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: 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: Anode subassembly sheets that include a lithium-metal layer sandwiched between a pair of separator layers to ease handling of the lithium metal to promote fast and efficient stacked-jellyroll assembly. In some embodiments, the separator layers are pressure laminated to the lithium-metal layer without any bonding agent. In some embodiments, a stacked jellyroll is made by alternatingly stacking anode subassembly sheets with cathode sheets. In some embodiments, a functional coating beneficial to the lithium-metal layer is provided to one or more separator layers prior to laminating the separator(s) to the lithium metal layer. Lithium-metal batteries made using stacked jellyrolls made in accordance with aspects of the disclosure are also described.

Abstract: Separators, for use in electrochemical devices, that each include a porous body and at least one ionic-flow-control layer that includes at least one copolymer blend tuned to melt at a design temperature so that, when melted, the copolymer blend block the flow of ions of an electrolyte through the porous separator. In some embodiments, each copolymer blend is applied to the porous body in particulate form. In some embodiments, two or more copolymer blends of differing design melting temperatures are provided to the ionic-flow-control layer. In embodiments having multiple differing copolymer blends of differing melting temperatures, the copolymer blends may be provided in the ionic-flow-control layer in discrete regions or as a mixture of un-melted particles. An ionic-flow-control layer may be provided separately from or integrally with a porous separator body. Electrochemical devices including ionic-flow-control layers are also disclosed.

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: A method of removing one or more target impurities from crude hydrogen bis(fluorosulfonyl)imide (HFSI) using a crystallization technique. In some embodiments, the method includes contacting the crude HFSI with at least one anhydrous solvent to create a solution. The solution is caused to have a temperature sufficient to cause HFSI in the solution to crystalize while the one or more impurities remain dissolved in the mother liquor of the solution. The crystalized HFSI and the mother liquor containing the one or more impurities are separated to obtained a purified HFSI product. Purified HFSI products are also disclosed, as are systems, such as secondary batteries, incorporating purified HFSI products.

Abstract: Aspects of the present disclosure include methods of charging secondary lithium metal batteries that include selectively and intentionally overcharging the battery to activate redox shuttling additives in order to reactivate dead lithium. Aspects of the present disclosure also include control systems for determining when to initiate a lithium reactivation charging process and for determining one or more parameters of a lithium reactivation charging protocol.

Abstract: Aspects of the present disclosure include control systems for controlling secondary lithium metal batteries and for controlling electric devices powered, at least in part, thereby, that enable access to reserve energy stored in the lithium metal battery that is not typically available during normal operation. In some examples, the control systems provide access to the reserve energy in response to an emergency, such as requiring excess energy to power an electric device to a safe location.

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: A secondary high energy density lithium ion cell includes a cathode comprising a high voltage cathode active material, a lithium metal anode, and a non-aqueous electrolyte, wherein the non-aqueous electrolyte comprises an imide salt with a fluorosulfonyl group and a perchlorate salt, wherein the electrolyte is electrochemically stable at operating voltages greater than 4.2V.

Abstract: Binary and ternary eutectic mixtures and corresponding electrolytes are disclosed. In some embodiments, binary eutectic mixtures and electrolytes each include a first salt, X1+Y1?, and a second salt, X2+Y2?, wherein each of X1+ and X2+ is an alkali metal cation and X1+ is different from X2+; and each of Y1? and Y2? is a sulfonimide anion and Y1? is different from Y2?. In ternary eutectic mixtures and electrolytes further include a third salt, X3+Y3?, wherein X3+ is different from each of X1+ and X2+. In some embodiments, the eutectic mixtures and electrolytes have melting points in a range of about 5° C. to about 70° C. Electrochemical devices containing such eutectic-mixture electrolytes 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.

Abstract: A lithium metal anode includes a lithium metal layer and a multi-layer polymer coating disposed over the lithium metal layer. The multi-layer polymer coating includes a first outer polymeric crosslinked gel layer positioned for contact with a battery electrolyte and a second inner polymer layer disposed between the lithium metal layer and the first outer polymeric crosslinked gel layer. The first outer polymeric crosslinked gel layer includes a first polymer, a soft segment polymer, and an electrolyte. The second inner polymer layer includes a second polymer. The second inner polymer layer provides mechanical strength and serves as a physical barrier to the lithium metal layer.

Abstract: A lithium metal anode includes a lithium metal layer and a multi-layer polymer coating disposed over the lithium metal layer. The multi-layer polymer coating includes a first outer polymeric crosslinked gel layer positioned for contact with a battery electrolyte and a second inner polymer layer disposed between the lithium metal layer and the first outer polymeric crosslinked gel layer. The first outer polymeric crosslinked gel layer includes a first polymer, a soft segment polymer, and an electrolyte. The second inner polymer layer includes a second polymer. The second inner polymer layer provides mechanical strength and serves as a physical barrier to the lithium metal layer.

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: A secondary high energy density lithium ion cell includes a cathode comprising a high voltage cathode active material, a lithium metal anode, and a non-aqueous electrolyte, wherein the non-aqueous electrolyte comprises an imide salt with a fluorosulfonyl group and a perchlorate salt, wherein the electrolyte is electrochemically stable at operating voltages greater than 4.2V.

Abstract: A rechargeable lithium battery is an electrochemical energy storage device that includes a cathode, an anode, and a liquid electrolyte as active components. The present disclosure relates to new rechargeable batteries that include a liquid electrolyte with high salt concentration that enables efficient deposition/dissolution of lithium metal on anode, during charge/discharge cycles. The battery can attain high energy density and improved cycle life.

Abstract: Presented herein is a rechargeable lithium battery that includes a cathode, a liquid electrolyte, a solid electrolyte, and an anode. The anode is at least partially coated or plated with the solid electrolyte. The cathode may be porous and infiltrated by the liquid electrolyte. The cathode may also include a binder having a solid graft copolymer electrolyte (GCE). In certain embodiments, the liquid electrolyte is a gel that includes a PIL and a GCE. The battery achieves a high energy density and operates safely over a wide range of temperatures.