Abstract: Provided are electrodes that include an electrode dry mixture and a dry electrolyte material intermixed with the electrode dry mixture; and a binder intermixed with the electrode dry mixture and the dry electrolyte material, said binder comprising fibrils; the electrode dry mixture, dry electrolyte material, and said binder in the form of a dry electrode film. The electrolyte material may include a glass ceramic and, optionally, an air-stabilizing dopant. The glass ceramic may include Li3PS4. The electrodes may include a composite cathode of the dry electrode film and optionally further include a solid-state electrolyte layer. Also provided are methods for forming the electrodes, optionally where the methods may be applicable for a solvent-free process to form electrodes and electrochemical cells and batteries including the electrodes.

Abstract: Provided are electrodes that include an electrode dry mixture and a dry electrolyte material intermixed with the electrode dry mixture; and a binder intermixed with the electrode dry mixture and the dry electrolyte material, said binder comprising fibrils; the electrode dry mixture, dry electrolyte material, and said binder in the form of a dry electrode film. The electrolyte material may include a glass ceramic and, optionally, an air-stabilizing dopant. The glass ceramic may include Li3PS4. The electrodes may include a composite cathode of the dry electrode film and optionally further include a solid-state electrolyte layer. Also provided are methods for forming the electrodes, optionally where the methods may be applicable for a solvent-free process to form electrodes and electrochemical cells and batteries including the electrodes.

Abstract: Methods for preparing an electrode may include compressing an electrode dry mixture comprising an active material and an electrolyte material to form an electrode film. An electrolyte dry mixture or a stand-alone solid-state electrolyte film is compressed against a surface of the electrode film to form a laminate of an electrolyte layer and the electrode film. The electrolyte dry mixture may include the electrolyte material. Compressing the electrode dry mixture may include calendering the electrode dry mixture. Compressing the electrolyte dry mixture or stand-alone electrolyte film may be accomplished also by calendering. The electrolyte material may include a glass ceramic and, optionally, an air-stabilizing dopant. The glass ceramic may include Li3PS4. Thus, the electrodes may include a composite cathode and a solid-state electrolyte layer. The methods may be applicable for a solvent-free process to form electrodes and electrochemical cells and batteries including the electrodes.

Abstract: Provided are methods of producing materials suitable for use as a component of an electrochemical cell such as electrode active layers or solid state electrolyte and/or separator materials. Processes include combining an active with a fibrillizable binder and intermixing in a screw fibrillator to produce a fibrillized material with greatly increased physical and optionally electrochemically characteristics relative to those materials produced by other processes such as simple slurry casting or intermixing in a jet mill.

Abstract: Methods for preparing an electrode may include compressing an electrode dry mixture comprising an active material and an electrolyte material to form an electrode film. An electrolyte dry mixture or a stand-alone solid-state electrolyte film is compressed against a surface of the electrode film to form a laminate of an electrolyte layer and the electrode film. The electrolyte dry mixture may include the electrolyte material. Compressing the electrode dry mixture may include calendering the electrode dry mixture. Compressing the electrolyte dry mixture or stand-alone electrolyte film may be accomplished also by calendering. The electrolyte material may include a glass ceramic and, optionally, an air-stabilizing dopant. The glass ceramic may include Li3PS4. Thus, the electrodes may include a composite cathode and a solid-state electrolyte layer. The methods may be applicable for a solvent-free process to form electrodes and electrochemical cells and batteries including the electrodes.