Patents by Inventor Steven J. Visco

Steven J. Visco has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20220045328
    Abstract: Batteries, component structures and manufacturing methods, in particular including a glassy embedded battery electrode assembly having a composite material structure composed of interpenetrating material components including a porous electroactive network including a solid electroactive material, and a continuous glassy medium including a Li ion conducting sulfide glass, can achieve enhanced power output, reduced charging time and/or improved cycle life.
    Type: Application
    Filed: June 4, 2021
    Publication date: February 10, 2022
    Applicant: PolyPlus Battery Company
    Inventors: Steven J. Visco, Yevgeniy S. Nimon, Bruce D. Katz, Vitaliy Nimon
  • Publication number: 20220045352
    Abstract: Battery component structures and manufacturing methods for solid-state battery cells include a unitary Li ion conducting sulfide glass solid electrolyte structure that serves as the basic building block around which a solid-state battery cell can be fabricated. The unitary glass structure approach can leverage precision controlled high throughput processes from the semiconductor industry that have been inventively modified as disclosed herein for processing a sulfide glass solid electrolyte substrate into a unitary Li ion conducting glass structure, for example, by using etching and lithographic photoresist formulations and methods. The glass substrate may be precision engineered to effectuate a dense glass portion and a porous glass portion that can be characterized as sublayers having predetermined thicknesses.
    Type: Application
    Filed: June 4, 2021
    Publication date: February 10, 2022
    Applicant: PolyPlus Battery Company
    Inventors: Steven J. Visco, Vitaliy Nimon, Valentina Loginova, Yevgeniy S. Nimon, Bruce D. Katz
  • Publication number: 20220045353
    Abstract: Chemically treating ionically conductive sulfide glass solid electrolyte separators or separator layers can improve performance. In particular, treatment involving chemically etching a surface or surface region of the sulfide glass separator to blunt, lessen or remove edge defects or surface flaws, and/or to enhance surface smoothness is cost effective, reliable and well suited for high production environments compared to physical methods of removing scratches or smoothing surfaces, such as mechanical grinding and polishing.
    Type: Application
    Filed: June 4, 2021
    Publication date: February 10, 2022
    Applicant: PolyPlus Battery Company
    Inventors: Steven J. Visco, Vitaliy Nimon, Alexei Petrov, Yevgeniy S. Nimon, Bruce D. Katz
  • Patent number: 11239495
    Abstract: Nanofilm-encapsulated sulfide glass solid electrolyte structures and methods for making the encapsulated glass structures involve a lithium ion conducting sulfide glass sheet encapsulated on its opposing major surfaces by a continuous and conformal nanofilm made by atomic layer deposition (ALD). During manufacture, the reactive surfaces of the sulfide glass sheet are protected from deleterious reaction with ambient moisture, and the nanofilm can be configured to provide additional performance advantages, including enhanced mechanical strength and improved chemical resistance.
    Type: Grant
    Filed: February 4, 2020
    Date of Patent: February 1, 2022
    Assignee: PolyPlus Battery Company
    Inventors: Steven J. Visco, Vitaliy Nimon, Yevgeniy S. Nimon, Bruce D. Katz
  • Publication number: 20220013857
    Abstract: Manufacturing methods for making a substantially rectangular and flat glass preform for manufacturing a Li ion conducting glass separator can involve drawing the preform to a thin sheet and may involve one or more of slumping, rolling or casting the glass within a frame that defines a space filling region and therewith the shape and size of the preform. The thickness of the rectangular flat preform so formed may be about 2 mm or less. The frame may be slotted having a back surface and widthwise wall portion that define the height and width of the space filling region. The flat backing surface and surfaces of the widthwise wall portions are defined may be coated by a material that is inert in direct contact with the heated glass material, such as gold.
    Type: Application
    Filed: May 4, 2021
    Publication date: January 13, 2022
    Applicant: PolyPlus Battery Company
    Inventors: Steven J. Visco, Yevgeniy S. Nimon, Bruce D. Katz
  • Publication number: 20210395128
    Abstract: Molding a Li ion conductive sulfide glass construct into a flat preform shape using a mold having a molding surface of a material that is chemically inert in direct contact with a glass blank when heated can improve molding performance.
