Abstract: A method for manufacturing patterned electrodes includes extruding a mixture including an active material, a conductive additive, a binder, and a solvent from an extruder to form an active material layer; laminating the active material layer and a current collector; and patterning the active material layer using a patterned roller including a plurality of projections that form a plurality of features extending into the active material layer.

Abstract: A battery that cycles lithium ions includes a negative electrode, a positive electrode spaced apart from the negative electrode, and a gel polymer electrolyte disposed between and configured to provide a medium for the conduction of lithium ions between the negative electrode and the positive electrode. The positive electrode includes a high-voltage electroactive material formulated to undergo lithium intercalation and deintercalation. The gel polymer electrolyte includes an aliphatic polyester, a lithium salt, and an ionic liquid. The aliphatic polyester includes a substituted or unsubstituted poly(ethylene carbonate) (PEC). The lithium salt includes lithium sulfonylimide, lithium borate, or a combination thereof.

Abstract: A method of manufacturing a composite structure for a battery that cycles lithium ions includes depositing a positive electrode precursor on a substrate to form a positive electrode layer, compacting the positive electrode layer, depositing a solid electrolyte precursor on the substrate over the positive electrode layer to form a solid electrolyte layer, compacting the solid electrolyte layer on the substrate over the positive electrode layer to form a composite structure, and heat treating the composite structure to sinter the solid electrolyte layer. The positive electrode precursor includes electroactive material particles, solid electrolyte particles, and electrically conductive particles. The solid electrolyte precursor includes solid electrolyte particles.

Abstract: A battery cell includes A anode electrodes including an anode active material layer arranged on an anode current collector, C cathode electrodes including a cathode active material layer arranged on a cathode current collector, S separators, where A, C, and S are integers, and a lithium-based electrolyte. The C cathode electrodes and the A anode electrodes exchange lithium ions. The cathode active material layer includes a cathode active material including nickel and an ionic conductive additive.

Abstract: A method for manufacturing a composite solid-state electrolyte (SSE)/electrode for a battery cell includes providing an electrode including an active material layer. The method includes one of: melting a solid-state electrolyte to create molten solid-state electrolyte and coating the active material layer using the molten solid-state electrolyte, and arranging a solid-state electrolyte on the active material layer and heating the electrode and the solid-state electrolyte to create a molten solid-state electrolyte. The method includes solidifying the molten solid-state electrolyte to form a solid-state electrolyte layer.

Abstract: A battery that cycles lithium ions includes a positive electrode and an electrolyte infiltrating the positive electrode. The positive electrode includes an electroactive material including a layered lithium transition metal oxide. The electrolyte includes an organic solvent, a lithium salt, and a fluorinated phosphate ester additive. The fluorinated phosphate ester includes at least one of: (i) a chemical compound comprising a phosphate group attached to two or three branched-chain fluorocarbon groups, or (ii) a chemical compound comprising a cyclic phosphate group attached to a fluorocarbon group.

Abstract: A hybrid material housing for a battery reduces or minimizes thermal runaway propagation. The housing includes a composite structure for the battery and optionally includes a polymeric matrix selected from the group consisting of: epoxy, phenolic resin, polyester, vinyl ester, and combinations thereof and a reinforcing material selected from the group consisting of: glass fibers, carbon fibers, basalt fibers, aromatic polyamide KEVLAR® fibers, and combinations thereof. A metal layer is disposed along an exterior surface of the composite structure that comprises aluminum, steel, stainless steel, alloys, and combinations thereof. In a first mode, the metal layer contacts the composite structure and in a second mode after exposure to a thermal load of greater than or equal to about 500° C., the metal layer at least partially delaminates from the exterior surface and forms insulating air gaps to define a thermal barrier. Methods of forming the hybrid material housings are also provided.

Abstract: A method for manufacturing an anode electrode includes providing a first substrate, a second substrate, and an anode current collector. The method includes forming a first lithium metal layer on the first substrate and a second lithium metal layer on the second substrate. The method includes pressing the first lithium metal layer and the second lithium metal layer into the anode current collector to form an anode electrode.

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: Aspects of the disclosure include a roll press design for manufacturing tailored porosity electrodes. An exemplary roll press includes a top roller and a bottom roller separated from the top roller by a gap. At least one of the top roller and the bottom roller includes a raised region and an indented region. The raised region includes a first radius and the indented region includes a second radius less than the first radius. The gap includes a distance selected to accommodate a current collector. The current collector includes a bare portion and a coated portion having thereon an electrode material of a first thickness. A difference between the first radius and the second radius is selected, based on the first thickness, to evenly distribute stress across the bare portion and the coated portion of the current collector during a calendering process for forming a tailored porosity electrode.

