Abstract: A battery includes positive and negative current collectors and a plurality of bipolar electrodes arranged in a stack between the positive and negative current collectors. The positive and negative current collectors and the stack of the plurality of bipolar electrodes are folded in an S-shape.

Abstract: The present disclosure provides a modified binder for use in an electrochemical cell that cycles lithium ions. The modified binder includes one or more agglomerates of polytetrafluoroethylene nanoparticles, where each of the polytetrafluoroethylene nanoparticles includes a polytetrafluoroethylene core and a polymeric shell that is disposed on exposed surfaces of the core. The polymeric shell can include a polymer selected from the group consisting of: polyethylene oxide, polyglycidyl methacrylate, polyvinylidene difluoride, fluoride-hexafluoropropylene, polypropylene oxide, polyacrylonitrile, polymethacrylonitrile, polymethyl methacrylate, derivatives and co-polymers, and combinations thereof, and in certain instances, also a humidity tolerant lithium salt.

Abstract: The present disclosure relates to a solid-state electrochemical cell having a uniformly distributed solid-state electrolyte and methods of fabrication relating thereto. The method may include forming a plurality of apertures within the one or more solid-state electrodes; impregnating the one or more solid-state electrodes with a solid-state electrolyte precursor solution so as to fill the plurality of apertures and any other void or pores within the one or more electrodes with the solid-state electrolyte precursor solution; and heating the one or more electrodes so as to solidify the solid-state electrolyte precursor solution and to form the distributed solid-state electrolyte.

Abstract: A method of manufacturing an electrode for an electrochemical cell includes providing an admixture including an electroactive material, a binder, and a solvent. The method further includes rolling the admixture to form a sheet and forming a multi-layer stack from the sheet. The method further includes forming an electrode film precursor by performing a plurality of sequential rollings, each including rolling the stack through a first gap. The plurality of sequential rollings includes first and second rollings. In the first rolling, the stack is in a first orientation. In the second rolling, the stack is in a second orientation different from the first orientation. The method further includes forming an electrode film by rolling the electrode film precursor through a second gap less than or equal to the first gap. The method further includes drying the electrode film to remove at least a portion of the solvent.

Abstract: A bipolar solid-state battery includes N solid-state battery cells. Each of the N solid-state battery cells includes M solid-state cores each comprising a first current collector, cathode active material, a separator, anode active material, and a second current collector, where N and M are integers greater than one. The M solid-state cores are connected in parallel by connecting the first current collectors of the M solid-state cores in each of the N solid-state battery cells together and by connecting the second current collectors of the M solid-state cores in each of the N solid-state battery cells together. N?1 clad plates including a first side made of a first material and a second side made of a second material. The N?1 clad plates are arranged between adjacent ones of the N solid-state battery cells and the N solid-state battery cells are connected in series by the N?1 clad plates.

Abstract: A bipolar battery includes N battery cores each comprising a cathode electrode, an anode electrode, and a separator, where N is an integer greater than one. N?1 bipolar plates include a first layer made of a first material, a second layer made of a second material, a center portion, and first and second sides extending transversely relative to the center portion. A battery enclosure including a cover and a lower portion including sides defining a cavity. The N?1 bipolar plates are arranged in the cavity between adjacent ones of the N battery cores and the N battery cores are connected in series by the N?1 bipolar plates. The first and second sides of the N?1 bipolar plates are one of inserted into “L”-shaped slots in the sides of the lower portion, and molded into the sides of the lower portion.

Abstract: A method for fabricating a dual-layer capacitive cabode electrode includes fabricating a first film including capacitive active material; fabricating a second film including cathode active material; hot jointing the first film and the second film to create a cabode film; and laminating the cabode film onto opposite sides of a current collector using conductive adhesive.