    Type: Application
    Filed: April 21, 2021
    Publication date: December 23, 2021
    Applicant: PolyPlus Battery Company
    Inventors: Steven J. Visco, Yevgeniy S. Nimon, Bruce D. Katz
  • Publication number: 20210380456
    Abstract: Li ion conductive sulfide glass, can be made by providing a pre-mix of precursor materials for making the Li ion conductive sulfide glass, providing a melting tank for processing the pre-mix to a molten state, and heating the melting tank to a temperature that is sufficient to melt form the Li ion conductive sulfide glass, wherein the melting tank is a metal vessel having inner wall surfaces that are coated with a corrosion resistant metal oxide layer.
    Type: Application
    Filed: April 2, 2021
    Publication date: December 9, 2021
    Applicant: PolyPlus Battery Company
    Inventors: Steven J. Visco, Yevgeniy S. Nimon, Bruce D. Katz
  • Patent number: 11171364
    Abstract: Solid-state laminate electrode assemblies and various methods for making the solid-state laminate electrode assemblies involve a lithium metal layer reactively bonded to a lithium ion conducting sulfide glass layer. During manufacture, highly reactive surfaces of the lithium metal layer and the lithium ion conducting sulfide glass layer are maintained in its substantially unpassivated state until they have been reactively bonded.
    Type: Grant
    Filed: May 29, 2020
    Date of Patent: November 9, 2021
    Assignee: PolyPlus Battery Company
    Inventors: Steven J. Visco, Vitaliy Nimon, Ian Wogan, Yevgeniy S. Nimon, Lutgard C. De Jonghe, Bruce D. Katz
  • Publication number: 20210340048
    Abstract: Manufacturing methods can involve use of a vessel apparatus for making Li ion conducting sulfide glass by melt processing the inside the vessel apparatus, the apparatus having a liner assembly in an ampoule assembly providing an interior wall component that is chemically compatible in direct contact with the molten sulfide glass and maintains intimate thermal contact with the interior wall surface of the ampoule assembly.
    Type: Application
    Filed: April 28, 2021
    Publication date: November 4, 2021
    Applicant: PolyPlus Battery Company
    Inventors: Steven J. Visco, Yevgeniy S. Nimon, Bruce D. Katz
  • Publication number: 20210320328
    Abstract: Preparation of anhydrous lithium sulfide (Li2S) purified suitably for applications in advanced batteries, and, in particular, for synthesis of solid electrolytes based on Li2S, including sulfide solid electrolytes of the type that may be described as crystalline (e.g., polycrystalline), amorphous (e.g., glass) and combinations thereof, such as sulfide glass-ceramic solid electrolyte materials.
    Type: Application
    Filed: March 16, 2021
    Publication date: October 14, 2021
    Applicant: PolyPlus Battery Company
    Inventors: Steven J. Visco, Alexei Petrov, Valentina Loginova, Vitaliy Nimon, Yevgeniy S. Nimon, Bruce D. Katz
  • Publication number: 20210218055
    Abstract: A sulfide glass solid electrolyte sheet can be protected from reaction with moisture by a thin metal layer coating converted to a thin electrochemically functional and protective compound layer. The converted protective compound layer is electrochemically functional in that it allows for through transport of lithium ions.
    Type: Application
    Filed: January 14, 2021
    Publication date: July 15, 2021
    Inventors: Steven J. Visco, Vitaliy Nimon, Yevgeniy S. Nimon, Bruce D. Katz
  • Publication number: 20210210819
    Abstract: Active metal and active metal intercalation electrode structures and battery cells having ionically conductive protective architecture including an active metal (e.g., lithium) conductive impervious layer separated from the electrode (anode) by a porous separator impregnated with a non-aqueous electrolyte (anolyte). This protective architecture prevents the active metal from deleterious reaction with the environment on the other (cathode) side of the impervious layer, which may include aqueous or non-aqueous liquid electrolytes (catholytes) and/or a variety electrochemically active materials, including liquid, solid and gaseous oxidizers. Safety additives and designs that facilitate manufacture are also provided.
    Type: Application
    Filed: January 5, 2021
    Publication date: July 8, 2021
    Inventors: Steven J. Visco, Bruce D. Katz, Yevgeniy S. Nimon, Lutgard C. De Jonghe
  • Publication number: 20210126236
    Abstract: Methods for making solid-state laminate electrode assemblies include methods of forming a solid electrolyte interphase (SEI) by ion implanting nitrogen and/or phosphorous into the glass surface by ion implantation.
    Type: Application
    Filed: October 2, 2020
    Publication date: April 29, 2021
    Applicant: PolyPlus Battery Company
    Inventors: Steven J. Visco, Vitaliy Nimon, Yevgeniy S. Nimon, Bruce D. Katz, Richard L. Swisher
  • Publication number: 20210111427
    Abstract: A sulfide glass solid electrolyte sheet can be protected during Li by a thin material layer coating for providing that protection (i.e., protective coating).
