Abstract: Testing devices for testing target test devices each composed of one or more battery cells, such as battery cells and battery packs. In some embodiments, a testing device may be considered self-contained in that it may include sufficient onboard systems and features to allow the testing device to conduct testing on one or more target test devices with minimal inputs, such as electrical power, higher-level instructions, and/or control inputs. In some embodiments, a testing device may include an explosion- and/or fire-proof or -resistant enclosure. In some embodiments, components of a testing device may be modularized for easy reconfiguring for different testing and/or different target test devices. In some embodiments, a plurality of testing devices can be controlled by a central testing controller. Related methods and systems are also disclosed.

Abstract: In some embodiments, hybrid-ether electrolytes that include a nonfluorinated hybrid-ether cosolvent system having at least one nonfluorinated cyclic ether and at least one nonfluorinated linear ether, wherein the number of cations, M, of an active metal (having a solvation number, SN) within the hybrid-ether electrolyte are provided in an amount such that a molar ratio between M and the number of oxygen atoms in the nonfluorinated hybrid-ether cosolvent system falls within a desired range. In some embodiments, a hybrid-ether electrolyte of this disclosure further includes at least one fluorinated ether. In some embodiments, a hybrid-ether electrolyte of this disclosure may optionally include one or more solvents differing from the solvents in the nonfluorinated hybrid-ether cosolvent system and, if provided, different from the fluorinated ether(s).

Abstract: Sulfonyl-based solvent systems for electrolytes used in electro-chemical devices, such as secondary batteries. In some embodiments, a solvent system of the disclosure includes a sulfonyl (—SO2—)-based solvent optionally in combination with one or more different sulfonyl-based solvents and/or one or more non-sulfonyl-based solvents. Five example chemical structures for a sulfonyl-based solvent usable in a sulfonyl-based solvent system of this disclosure are disclosed. Also disclosed are electrolytes that include one or more salts, such as one or more alkali-metal salts, dissolved in a sulfonyl-based solvent system of the present disclosure. Proper formulation of a disclosed electrolyte can lead to one or more benefits, including but not limited to, improved cycle life, improved low-temperature operation, and reduced flammability.

Abstract: Methods of producing N,N-branched sulfamoyl fluoride compounds of the formula F-S(O)2-NR2 by contacting bismuth trifluoride with an N,N-branched sulfamoyl nonfluorohalide compound of the formula X-SO2NR2, wherein X=chlorine (Cl), bromine (Br), or iodine (I), and each R is, independently, a linear or branched alkyl, fluoroalkyl, alkenyl, fluoroalkenyl, alkynyl, or fluoroalkynyl with 1 to 12 carbon atoms, to fluorinate the N,N-branched sulfamoyl nonfluorohalide compound. This is a non-aqueous method, the purity of product is very high, and the desired product can be isolated in quantitative yield. The N,N-branched sulfamoyl fluoride compounds so produced are useful in various applications including as electrolyte solvents and additives in electrochemical devices, such as lithium batteries and capacitors, and in biological fields, among others.

Abstract: Battery core packs employing minimum cell-face pressure containment devices and methods are disclosed for minimizing dendrite growth and increasing cycle life of metal and metal-ion battery cells.

Abstract: Processes for producing a N,N-dialkyl perfluoroalkyl-sulfonamide product of the formula Rf—S(O)2—NRaRb (I) in which Rf represents fully or partially fluorinated alkyl groups with carbon 1 to 12 and Ra and Rb represents linear or branched or cyclic alkyl, alkene or alkyne groups with carbon 1 to 12, wherein Ra=Rb or Ra?Rb. In some embodiments, a reaction proceeds by contacting a perfluoroalkylsulfonyl halide of the formula: X—S(O)2—Rf, (II), in which X represents F, Cl, Br or I, with dialkylamine of the formula HNRaRb, under conditions sufficient to produce the desired N,N-dialkyl perfluoroalkylsulfonamide product of Formula I. In some embodiments, the reaction is carried out using a solvent of Formula I.