Abstract: Aspects of the disclosure include an electrode calendering system for manufacturing electrodes with enhanced edge quality. An exemplary system includes an active material supply including an electrode material and a coating roll coupled to the active material supply. The coating roll is positioned to coat a current collector with the electrode material. A back roll is positioned to transfer the current collector to the coating roll. The system includes at least one of a bare foil supporting material roll and a coated foil supporting material roll. The bare foil supporting material roll is positioned to apply a support material onto a first portion of the current collector prior to the current collector being coated with the electrode material. The coated foil supporting material roll is positioned to apply the support material onto the first portion of the current collector after the current collector is coated with the electrode material.

Abstract: A positive electrode for a battery that cycles lithium ions includes an electroactive material and an electrochemically inactive oxygen storage material (OSM). The electroactive material comprises a lithium transition metal oxide (LiTMO) formulated to undergo the reversible intercalation of lithium ions. The OSM is formulated to store oxygen released from the LiTMO.

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: Lithium-ion cells and methods for producing such cells are provided. The lithium-ion cells include a lithium metal anode (LMA), a cathode, and an electrolyte between the LMA and the cathode. The LMA includes a current collector and a deformable layer on a surface of the current collector. The deformable layer is lithium-ion conductive and includes a polymeric material. The cathode has a lithium intercalation material. In some examples, lithium metal is plated on the deformable layer during charge of the lithium-ion cell to define a plated lithium layer between the deformable layer and the electrolyte, and a solid electrolyte interphase (SEI) layer forms on the plated lithium layer separating the plated lithium layer from the electrolyte.

Abstract: A battery pack for a vehicle includes a housing including at least one pack vent between an interior and an exterior of the housing. A plurality of battery cells are contained within the housing. A channel tray includes channel arrays having a plurality of vent openings each positioned in connection with a vent on each of the plurality of battery cells. The channel arrays are in connection with the at least one vent of the housing, wherein the channel system is enclosed from the rest of the volume of the pack and the plurality of vent openings are each provided with a vent cover.

Abstract: An anode for a rechargeable battery cell includes an electrode substrate and a current collector fixed to the electrode substrate. The anode also includes an active layer arranged on the current collector and having discrete first material sections and at least one second material section arranged in an alternating pattern. Each discrete material section is aligned parallel to the current collector. The active layer is configured to intercalate transient ions during charging of the battery cell and de-intercalate the transient ions during discharging of the battery cell. A method of manufacturing such an anode for a rechargeable battery cell is also considered.

Abstract: An anode for a rechargeable battery cell includes an electrode substrate and a current collector fixed to the electrode substrate. The anode also includes an active layer arranged on the current collector and having discrete first material sections and second material sections arranged in an alternating pattern. Each discrete material section is aligned perpendicular to the current collector. The active layer is configured to intercalate transient ions during charging of the battery cell and de-intercalate the transient ions during discharging of the battery cell. A method of manufacturing such an anode for a rechargeable battery cell is also considered.

Abstract: An enclosure for one of a battery module or battery pack includes a body configured to receive at least one of a plurality of battery modules and a plurality of battery cells. A cover is arranged over the body and includes an outer metallic layer, a composite layer arranged adjacent to an inner surface of the outer metallic layer and including reinforcing fibers encapsulated in resin, and a coating layer arranged on an inner surface of the composite layer and including a molecular nitrogen releasing agent.

Abstract: An anode electrode comprises an anode current collector. An anode active material layer comprises anode active material comprising at least one of lithium silicon oxide, silicon oxide, lithium silicon oxide and graphite, and silicon oxide and graphite. The anode active material layer further comprises a binder comprising a mixture of styrene butadiene rubber (SBR), sodium carboxymethyl cellulose (NaCMC) and sodium polyacrylic acid (NaPAA), wherein SBR comprises greater than 60% wt of the binder.

Abstract: A battery that cycles lithium ions includes a positive electrode, a negative electrode, and an electrolyte infiltrating the positive electrode and the negative electrode. The negative electrode comprises a silicon-containing electroactive active material. The electrolyte includes an organic solvent, an inorganic lithium salt, and a fluoroalkoxysilane additive.