    Type: Application
    Filed: October 9, 2020
    Publication date: April 15, 2021
    Inventors: Steven J. Visco, Yevgeniy S. Nimon, Vitaliy Nimon, Bruce D. Katz
  • Publication number: 20210098819
    Abstract: A standalone lithium ion-conductive solid electrolyte including a freestanding inorganic vitreous sheet of sulfide-based lithium ion conducting glass is capable of high performance in a lithium metal battery by providing a high degree of lithium ion conductivity while being highly resistant to the initiation and/or propagation of lithium dendrites. Such an electrolyte is also itself manufacturable, and readily adaptable for battery cell and cell component manufacture, in a cost-effective, scalable manner.
    Type: Application
    Filed: October 1, 2020
    Publication date: April 1, 2021
    Applicant: PolyPlus Battery Company
    Inventors: Steven J. Visco, Yevgeniy S. Nimon, Lutgard C. De Jonghe, Bruce D. Katz, Vitaliy Nimon
  • Publication number: 20210098818
    Abstract: A lithium ion-conductive solid electrolyte including a freestanding inorganic vitreous sheet of sulfide-based lithium ion conducting glass is capable of high performance in a lithium metal battery by providing a high degree of lithium ion conductivity while being highly resistant to the initiation and/or propagation of lithium dendrites. Such an electrolyte is also itself manufacturable, and readily adaptable for battery cell and cell component manufacture, in a cost-effective, scalable manner.
    Type: Application
    Filed: October 1, 2020
    Publication date: April 1, 2021
    Applicant: PolyPlus Battery Company
    Inventors: Steven J. Visco, Yevgeniy S. Nimon, Lutgard C. De Jonghe, Bruce D. Katz, Vitaliy Nimon
  • Patent number: 10916753
    Abstract: Active metal and active metal intercalation electrode structures and battery cells having ionically conductive protective architecture including an active metal (e.g., lithium) conductive impervious layer separated from the electrode (anode) by a porous separator impregnated with a non-aqueous electrolyte (anolyte). This protective architecture prevents the active metal from deleterious reaction with the environment on the other (cathode) side of the impervious layer, which may include aqueous or non-aqueous liquid electrolytes (catholytes) and/or a variety electrochemically active materials, including liquid, solid and gaseous oxidizers. Safety additives and designs that facilitate manufacture are also provided.
    Type: Grant
    Filed: November 25, 2019
    Date of Patent: February 9, 2021
    Assignee: PolyPlus Battery Company
    Inventors: Steven J. Visco, Bruce D. Katz, Yevgeniy S. Nimon, Lutgard C. De Jonghe
  • Publication number: 20200395633
    Abstract: Solid-state laminate electrode assemblies and various methods for making the solid-state laminate electrode assemblies involve a lithium metal layer reactively bonded to a lithium ion conducting sulfide glass layer. During manufacture, highly reactive surfaces of the lithium metal layer and the lithium ion conducting sulfide glass layer are maintained in its substantially unpassivated state until they have been reactively bonded.
    Type: Application
    Filed: May 29, 2020
    Publication date: December 17, 2020
    Inventors: Steven J. Visco, Vitaliy Nimon, Ian Wogan, Yevgeniy S. Nimon, Lutgard C. De Jonghe, Bruce D. Katz
  • Patent number: 10868293
    Abstract: Methods for making solid-state laminate electrode assemblies include methods of forming a solid electrolyte interphase (SEI) by ion implanting nitrogen and/or phosphorous into the glass surface by ion implantation.
    Type: Grant
    Filed: October 24, 2019
    Date of Patent: December 15, 2020
    Assignee: POLYPLUS BATTERY COMPANY
    Inventors: Steven J. Visco, Vitaliy Nimon, Yevgeniy S. Nimon, Bruce D. Katz, Richard L. Swisher
  • Patent number: 10862171
    Abstract: Methods for making solid-state laminate electrode assemblies include methods to prevent devitrifying and damaging a lithium ion conducting sulfide glass substrate during thermal evaporation of lithium metal, as well as methods for making thin extruded lithium metal foils.
    Type: Grant
    Filed: July 17, 2018
    Date of Patent: December 8, 2020
    Assignee: POLYPLUS BATTERY COMPANY
    Inventors: Steven J. Visco, Vitaliy Nimon, Yevgeniy S. Nimon, Bruce D. Katz, Richard L. Swisher