Abstract: A system for inspecting a battery component includes a heating device configured to heat a surface of the battery component to a selected temperature, an optical-visible imaging device configured to take an optical image of the surface, a thermal imaging device configured to take a thermal image of the surface, and a processor configured to acquire the optical image and the thermal image. The processor is configured to correlate the thermal image with the optical image, identify a feature of interest in at least one of the optical image and the thermal image, determine a geometric characteristic and a temperature characteristic associated with the feature of interest, and determine whether the feature of interest is a defect based on the geometric characteristic and the temperature characteristic.

Abstract: A method to create a garnet-based solid electrolyte separator for a battery cell is provided. The method includes coating a garnet-based material powder, initially including a lithium carbonate layer upon an outer surface of the garnet-based material powder, with aluminum fluoride to create a fluoride-treated garnet-based material powder. The method further includes operating a solid-state reaction upon the fluoride-treated garnet-based material powder, such that the aluminum fluoride reacts with the lithium carbonate layer to create aluminum oxide, carbon dioxide, and lithium fluoride. The solid-state reaction creates a fluoride-treated and solid-state reacted garnet-based material powder including the aluminum oxide and the lithium fluoride. The method further includes sintering the fluoride-treated and solid-state reacted garnet-based material powder including the aluminum oxide and the lithium fluoride.

Abstract: An electrode stack for a solid-state battery is provided. The electrode stack includes a cathode. The cathode includes a cathode current collector and a first layer of material applied to the cathode current collector. The first layer of material includes a cathode active material, a first ionomer configured as a first binder, and a conductive material. The electrode stack further includes a solid electrolyte separator layer, including a second ionomer configured as a second binder. The electrode stack further includes an anode including a layer including lithium metal, silicon, or graphite and an anode current collector. One of the first ionomer and the second ionomer includes a shape-memory ionomer configured for selectively restoring the electrode stack to an original shape.

Abstract: A thermal barrier component for an electrochemical cell according to various aspects of the present disclosure includes a functional material. The functional material includes at least one of a hydrate of a metal carbonate and a hydrate of a metal phosphate. The functional material is configured to release water vapor at a first temperature of greater than or equal to about 100° C. and decompose to release a gaseous fire retardant at a second temperature of greater than or equal to about 300° C. Another thermal barrier component according to various aspects of the present disclosure includes a hydrate and a fire retardant. The hydrate is configured to release water in an amount greater than or equal to about 1 kg at a first temperature of greater than or equal to about 100° C. The fire retardant is configured to decompose at a second temperature of greater than or equal to about 300° C.

Abstract: A thermal barrier component for an electrochemical cell (e.g., a battery) includes a mat, a functional material, and a polymer binder. The mat includes a porous matrix. The functional material is in pores of the porous matrix. The functional material includes an oxide. In certain aspects, the functional material may be a composite material. The polymer binder is in contact with the porous matrix and the functional material. At least one of the porous matrix, the functional material, and the polymer binder is configured to serve as an intumescent carbon source. The oxide is configured to catalyze thermal degradation of the intumescent carbon source to form intumescent carbon at a first temperature. The first temperature is greater than or equal to about 300° C. The thermal barrier component is configured to mitigate thermal runaway in an electrochemical cell. The thermal barrier component may include one or more layers.

Abstract: A method to create a battery cell is provided. The method includes, within a vacuum or an inert atmosphere, utilizing an etching process to remove a passivation layer from a primary surface of a solid electrolyte. The method further includes applying a surface coating to the primary surface. The method further includes, within the battery cell, disposing the solid electrolyte including the surface coating between an anode and a cathode.

Abstract: A pressing machine includes pressing devices, actuators and a control module. At least one of the pressing devices includes a surface having a fluoropolymer material. At least one of the actuators is configured to adjust pressure of the pressing devices on one or more lithium foils, such that the surface presses against one of the one or more lithium foils to form a protective layer. The control module is configured to control the at least one of the actuators to adjust a parameter to control at least one of thickness of the protective layer and fluoride content of the protective layer.

Abstract: A self-protecting functional separator for a battery cell is provided. The self-protecting functional separator includes a polymer substrate including a first primary surface and a second primary surface. The self-protecting functional separator further includes a functional layer applied to the first primary surface. The functional layer including a mixture includes a first piezoelectric material including a single crystal-type material and a second piezoelectric material.

Abstract: A negative electrode for a secondary lithium battery is provided herein, as well as a method for assembling a secondary lithium battery including the negative electrode. The negative electrode includes a current collector having a first side and an opposite second side. A first negative electrode layer is disposed on the first side of the current collector and a second negative electrode layer is disposed on the second side of the current collector. A lithium metal layer is disposed (i) between the first and second negative electrode layers or (ii) on a major facing surface of the first or second negative electrode layer. An electrolyte infiltrates the first and second negative electrode layers and is in contact with the lithium metal layer. The electrolyte establishes a lithium ion transport path between the lithium metal layer and at least one of the first or second negative electrode layers.

