Abstract: A method for fabricating a composite panel includes providing a preform including a peripheral edge portion and a central portion. The central portion has a first thickness, the peripheral edge portion has a second thickness that is greater than the first thickness, and a first step is arranged between the central portion and the peripheral edge portion. The method includes providing a tool including a binder defining a second step, an upper punch, and a lower tool; arranging the preform between the binder and the upper punch and the lower tool; shaping the preform using the tool; and injection molding the preform in the tool to create the composite panel.

Abstract: A battery cathode includes: a current collector; and a coating applied to the current collector, the coating including: conductive carbon; polyvinylidene fluoride binder polymer; acid-functionalized dispersant polymer; and electrochemically active layered metal oxide.

Abstract: A method of manufacturing an electrode for an electrochemical cell includes providing an admixture including an electroactive material, a binder, and a solvent. The method further includes rolling the admixture to form a sheet and forming a multi-layer stack from the sheet. The method further includes forming an electrode film precursor by performing a plurality of sequential rollings, each including rolling the stack through a first gap. The plurality of sequential rollings includes first and second rollings. In the first rolling, the stack is in a first orientation. In the second rolling, the stack is in a second orientation different from the first orientation. The method further includes forming an electrode film by rolling the electrode film precursor through a second gap less than or equal to the first gap. The method further includes drying the electrode film to remove at least a portion of the solvent.

Abstract: A composite panel includes a backing substrate and a first plurality of fiber tows. The first plurality of fiber tows is stitched to a first surface of the backing substrate in a predetermined pattern to form a fiber reinforced insert. A first polymer layer encapsulates the first surface of the backing substrate and the first plurality of fiber tows.

Abstract: An electrochemical cell that cycles lithium ions is provided. The electrochemical cell may include a first porous electrode, a second porous electrode, and a separating layer disposed between the first electrode and the second electrode. The first porous electrode includes an electrolyte intermingled with a nickel-rich positive electroactive material. The second porous electrode includes the electrolyte intermingled a silicon-based negative electroactive material. The electrolyte includes greater than or equal to about 1 wt. % to less than or equal to about 3 wt. % of an electrolyte additive and a solvent mixture. The electrolyte additive may be selected from the group consisting of: succinic anhydride (SA), maleic anhydride, N-carboxyanhydride, glutaric anhydride, isatin anhydride, citraconic anhydride, and combinations thereof. The solvent mixture may include ethylene carbonate (EC) and dimethyl carbonate (DMC) in mass ratio of about 3:7.

Abstract: A composite panel includes a backing substrate and a first plurality of fiber tows. The first plurality of fiber tows is stitched to a first surface of the backing substrate in a predetermined pattern to form a fiber reinforced insert. A first polymer layer encapsulates the first surface of the backing substrate and the first plurality of fiber tows.

Abstract: The present disclosure provides an electrochemical cell that cycles lithium ions. The electrochemical cell includes a first electrode, a second electrode, and a separating layer disposed between the first electrode and the second electrode. The first electrode includes an electrolyte intermingled with a nickel-rich positive electroactive material. The second electrode also includes the electrolyte, and the electrolyte is intermingled a silicon-based negative electroactive material. The electrolyte includes an electrolyte additive and a solvent mixture. The solvent mixture includes vinylene carbonate, fluoroethylene carbonate, ethylene carbonate, and dimethyl carbonate. The electrolyte additive is selected from the group consisting of: lithium difluorophosphate, ethylene sulfate, and combinations thereof.

Abstract: The present disclosure provides an electrode assembly for use in an electrochemical cell that cycles lithium ions. The electrode assembly includes a current collector, an electroactive material layer disposed parallel with the current collector, and a protective coating disposed between the current collector and the electroactive material layer. The electroactive material layer is defined by a plurality of electroactive material particles. At least a portion of the electroactive material particles of the plurality of electroactive material particles includes a protective particle coating. The protective particle coating is a carbon coating that includes a first carbonaceous material. The protective coating is a carbon layer that includes a second carbonaceous material.

Abstract: An electrochemical cell that cycles lithium ions is provided. The electrochemical cell includes a porous positive electrode that includes a positive electroactive material represented by: LiM1xM2yM3zM4(1-x-y-z)O2, where M1, M2, M3, and M4 are transition metals independently selected from the group consisting of: nickel (Ni), manganese (Mn), cobalt (Co), aluminum (Al), iron (Fe), and combinations thereof, 0?x?1, 0?y?1, and 0?z?1. The electrochemical cell also includes a porous negative electrode physically separated from the positive electrode, and an electrolyte disposed in pores of the positive and negative electrodes. The electrolyte may include a lithium salt, an electrolyte additive having one or more alkene amide groups, and a solvent. The negative electrode can include a silicon-based negative electroactive material.

Abstract: A composite component includes a substrate including a first region and a second region. A plurality of first fiber tows is arranged in the first region and including non-conductive filaments. First stitches attach the plurality of first fiber tows to a first surface of the substrate. A plurality of second fiber tows are arranged in the second region and including conductive filaments. Second stitches attach the plurality of second fiber tows to the first surface of the substrate.

Abstract: An electrode assembly for an electrochemical cell that cycles lithium ions is provided. The electrode includes a current collector, a binder material layer disposed on or near a surface of the current collector, and an electroactive material layer disposed on or near a surface of the binder material layer that faces away from the current collector. The electroactive material layer includes a plurality of electroactive material particles having an average specific surface area greater than or equal to about 1 m2/g to less than or equal to about 30 m2/g, and average particle size greater than or equal to about 0.1 micrometer to less than or equal to about 10 micrometers.

