided herein.

Abstract: A negative electrode for an electrochemical cell of a lithium metal battery may be manufactured by welding together a lithium metal layer and a metallic current collector layer. The lithium metal layer and the current collector layer may be arranged adjacent one another and in an at least partially lapped configuration such that faying surfaces of the layers confront one another and establish a faying interface therebetween at a weld site. A laser beam may be directed at an outer surface of the current collector layer at the weld site to melt a portion of the lithium metal layer adjacent the faying surface of the current collector layer and produce a lithium metal molten weld pool. The laser beam may be terminated to solidify the molten weld pool into a solid weld joint that physically bonds the lithium metal layer and the current collector layer together at the weld site.

Abstract: A negative electrode for an electrochemical cell of a secondary lithium metal battery may comprise a negative electrode current collector and a three-dimensional columnar lithium metal layer formed on a surface of the current collector. The columnar lithium metal layer may comprise a plurality of lithium metal columns and may be formed on the current collector using an electrochemical deposition process. In such process, the current collector and a counter electrode may be at least partially submerged in a nonaqueous liquid electrolyte solution and an electrical potential may be established between the metal substrate and the counter electrode such that lithium ions in the electrolyte solution are reduced to metallic lithium and deposited on the surface of the current collector in the form of a three-dimensional columnar lithium metal layer. The electrolyte solution may comprise lithium bis(fluorosulfonyl)imide (LiFSI) in a solution of fluoroethylene carbonate (FEC) and dimethyldicarbonate (DMDC).

Abstract: A negative electrode for an electrochemical cell of a lithium metal battery may be manufactured by joining together a metallic current collector piece and a lithium metal piece. The metallic current collector piece may be positioned adjacent the lithium metal piece in an at least partially lapped configuration at a weld site. A laser beam may be directed at an upper surface of the metallic current collector piece at the weld site to melt a portion of the lithium metal piece adjacent the metallic current collector piece and produce a lithium metal molten weld pool. The second laser beam may be terminated to solidify the lithium metal molten weld pool into a solid weld joint that physically bonds the lithium metal piece and the metallic current collector piece together at the weld site.

Abstract: A negative electrode according to various aspects of the present disclosure includes a negative electroactive material and a layer. The negative electroactive material includes a lithium-aluminum alloy. The layer is disposed directly on at least a portion of the negative electroactive material and coupled to the negative electroactive material. The layer includes anodic aluminum oxide and has a plurality of pores. The present disclosure also provides an electrochemical cell including the negative electrode. In certain aspects, the negative electroactive material is electrically conductive and functions as a negative electrode current collector such that the electrochemical cell is free of a distinct negative electrode current collector component. In certain aspects, the layer is ionically conductive and electrically insulating and functions as a separator such that the electrochemical cell is free of a distinct separator component.

Abstract: Composite cathode-separator laminations (CSL) include a current collector with sulfur-based host material applied thereto, a coated separator comprising an electrolyte membrane separator with a carbonaceous coating, and a porous, polymer-based interfacial layer (PBIL) forming a binding interface between the carbonaceous coating and the host material. The host material includes less than about 6% polymeric binder, and less than about 40% electrically conductive carbon, with the balance comprising one or more sulfur compounds. The PBIL can have a thickness of less than about 5 ?m and a porosity of about 5% to about 40%. The host material can comprise less than about 40% conductive carbon (e.g., graphene) and have a porosity of less than about 40%. The carbonaceous coating (e.g., graphene) can have a thickness of about 1 ?m to about 5 ?m. The CSL can be disposed with an anode within an electrolyte to form a lithium-sulfur battery cell.

Abstract: A ceramic-coated separator for a lithium-containing electrochemical cell and methods of preparing the ceramic-coated separator are provided. The ceramic-coated separator may be manufactured by preparing a slurry that includes one or more lithiated oxides and a binder and disposing the slurry onto one or more surfaces of a porous substrate. The slurry may be dried to from a ceramic coating on the one or more surfaces of the porous substrate so as to create the ceramic-coated separator. The ceramic coating may include one or more lithiated oxides selected from Li2SiO3, LiAlO2, Li2TiO3, LiNbO3, Li3PO4, Li2CrO4, and Li2Cr2O7.

Abstract: A method of manufacturing an electrochemical cell may comprise exposing a surface of a metal substrate to a chalcogen in gas phase such that a metal chalcogenide layer forms on the surface of the metal substrate. A lithium metal foil may be laminated onto the metal chalcogenide layer on the surface of the metal substrate such that a surface of the lithium metal foil physically and chemically bonds to the metal chalcogenide layer on the surface of the metal substrate.

Abstract: In a method of manufacturing an electrochemical cell, a porous or non-porous electrically conductive metal substrate may be provided. A conformal metal chalcogenide layer may be formed on a surface of the metal substrate. The metal substrate with the conformal metal chalcogenide layer may be immersed in a nonaqueous liquid electrolyte solution comprising a lithium salt dissolved in a polar aprotic organic solvent. An electrical potential may be established between the metal substrate and a counter electrode immersed in the nonaqueous liquid electrolyte solution such that lithium ions in the electrolyte solution are reduced to metallic lithium and deposited on the surface of the metal substrate over the metal chalcogenide layer to form a conformal lithium metal layer on the surface of the metal substrate over the metal chalcogenide layer.