Abstract: Processes for producing a N,N-dialkyl perfluoroalkyl-sulfonamide product of the formula Rf—S(O)2—NRaRb (I) in which Rf represents fully or partially fluorinated alkyl groups with carbon 1 to 12 and Ra and Rb represents linear or branched or cyclic alkyl, alkene or alkyne groups with carbon 1 to 12, wherein Ra=Rb or Ra?Rb. In some embodiments, a reaction proceeds by contacting a perfluoroalkylsulfonyl halide of the formula: X—S(O)2—Rf, (II), in which X represents F, Cl, Br or I, with dialkylamine of the formula HNRaRb, under conditions sufficient to produce the desired N,N-dialkyl perfluoroalkylsulfonamide product of Formula I. In some embodiments, the reaction is carried out using a solvent of Formula I.

Abstract: Alkali metal secondary batteries that include anodes constructed from alkali metal foil applied to only one side of a porous current collector metal foil. Openings in the porous current collectors permit alkali metal accessibility on both sides of the anode structure. Such anode constructions enable the utilization of lower-cost and more commonly available alkali metal foil thickness, while still achieving high cell cycle life at a significantly reduced cost. Aspects of the present disclosure also include batteries with porous current collectors having increased volumetric and gravimetric energy densities, and methods of manufacturing anodes with porous current collectors.

Abstract: Alkali metal secondary batteries that include anodes constructed from alkali metal foil applied to only one side of a porous current collector metal foil. Openings in the porous current collectors permit alkali metal accessibility on both sides of the anode structure. Such anode constructions enable the utilization of lower-cost and more commonly available alkali metal foil thickness, while still achieving high cell cycle life at a significantly reduced cost. Aspects of the present disclosure also include batteries with porous current collectors having increased volumetric and gravimetric energy densities, and methods of manufacturing anodes with porous current collectors.

Abstract: Alkali metal secondary batteries that include anodes constructed from alkali metal foil applied to only one side of a porous current collector metal foil. Openings in the porous current collectors permit alkali metal accessibility on both sides of the anode structure. Such anode constructions enable the utilization of lower-cost and more commonly available alkali metal foil thickness, while still achieving high cell cycle life at a significantly reduced cost. Aspects of the present disclosure also include batteries with porous current collectors having increased volumetric and gravimetric energy densities, and methods of manufacturing anodes with porous current collectors.

Abstract: Localized high-salt-concentration electrolytes each containing a salt, a glyme as a solvent, and a fluorinated diluent. In some embodiments, the glyme has a chemical formula R1—(O—CH2—CH2)n—O—R2, wherein n=1 to 4 and at least one of R1 and R2 is a hydrocarbon sidechain having at least 2 carbon atoms and wherein the salt is soluble in the glyme. In some embodiments, the fluorinated diluent is selected from the group consisting of a fluorinated glyme and a fluorinated ether. In some embodiments, the salt includes an alkali-metal salt. In some embodiments, the salt includes an alkali-earth-metal salt. The salt may include a perfluorinated sulfonimide salt. Electrochemical devices that include localized high-salt-concentration electrolytes of the present disclosure are also disclosed.

Abstract: A high energy density, high power lithium metal anode rechargeable battery having volumetric energy density of >1000 Wh/L and/or a gravimetric energy density of >350 Wh/kg, that is capable of >1 C discharge at room temperature. In some embodiments, a high power lithium metal anode rechargeable battery of the present disclosure includes a lithium metal anode having a thickness of less than 20 ?m and a ratio of anode capacity (n) to cathode capacity (p) in a discharged state, i.e., n/p, in a range of 0.8 to less than or equal to 1 or in a range of 0.9 to less than or equal to 1. In some embodiments, a high power lithium metal anode rechargeable battery of the present disclosure further includes a high-voltage cathode and a hybrid separator.

Abstract: Localized high-salt-concentration electrolytes each containing a salt, a glyme as a solvent, and a fluorinated diluent. In some embodiments, the glyme has a chemical formula R1—(O—CH2—CH2)n—O—R2, wherein n=1 to 4 and at least one of R1 and R2 is a hydrocarbon sidechain having at least 2 carbon atoms and wherein the salt is soluble in the glyme. In some embodiments, the fluorinated diluent is selected from the group consisting of a fluorinated glyme and a fluorinated ether. In some embodiments, the salt includes an alkali-metal salt. In some embodiments, the salt includes an alkali-earth-metal salt. The salt may include a perfluorinated sulfonimide salt. Electrochemical devices that include localized high-salt-concentration electrolytes of the present disclosure are also disclosed.

