Abstract: Disclosed is a method for making a lithium-ion cell by depositing from an atmospheric plasma deposition device inorganic oxide particles produced from a precursor in an atmospheric plasma as a coating on a surface of a lithium-ion electrochemical cell component. The coating formed by the inorganic oxide particles may be an insulating coating or may provide dimensional stability during a thermal runaway.

Abstract: Disclosed is a method for making a lithium-ion cell by depositing from an atmospheric plasma deposition device inorganic oxide particles produced from a precursor in an atmospheric plasma as a coating on a surface of a lithium-ion electrochemical cell component. The coating formed by the inorganic oxide particles may be an insulating coating or may provide dimensional stability during a thermal runaway.

Abstract: A method of making an electrode material for a lithium-ion electrochemical cell includes sputtering a wire of metal or metal alloy in an atmospheric plasma to produce activated particles of metal or metal alloy and contacting the activated particles of the metal or metal alloy with particles of a lithium-ion cell active electrode material to produce composite particles in which particles of the first lithium-ion cell active electrode material are adhered to particles of the metal or metal alloy.

Abstract: Disclosed is a method and apparatus for making a lithium-ion electrochemical cell component by advancing a substrate for a lithium ion cell between opposing first and second calendering rolls, depositing by atmospheric plasma deposition particles of electrode material comprising an active electrode material and a metal into a gap between a first side of the substrate and the first calendering roll, wherein the metal is surface-activated by the atmospheric plasma; and pressing the deposited particles of the active electrode material and the metal particles between the first and second calendering rolls into an electrode layer on the first side of the substrate.

Abstract: Disclosed is a method for making a lithium-ion cell by depositing from an atmospheric plasma deposition device inorganic oxide particles produced from a precursor in an atmospheric plasma as a coating on a surface of a lithium-ion electrochemical cell component. The coating formed by the inorganic oxide particles may be an insulating coating or may provide dimensional stability during a thermal runaway.

Abstract: An anode component for a lithium-ion cell is formed using an atmospheric plasma deposition. The anode component has an anode material layer comprising high lithium-intercalating capacity silicon particles as active anode material in pores of a bonded layer of metal particles. The atmospheric plasma deposition process deposits metal particles and smaller silicon-containing particles concurrently or sequentially on an anode current collector substrate or polymeric separator substrate for the lithium-ion cell. The anode material layer may optionally be lithiated in the atmospheric plasma deposition process. The plasma deposition process is used to form a porous electrode layer on the substrate consisting essentially of a porous metal matrix containing smaller particles of the electrode material particles supported and carried in the pores of the matrix. When the anode component is assembled into a cell, remaining pore capacity is filled with a lithium-ion containing liquid electrolyte solution.

Abstract: An anode component for a lithium-ion cell is formed using an atmospheric plasma deposition. The anode component has an anode material layer comprising high lithium-intercalating capacity silicon particles as active anode material in pores of a bonded layer of metal particles. The atmospheric plasma deposition process deposits metal particles and smaller silicon-containing particles concurrently or sequentially on an anode current collector substrate or polymeric separator substrate for the lithium-ion cell. The anode material layer may optionally be lithiated in the atmospheric plasma deposition process. The plasma deposition process is used to form a porous electrode layer on the substrate consisting essentially of a porous metal matrix containing smaller particles of the electrode material particles supported and carried in the pores of the matrix. When the anode component is assembled into a cell, remaining pore capacity is filled with a lithium-ion containing liquid electrolyte solution.

Abstract: An anode component for a lithium-ion cell is formed using an atmospheric plasma deposition. The anode component has an anode material layer comprising high lithium-intercalating capacity silicon particles as active anode material in pores of a bonded layer of metal particles. The atmospheric plasma deposition process deposits metal particles and smaller silicon-containing particles concurrently or sequentially on an anode current collector substrate or polymeric separator substrate for the lithium-ion cell. The anode material layer may optionally be lithiated in the atmospheric plasma deposition process. The plasma deposition process is used to form a porous electrode layer on the substrate consisting essentially of a porous metal matrix containing smaller particles of the electrode material particles supported and carried in the pores of the matrix. When the anode component is assembled into a cell, remaining pore capacity is filled with a lithium-ion containing liquid electrolyte solution.

Abstract: An anode component for a lithium-ion cell is formed using an atmospheric plasma deposition. The anode component has an anode material layer comprising high lithium-intercalating capacity silicon particles as active anode material in pores of a bonded layer of metal particles. The atmospheric plasma deposition process deposits metal particles and smaller silicon-containing particles concurrently or sequentially on an anode current collector substrate or polymeric separator substrate for the lithium-ion cell. The anode material layer may optionally be lithiated in the atmospheric plasma deposition process. The plasma deposition process is used to form a porous electrode layer on the substrate consisting essentially of a porous metal matrix containing smaller particles of the electrode material particles supported and carried in the pores of the matrix. When the anode component is assembled into a cell, remaining pore capacity is filled with a lithium-ion containing liquid electrolyte solution.