Abstract: The present disclosure provides an electrochemical device that cycles lithium ions. The electrochemical device includes at least one first cell unit and at least one second cell unit. The at least one first cell unit includes a nickel-rich positive electroactive material. The nickel-rich positive electroactive material can be represented by: LiM1xM2yM3zM4(1-x-y-z)O2 where M1, M2, M3, and M4 are each a transition metal independently selected from the group consisting of: nickel, manganese, cobalt, aluminum, and combinations thereof, where 0?x?1, 0?y?1, and 0?z?1. The at least one second cell unit includes a phosphate-based positive electroactive material. The phosphate-based electroactive material can be selected from the group consisting of: lithium manganese iron phosphates (LiMnxFe1-xPO4, where 0?x?1) (LMFP), lithium vanadium oxygen phosphates (LixVOPO4, where 0?x?1), lithium vanadium phosphates, lithium vanadium fluorophosphates, and combinations thereof.

Abstract: A battery cell includes a plurality of cathodes and a plurality of anodes. A plurality of solid electrolyte layers are arranged between first adjacent ones of the plurality of cathodes and the plurality of anodes. A plurality of clad current collectors are arranged between second adjacent ones of the plurality of cathodes and the plurality of anodes. The plurality of clad current collector includes a first foil layer, a second foil layer and a thermal interface layer including adhesive and at least one material that increases thermal and electrical conductivity of the thermal interface layer.

Abstract: A method of making a capacitor-assisted hybrid electrode for a lithium-ion electrochemical cell includes admixing a solvent, a cellulose-based dispersant, and a plurality of capacitive particles comprising carbon to form a dispersion. The cellulose-based dispersant forms hydrogen bonds with one or more carbonyl-groups on the capacitive particles comprising carbon. The dispersion is combined with an electroactive material, an electrically conductive material, and a binder to form a slurry. The slurry is applied to a current collector and solidified to form the capacitor-assisted hybrid electrode having a composite hybrid active layer on the current collector. Capacitor-assisted hybrid electrodes formed from such methods are also provided.

Abstract: An electrode assembly for an electrochemical cell that cycles lithium ions is provided. The electrode assembly includes one or more electroactive material layers including a plurality of electroactive material particles and a plurality of binder material fibers dispersed with the electroactive material particles. At least one electroactive material particle of the plurality may have a first protective layer coated thereon, and at least one binder material fiber of the plurality may have a second protective layer coated thereon. The first and second protective layers may be the same or different. The binder material fibers can include polytetrafluoroethylene (PTFE).

Abstract: An electrochemical cell that includes a first electrode, a second electrode, and an electrolyte layer that is disposed between the first electrode and the second electrode is provided. The electrolyte layer includes a porous scaffold having a porosity greater than or equal to about 50 vol. % to less than or equal to about 90 vol. %, and a solution-processable solid-state electrolyte that at least partially fills the pores of the porous scaffold. The porous scaffold is defined by a plurality of fibers having an average diameter greater than or equal to about 0.01 micrometer to less than or equal to about 10 micrometers and an average length greater than or equal to about 1 micrometer to less than or equal to about 20 micrometers. The solution-processable solid-state electrolyte includes is selected from the group consisting of: sulfide-based solid-state particles, halide-based solid-state particles, hydride-based solid-state particles, and combinations thereof.

Abstract: A hybridized lithium-ion battery that includes one or more positive electrode assemblies is provided. Each of the one or more positive electrode assemblies includes a positive electrode current collector and one or more positive electroactive material layers disposed on one or more surfaces of the positive electrode current collector. The hybridized lithium-ion battery also includes two or more negative electrode current collectors, and one or more negative electroactive material layers disposed on one or more surfaces of at least one of the two or more negative electrode current collectors, where a total number of the one or more positive electroactive material layers is greater than a total number of negative electroactive material layers. The hybridized lithium-ion battery also includes two or more separating layers physically separating the positive electrode assemblies and the negative electroactive material layers or the positive electrode assemblies and the negative electrode current collectors.

Abstract: A polymer blocker for use in an electrochemical battery that cycles lithium ions is provided. The polymer blocker includes a polymeric layer, a first adhesive layer that includes a first adhesive and is disposed on or near a first surface of the polymeric layer, and a second adhesive layer that includes a second adhesive and is disposed on or near a second surface of the polymeric layer. The polymeric layer has a porosity greater than or equal to about 50 vol. % to less than or equal to about 95 vol. %. A portion of the first adhesive impregnates a first portion of the polymeric layer, and a portion of the second adhesive impregnating a second portion of the polymeric layer. The first and second portions of the polymeric layer may be the same or different.