Abstract: A coated polymer separator for a battery cell is provided. The coated polymer separator includes a polymer separator including a first primary surface and a second primary surface. The coated polymer separator further includes a ceramic-based composite coating disposed on the first primary surface and the second primary surface. The ceramic-based composite coating includes lithiated zeolite particles and particles of a second ceramic material including an oxide.

Abstract: Electrochemical cells and methods for making electrochemical cells are provided. In one example, an electrochemical cell includes a positive electrode, a negative electrode, and a separator that is disposed between the positive and negative electrodes. The separator is electrically insulating and ionically conductive. An electrolyte is operatively disposed between the positive and negative electrodes and interfaces with the separator to conduct ions between the positive and negative electrodes. A porous ceramic powder impregnated with an intermediate oxidation state alkali metal compound is coupled to one of the separator and the positive electrode.

Abstract: An electrode for an electrochemical cell is provided. The electrode includes a carbon membrane having a first face and an opposing second face, wherein at least a portion of the carbon membrane is modified to include an elevated number of nucleation sites for lithium relative to the carbon membrane when unmodified.

Abstract: A battery cell includes an inner plastic layer, an outer plastic layer, and a middle metal layer. The inner and outer plastic layers extends along at least three of sides of the battery cell. The middle metal layer is disposed between the inner and outer plastic layers. The middle metal layer extends along the at least three sides of the battery cell and projects from at least a fourth side of the battery cell to form at least one heat dissipation tab. The at least one heat dissipation tab is configured to transfer heat to at least one cooling plate through thermal conduction. The fourth side of the battery cell connects two of the at least three sides to one another.

Abstract: The present disclosure relates to a negative electrode material and methods of preparation and use relating thereto. The electrode material comprises a plurality of electroactive material particles, where each electroactive material particle includes an electroactive material core and an electronically conductive coating. The method includes contacting an electroactive material precursor including a plurality of electroactive material particles with a solution so as to form an electronically conductive coating on each of the electroactive material particles. The solution includes a solvent and one or more of copper fluoride (CuF2), titanium tetrafluoride (TiF3 or TiF4), iron fluoride (FeF3), nickel fluoride (NiF2), manganese fluoride (MnF2, MnF3, or MnF4), and vanadium fluoride (VF3, VF4, VF5). The electronically conductive coating includes a plurality of first regions and a plurality of second regions. The plurality of first regions include lithium fluoride.

Abstract: A method of reforming a negative electrode layer of a secondary lithium battery may include execution of a reforming cycle that reforms a major facing surface of the negative electrode layer by eliminating at least a portion of a lithium dendrite or other lithium-containing surface irregularity that has formed on the major facing surface of the negative electrode layer.

Abstract: An electrochemical cell includes a first electrode that includes a first current collector and a first electroactive material layer disposed on or near the first current collector, a second electrode that includes a second current collector and a second electroactive material layer disposed on or near the second current collector, and a separating layer disposed between the first electroactive material layer and the second electroactive material layer. The second electroactive material layer includes a plurality of hierarchical silicon columns, each of the hierarchical silicon columns has a longest dimension perpendicular to a major axis of the second current collector. The second electroactive material layer also includes a carbonaceous network that at least partially fills interstices defined between hierarchical silicon columns of the plurality of hierarchical silicon columns. The carbonaceous network includes linked carbon atoms that define a plurality of pores.

Abstract: A battery cell includes an anode electrode comprising a first current collector. Anode active material is arranged on a first surface of the first current collector and is configured to exchange lithium ions. The anode active material comprises silicon. Empty spaces are formed in the anode active material in a predetermined pattern. A solid electrolyte layer is arranged adjacent to the anode electrode. A cathode electrode comprises a second current collector and cathode active material configured to exchange lithium ions and arranged adjacent to the solid electrolyte layer.

Abstract: A solid-state electrochemical cell that cycles lithium ions includes a solid-state electrolyte that defines a first major surface and an electrode that defines a second major surface. The solid-state electrochemical cell also includes an interfacial layer disposed between the first major surface of the solid-state electrolyte and the second major surface of the electrode. The interfacial layer may include an ion-conductor disposed in an organic matrix.

Abstract: Catalyst systems that are resistant to high-temperature sintering and methods for preparing such catalyst systems that are resistant to sintering at high temperatures are provided. Methods of forming such catalyst systems include contacting a support having a surface including a catalyst particle with a solution comprising a metal salt and having an acidic pH. The metal salt is precipitated onto the surface of the support. Next, the metal salt is calcined to selectively generate a porous coating of metal oxide on the surface of the support distributed around the catalyst particle.

Abstract: Presented are silicon and other anodes and methods for producing same. In one aspect of the disclosure, a pristine anode material is prelithiated to produce a prelithiated anode substrate. Precursors are combined, such as using a flow into a deposition chamber, to produce a target chemical formulation formed as a hydrophobic and hermetic protective coating over the prelithiated Si-anode substrate. The result is a protected anode substrate. A laser may thereafter be used for further processing of the protected the protected anode substrate to form an anode. In other embodiments, a silicon oxide anode, a graphite anode, or a silicon-graphite blended anode is used.