Abstract: A method of making a negative electrode for an electrochemical cell of a secondary lithium battery. The negative electrode includes composite Li—Si alloy particles dispersed in a polymer binder. The composite Li—Si alloy particles are formed by contacting Li—Si alloy particles with a precursor solution that includes a phosphorus sulfide compound dissolved in an organic solvent to form a lithium thiophosphate solid electrolyte layer over an entire outer surface of each of the Li—Si alloy particles.

Abstract: The present disclosure provides a composite material housing for a battery pack for reducing or minimizing thermal runaway propagation. The composite material housing includes a polymeric structure defining an interior-facing surface and an exterior-facing surface. The polymeric structure includes a fire resistant material layer and a reinforcing material layer, where the fire resistant material layer defines an interior-facing surface, and the reinforcing material layer defines the exterior-facing surface. The composite material further includes a metallic layer disposed along the exterior-facing surface, where in a first operational mode the metallic layer contacts the exterior-facing surface and in a second operational mode, after exposure to a thermal load of greater than or equal to about 500° C., the metallic layer at least partially delaminates from the exterior-facing surface and forms one or more insulating air gaps that define a thermal barrier.

Abstract: The present disclosure provides an electrode for an electrochemical cell that cycles lithium ions. The electrode includes a silicon-containing electroactive material, a first carbon additive having a first aspect ratio greater than or equal to about 1 to less than or equal to about 3, a second carbon additive having a second aspect ratio greater than or equal to about 3 to less than or equal to about 500, and a third carbon additive having a third aspect ratio greater than or equal to about 20 to less than or equal to about 10,000. The electrode includes between about 80 wt. % and about 97 wt. % of the silicon-containing electroactive material, between about 0.5 wt. % and about 15 wt. % of the first carbon additive, between about 0.1 wt. % and about 15 wt. % of the second carbon additive, and between about 0.01 wt. % and about 5 wt. % of the third carbon additive.

Abstract: A containment system for a rechargeable energy storage device (RESS) is described includes an enclosure having a first compartment adjoining a second compartment. The first compartment is arranged to house a plurality of power electronics devices, and the second compartment is arranged to house a plurality of battery cells. The second compartment includes a tub that defines a bottom portion, and a floor plate. The tub includes opposed end walls and opposed sidewalls. A top plate is arranged overtop of the first compartment and the second compartment. A first one of the end walls and the top plate define a first slot between the first compartment and the second compartment. A first removable panel is arranged to enclose the first compartment. The plurality of battery cells connect to the plurality of power electronics devices via a high-voltage DC power bus that is arranged to pass through the first slot.

Abstract: In a method of making a negative electrode for an electrochemical cell of a secondary lithium battery, a precursor mixture is prepared that includes electrochemically active Li—Si alloy particles, electrically conductive carbon particles, and an inert polymer binder dissolved in a nonpolar organic solvent.

Abstract: An injection molded composite component includes a groove extending from a first surface of the composite component and a tubing material placed within the groove and formed integrally with the composite component such that the tubing material forms an integrated conduit on the first surface of the composite component.

Abstract: Presented are hybrid metal and fiber-reinforced polymer (FRP) composite wheels for vehicle wheel assemblies, methods for making/using such wheels, and motor vehicles equipped with such wheels. A wheel for a motor vehicle wheel assembly includes a wheel face with multiple spokes that are circumferentially spaced about and project radially outward from a central hub. The central hub rotatably attaches to the vehicle's body, e.g., via a corner module. The wheel face is fabricated, e.g., as a one-piece structure, from an FRP material. A wheel barrel, which circumscribes the wheel face, includes an annular rim that mounts thereon an inflatable tire. The wheel barrel is fabricated, e.g., as a one-piece structure, from a metallic material. Multiple overmold through holes and/or inset tabs are circumferentially spaced about the annular rim. The FRP material extends through and/or surrounds the overmold through holes/inset tabs and thereby mounts the wheel face to the wheel barrel.

Abstract: In various aspects, the present disclosure provides a component. The vehicle component includes a polymer matrix, a plurality of fibers in the polymer matrix, and a heating element embedded in the polymer matrix. The heating element may be (i) a discrete heating element, (ii) at least a portion of the plurality of fibers, or both (i) and (ii). The heating element is configured to be coupled to an external circuit to generate heat. In one aspect, the vehicle component is a vehicle header including an elongated body extending between a first side and a second side.

Abstract: The present disclosure provides a method of making a negative electrode material for an electrochemical cell that cycles lithium ions. The method includes centrifugally distributing a precursor including silicon, lithium, and an additional metal (M) selected from the group consisting of: aluminum (Al), chromium (Cr), titanium (Ti), niobium (Nb), molybdenum (Mo), zirconium (Zr), yttrium (Y), cerium (Ce), and combinations thereof by contacting the precursor with a rotating surface in a centrifugal atomizing reactor and solidifying the precursor to form a plurality of substantially round solid electroactive particles that include Li4.4xSixMy, where x is greater than 0 to less than or equal to about 0.85 and y corresponds to a weight percent of M that is greater than or equal to 0.1 wt. % to less than or equal to about 10 wt. %.