Abstract: Methods of forming a battery via in situ polymerization are provided. A precursor of a first blocker composition is applied to select edge regions of at least one bipolar electrode and terminal negative and positive electrodes. The components are assembled to form a stack with at least two insulating interlayers disposed between electrodes of opposite polarities. The precursor is reacted to form a first blocker composition sealing three sides of the stack to define a fillable interior region. Next, a polymer electrolyte precursor is injected into the fillable interior region. A precursor of a second blocker composition is applied to a terminal region of the fourth side of the stack. The precursors are concurrently reacted to form a polymer electrolyte and a second blocker composition along the fourth side. The first and second blocker compositions define a sealed pouch including the stack comprising the polymer electrolyte.

Abstract: A capacitor-assisted electrode for an electrochemical cell that cycles lithium ions is provided. The capacitor-assisted electrode may include at least two electroactive materials disposed on one or more surfaces of a current collector. A first electroactive material of the at least two electroactive materials may have a first reversible specific capacity and forms a first electroactive material having a first press density. A second electroactive material of the at least two electroactive materials has a second reversible specific capacity and forms a second electroactive material having a second press density. The second reversible specific capacity may be different from the first reversible specific capacity. The second press density may be different from the first press density. One or more capacitor materials may be disposed on or intermingled with one or more of the at least two electroactive materials.

Abstract: An electrochemical cell that cycles lithium ions includes a positive electrode, a negative electrode current collector spaced apart from the positive electrode, and an ionically conductive electrolyte disposed between the positive electrode and the negative electrode current collector. The negative electrode current collector is of unitary one-piece construction and has a three-dimensional porous structure that defines an interconnected network of open pores. During charging of the electrochemical cell, lithium metal is deposited within the open pores of the negative electrode current collector.

Abstract: A negative electrode for an electrochemical cell that cycles lithium ions includes a particulate component embedded in a polymeric matrix component that comprises polytetrafluoroethylene. The particulate component includes a plurality of composite particles, with each of the composite particles having a core and a selective barrier layer disposed on a surface of the core. The core of each of the composite particles includes an electroactive negative electrode material. The selective barrier layer of each of the composite particles is formulated to prevent or inhibit electrochemical reactions from occurring between lithium stored in the electroactive negative electrode material of the core and the polytetrafluoroethylene in the polymeric matrix component.

Abstract: A free-standing electrolyte layer for use in an electrochemical cell is provided. The free-standing electrolyte layer includes a plurality of solid-state electrolyte particles, a (first) ionic liquid that surrounds each solid-state electrolyte particle of the plurality of solid-state electrolyte particles, and a plurality of polytetrafluoroethylene fibrils that provides a structural framework for the solid-state electrolyte particles. The free-standing electrolyte layer has an ionic conductivity greater than or equal to about 0.1 mS/cm at 40° C., and a thickness greater than or equal to about 5 micrometers to less than or equal to about 500 micrometers. Each of the polytetrafluoroethylene fibrils of the plurality of polytetrafluoroethylene fibrils has an average length of greater than or equal to about 2 micrometers to less than or equal to about 100 micrometers.

Abstract: A battery system includes a battery cell, which includes an anode including a first current collector and an anode layer disposed on the first collector and including an anode active material. The cell includes a cathode including a second current collector and a cathode layer disposed on the second collector and including a cathode active material. The cell includes a solid-state electrolyte including one of a reduction tolerable solid electrolyte disposed in contact with the anode and an oxidation tolerable solid electrolyte disposed in contact with the cathode. The reduction tolerable solid electrolyte is present in an amount of from 0.1 part by weight to 5 parts by weight based upon 100 parts by weight of the anode layer. The oxidation tolerable solid electrolyte is present in an amount of from 1 part by weight to 10 parts by weight based upon 100 parts by weight of the cathode layer.