Abstract: Electrochemical cells that cycle lithium ions are provided. The electrochemical cells have an electrode that includes a silicon-containing electroactive material that undergoes volumetric expansion and contraction during the cycling of the electrochemical cell; and an electrolyte system that promotes passive formation of a flexible protective layer comprising a lithium fluoride-polymer composite on one or more exposed surface regions of the silicon-containing electroactive material. The electrolyte system includes a lithium salt, at least one cyclic carbonate, and two or more linear carbonates. At least one of the two or more linear carbonate-containing co-solvents is a fluorinated carbonate-containing co-solvent. The electrolyte system accommodates the volumetric expansion and contraction of the silicon-containing electroactive material to promote long term cycling stability.

Abstract: In certain aspects, electrolytic deposition and electroless displacement deposition methods are provided to form bimetallic structures that may be used as a bipolar current collector in a battery or a substrate for forming graphene sheets. In other aspects, bipolar current collectors for lithium-ion based electrochemical cells are provided. The bimetallic current collector may have an aluminum-containing surface and a continuous copper coating. In other aspects, a flexible substrate may be coated with one or more conductive materials, like nickel, copper, graphene, aluminum, alloys, and combinations thereof. The flexible substrate is folded to form a bipolar current collector. New stack assemblies for lithium-ion based batteries incorporating such bipolar current collectors are also provided that can have cells with a tab-free and/or weld-free design.

Abstract: An ionic liquid electrolyte composition is provided. The ionic liquid electrolyte composition includes an ionic liquid, a conductive salt, and optionally a stabilizing agent. The stabilizing agent is an oxidant, an interface additive, a co-solvent, or a combination thereof.

Abstract: A highly-concentrated electrolyte system for an electrochemical cell is provided, along with methods of making the electrolyte system. The electrolyte system includes a bound moiety having an ionization potential greater than an electron affinity and comprising one or more salts selected from the group consisting of: lithium bis(fluorosulfonyl)imide, sodium bis(fluorosulfonyl)imide, potassium bis(fluorosulfonyl)imide, and combinations thereof bound to a solvent comprising one or more solvents selected from the group consisting of: dimethyl carbonate, dimethyl dicarbonate, and combinations thereof. The salts have a concentration in the electrolyte system of greater than or equal to about 4 M. A molar ratio of the salts to the dimethyl carbonate is about 0.5. A molar ratio of the salts to the dimethyl dicarbonate is about 1.

Abstract: Methods for manufacturing sulfur electrodes include providing an electrode, wherein the electrode includes a current collector having a first surface, and a sulfur-based host material applied to the first surface of the current collector, wherein the sulfur-based host material comprises one or more sulfur compounds, one or more electrically conductive carbon materials, and one or more binders. The methods further include forming a plurality of channels within the sulfur-based host material using a laser or electron beam, wherein the plurality of channels define a plurality of host material columns, each column having one or more exterior surfaces contiguous which one or more of the channels which extend outward from the first surface of the current collector. Each of the one or more exterior surfaces can define a heat affected zone comprising a higher concentration of sulfur than the host material column prior to forming the plurality of channels.

Abstract: Disclosed are methods for manufacturing a pouch-type battery cells, and include disposing an anode and a cathode, and optionally a reference electrode, between a first pouch layer and a second pouch layer, and applying heat to the outer corrosion resistant polymer layer of the first pouch layer or the second pouch layer via a laser along a peripheral seal path forming a peripheral seal joining the first pouch layer and the second pouch layer to form a pouch encasing the anode and the cathode, and optionally the reference electrode. Each pouch layer includes an inner heat-activated polymer adhesive layer, a middle aluminum layer, and an outer corrosion resistant polymer layer. The outer corrosion resistant polymer layer of the first pouch layer and/or the second pouch layer can have a laser absorptivity of less than about 10%. The laser can have a wavelength of about 800 nanometers to about 2,000 nanometers.

Abstract: A modified separator for a high-energy lithium metal-based electrochemical cell and methods of formation relating thereto are provided. The modified separator includes a substrate including a dopant and a coating layer disposed on the doped substrate. The dopant and compound comprising the coating layer are independently selected from the group consisting of: aluminum oxide (Al2O3), titanium dioxide (TiO2), zirconium dioxide (ZrO2), zinc oxide (ZnO), iron oxide (Fe2O3), tin oxide (SnO), silicon oxide (SiO2), tantalum oxide (Ta2O5), lanthanum oxide (La2O3), hydrofluoroolefin (HfO), cerium oxide (CeO2), and combinations thereof.

Abstract: Provided are 1,3-dimethoxypropane (DMP)-containing battery electrolytes, and lithium ion batteries utilizing the same. The batteries comprise an electrolyte including DMP, a lithium anode disposed within the electrolyte, and a cathode disposed within the electrolyte. The cathode can comprise a lithium metal oxide or a chalcogen material. The lithium metal oxide can be LiNixCoyMnzO2 or lithium iron phosphate. The chalcogen material can include sulfur and/or selenium. The electrolyte can include one or more co-solvents including tetrahydrofuran, 2-methyltetrahydrofuran and 1,3-dioxolane. The electrolyte can include one or more lithium salts, including LiClO4, LiAlCl4, LiI, LiBr, LiSCN, LiBF4, LiB(C6H5)4LiAsF6, LiCF3SO3, LiN(CF3SO2)2, and LiPF6.

Abstract: A composite electrode for use in an all-solid-state electrochemical cell that cycles lithium ions is provided. The composite electrode comprises a solid-state electroactive material that undergoes volumetric expansion and contraction during cycling of the electrochemical cell and a solid-state electrolyte. The solid-state electroactive material is in the form of a plurality of particles and each particle has a plurality of internal pores formed therewithin. Each particle has an average porosity ranging from about 10% to about 75%, and the composite electrode has an interparticle porosity between the solid-state electroactive material and solid-state electrolyte particles ranging from about 5% to about 40%.