Abstract: A battery structure with a cathode, an electrolyte, and a lithium metal anode is coated with a composite coating including a mixture of a polymer and a reinforcing fiber. The cathode and the lithium metal are held apart by a porous separator soaked with the electrolyte. The reinforcing fiber is dispersed in the polymer matrix. The composite coating is porous or non-porous. The composite coating conducts lithium ions. The reinforcing fiber is chemically functionalized.

Abstract: Methods for making high-purity LiFSI salts and intermediate products using one, the other, or both of a reactive-solvent removal/replacement method and an LiFSI purification method. In some embodiments, the reactive-solvent removal/replacement method includes using non-reactive anhydrous organic solvents to remove and/or replace one or more reactive solvents in a crude LiFSI. In some embodiments, the LiFSI purification method includes using anhydrous organic solvents to remove impurities, such as synthesis impurities, from a crude LiFSI. In some embodiments, crude LiFSI can be made using an aqueous-based neutralization process. LiFSI salts and products made using methods of the disclosure are also described, as are uses of such salts and products and electrochemical devices that include such salts and products.

Abstract: Methods for making high-purity LiFSI salts and intermediate products using one, the other, or both of a reactive-solvent removal/replacement method and an LiFSI purification method. In some embodiments, the reactive-solvent removal/replacement method includes using non-reactive anhydrous organic solvents to remove and/or replace one or more reactive solvents in a crude LiFSI. In some embodiments, the LiFSI purification method includes using anhydrous organic solvents to remove impurities, such as synthesis impurities, from a crude LiFSI. In some embodiments, crude LiFSI can be made using an aqueous-based neutralization process. LiFSI salts and products made using methods of the disclosure are also described, as are uses of such salts and products and electrochemical devices that include such salts and products.

Abstract: Methods of removing target impurities from a crude lithium bis(fluorosulfonyl)imide (LiFSI) to make a purified LiFSI product. In some embodiments, a purification method includes contacting crude LiFSI with a first anhydrous organic solvent to create a solution containing LiFSI and the target impurity(ies), wherein the LiFSI is soluble and the impurity(ies) is/are substantially insoluble. In some embodiments, a second anhydrous organic solvent is added to the solution to precipitate the target impurity(ies), which is then filtered to obtain a filtrate. In some embodiments, solvent is removed from the filtrate to obtain a solid mass containing LiFSI, which may then be contacted with a third anhydrous organic solvent in which the LiFSI is insoluble. The LiFSI may then be isolated from the third anhydrous organic solvent to obtain the purified LiFSI product. Also disclosed are purified LiFSI products and electrochemical devices utilizing purified LiFSI products, among other things.

Abstract: Battery core packs employing minimum cell-face pressure containment devices and methods are disclosed for minimizing dendrite growth and increasing cycle life of metal and metal-ion battery cells.

Abstract: Free-solvent-free lithium sulfonimide salt compositions that are liquid at room temperature, and methods of making free-solvent-free liquid lithium sulfonimide salt compositions. In an embodiment, the methods include mixing one or more lithium sulfonimide salts with one or more ether-based solvents and then removing the free solvent(s) under suitable vacuum, temperature, and time conditions so as to obtain a free-solvent-free liquid lithium sulfonimide salt composition that is liquid at room temperature. In an embodiment, the only solvent molecules that remain in the liquid lithium sulfonimide salt composition are adducted with lithium sulfonimide salt molecules. An example automated processing system for making free-solvent-free liquid lithium sulfonimide salts is also disclosed.

Abstract: Localized high-salt-concentration electrolytes each containing a salt, a glyme as a solvent, and a fluorinated diluent. In some embodiments, the glyme has a chemical formula R1—(O—CH2—CH2)n—O—R2, wherein n=1 to 4 and at least one of R1 and R2 is a hydrocarbon sidechain having at least 2 carbon atoms and wherein the salt is soluble in the glyme. In some embodiments, the fluorinated diluent is selected from the group consisting of a fluorinated glyme and a fluorinated ether. In some embodiments, the salt includes an alkali-metal salt. In some embodiments, the salt includes an alkali-earth-metal salt. The salt may include a perfluorinated sulfonimide salt. Electrochemical devices that include localized high-salt-concentration electrolytes of the present disclosure are also disclosed.