Abstract: A current collector plate, also called a bipolar plate, for a fuel cell includes two facing metal sheets with fluid channels for the fuel (often hydrogen) on the non-facing side of one sheet and fluid channels for air on the non-facing side of the other sheet. Such a plate is made by applying a patterned coating of particles of a soft and reactive metal to at least one of the sheets and rolling them together so that the soft metal particles deform and interact with the facing sheets to selectively join them at the patterned areas. Pressurized fluid is introduced between the sheets to expand non-bonded portions and define the fluid channels.

Abstract: The present invention is directed to additives for improved weldable composites. A metal composite structure (10) features two metal members (12)(14) sandwiching a viscoelastic layer (26) where the viscoelastic layer entrains carbide-forming, carbon trapping particles (28) configured and sized to provide an effective inhibitor to carbon migration from the viscoelastic layer during welding.

Abstract: A method for making a current collector plate includes providing a first sheet of material having a first bonding face and a first outer face. A second sheet of material is provided having a second bonding face and a second outer face. A work area is defined on at least one of the first bonding face and the second bonding face. The first and second sheets are bonded together at a bonding area which is different from the work area. The bonded first and second sheet is placed into a die having a pattern defining at least one flow channel. Fluid is injected between the first and second sheets thereby causing at least one of the first and second sheets to project outward at the work area causing at least one flow channel to be formed in the work area as defined by the die pattern.

Abstract: In an assembly of facing metal sheets separated by a polymer layer, welded metallurgical bonds are formed between the metal sheets by use of a friction stir weld tool. A rotating tool penetrates the first sheet, locally displaces the encountered portion of polymer film and penetrates into the second sheet. The affected metal of the two sheets is momentarily plasticized and stirred, and the plasticized metal of the two sheets combines to form a weld between the metal sheets. The interposed polymer film may be intended to serve as an adhesive or a vibration damping medium or the like. The facing metal sheets can be layers of facing laminated metal sheet structures that each comprise two metal sheets bonded by an adhesive interlayer.

Abstract: An anti-bonding material is placed in a desired pattern onto a first sheet of conductive material. A second sheet of conductive material is roll bonded with the first sheet of material. Fluid is injected between the bonded first and second sheets of material to expand the sheets of material at the desired pattern. A flow channel is formed at the desired pattern between the first and second sheet during fluid injection.

Abstract: One side of a metal sheet is joined to a polymer layer by applying heat to a joining area on the opposite side of the metal. The heat flows through the thin metal to activate a thermoplastic material or heat setting polymer into a bond with the metal. The method can be used to bond the metal sheet to a plastic body or another metal member. It is preferred to use a friction or friction stir tool to heat the metal surface.

Abstract: The present invention is directed to additives for improved weldable composites. A metal composite structure (10) features two metal members (12) (14) sandwiching a viscoelastic layer (26) where the viscoelastic layer entrains carbide-forming, carbon trapping particles (28) that provide an effective inhibitor to carbon migration from the viscoelastic layer during welding.

Abstract: The present invention is directed to improved weldable metal composites and methods. A metal composite structure (10) features two metal members (12) (14) sandwiching a viscoelastic layer (26) where the viscoelastic layer entrains electrically conductive particles (28) and a carbon extracting attractant layers (32) (34) to inhibit and/or prevent carbon migration and carbide formation during welding.

Abstract: Laminated composites such as noise damping sheet metal sandwiches with viscoelastic adhesive cores are strengthened against delamination during forming and made more conductive for welding. Electrically conductive, metal-element containing particles, wires, wire meshes, or the like conductive bonding elements are included in the core material and fused to facing surfaces of the metal sheets to provide many mechanical bonding connections and electrical connections over the bonded area of the composites.

Abstract: A current collector plate, also called a bipolar plate, for a fuel cell includes two facing metal sheets with fluid channels for the fuel (often hydrogen) on the non-facing side of one sheet and fluid channels for air on the non-facing side of the other sheet. Such a plate is made by applying a patterned coating of particles of a soft and reactive metal to at least one of the sheets and rolling them together so that the soft metal particles deform and interact with the facing sheets to selectively join them at the patterned areas. Pressurized fluid is introduced between the sheets to expand non-bonded portions and define the fluid channels.

Abstract: A method for making a current collector plate includes providing a first sheet of material having a first bonding face and a first outer face. A second sheet of material is provided having a second bonding face and a second outer face. A work area is defined on at least one of the first bonding face and the second bonding face. The first and second sheets are bonded together at a bonding area which is different from the work area. The bonded first and second sheet is placed into a die having a pattern defining at least one flow channel. Fluid is injected between the first and second sheets thereby causing at least one of the first and second sheets to project outward at the work area causing at least one flow channel to be formed in the work area as defined by the die pattern.