Abstract: Methods for manufacturing electrodes include applying a fluoropolymer film to a lithium-based host material, defluorinating the fluoropolymer film by heating to produce a lithium electrode having a solid electrolyte interface (SEI) layer including defluorinated fluoropolymers and at least about 5 wt. % LiF. The fluoropolymers can include one or more of fluorinated ethylenepropylene, perfluoroalkoxy alkanes, vinylidenefluoride, and copolymers of perfluoromethylvinylether and tetrafluoroethylene. The fluoropolymers can include one or more fluorinated monomers, including hexafluoropropylene, tetrafluoroethylene, ethylene-tetrafluoroethylene, perfluoroethers, and vinylidene fluoride. The —CF3 functional groups of the defluorinated fluoropolymers can be about 3 wt. % to about 10 wt. % of the SEI layer. The SEI layer can include about 30 wt. % to about 50 wt. % LiF.

Abstract: An electrode includes a domain material present in an amount of from about 90 to about 95 weight percent based on a total weight of the electrode. The domain material includes a component that has the formula: xLi2MnO3.(1?x)LiNiaMnbCo(1-a-b)O2, wherein x is greater than 0 and less than 1 and each of a and b is independently from about 0.1 to about 0.9 and the component is present in an amount of from about 50 to about 90 weight percent based on a total weight of the domain material. The domain material also includes an additive component having the formula LiFe1-yMnyPO4, wherein y is greater than 0 and less than 1, wherein the additive component is present in an amount of from about 10 to about 50 weight percent based on a total weight of the domain material. The electrode itself further includes a carbonaceous material and a binder.

Abstract: Solvent-free methods of making a component, like an electrode, for an electrochemical cell are provided. A particle mixture is processed in a dry-coating device having a rotatable vessel defining a cavity with a rotor. The rotatable vessel is rotated at a first speed in a first direction and the rotor at a second speed in a second opposite direction. The particle mixture includes first inorganic particles (e.g., electroactive particles), second inorganic particles (e.g., ceramic HF scavenging particles), and third particles (e.g., electrically conductive carbon-containing particles). The dry coating creates coated particles each having a surface coating (including second inorganic particles and third particles) disposed over a core region (the first inorganic particle). The coated particles are mixed with polymeric particles in a planetary and centrifugal mixer that rotates about a first axis and revolves about a second axis. The polymeric particles surround each of the plurality of coated particles.

Abstract: A negative electrode according to various aspects of the present disclosure includes a negative electroactive material and a layer. The negative electroactive material includes a lithium-aluminum alloy. The layer is disposed directly on at least a portion of the negative electroactive material and coupled to the negative electroactive material. The layer includes anodic aluminum oxide and has a plurality of pores. The present disclosure also provides an electrochemical cell including the negative electrode. In certain aspects, the negative electroactive material is electrically conductive and functions as a negative electrode current collector such that the electrochemical cell is free of a distinct negative electrode current collector component. In certain aspects, the layer is ionically conductive and electrically insulating and functions as a separator such that the electrochemical cell is free of a distinct separator component.

Abstract: A ceramic-coated separator for a lithium-containing electrochemical cell and methods of preparing the ceramic-coated separator are provided. The ceramic-coated separator may be manufactured by preparing a slurry that includes one or more lithiated oxides and a binder and disposing the slurry onto one or more surfaces of a porous substrate. The slurry may be dried to from a ceramic coating on the one or more surfaces of the porous substrate so as to create the ceramic-coated separator. The ceramic coating may include one or more lithiated oxides selected from Li2SiO3, LiAlO2, Li2TiO3, LiNbO3, Li3PO4, Li2CrO4, and Li2Cr2O7.

Abstract: A method of modifying a carbonate layer formed on a surface of an electrochemical cell component is provided. The surface includes a ceramic oxide. The carbonate layer includes a carbonate and is substantially non-conductive to lithium ions and sodium ions. The method includes contacting the carbonate layer with a modifying agent to form a mixture and causing the modifying agent to incorporate into the carbonate layer and form a modified hybrid layer including a eutectic mixture of the modifying agent and the carbonate. The modified hybrid layer is conductive to lithium ions and sodium ions.

Abstract: A method of making an electrode material for an electrode in an electrochemical cell that cycles lithium ions is provided, where a protective coating is applied to an electrode precursor material. The electrode precursor may be a silicon-containing composition. The protective coating is selected from the group consisting of: an oxide-based coating, a fluoride-based coating, and a nitride-based coating. The method also includes lithiating the electrode precursor material in a continuous process. The continuous process is conducted in a reactor having a first reaction chamber and a second reaction chamber to form a lithiated electrode material comprising the protective coating.

Abstract: A negative electrode for an electrochemical cell of a secondary lithium metal battery may comprise a metal substrate, a lithium metal layer overlying a major surface of the metal substrate, and a protective interfacial layer formed on a major surface of the lithium metal layer over the metal substrate. The protective interfacial layer may comprise a stack of monomolecular layers including at least one aryl siloxane monomolecular layer overlying the major surface of the lithium metal layer. The protective interfacial layer may be formed on the major surface of the lithium metal layer by applying a mixture of monoaryl silanes to the major surface of the lithium metal layer.

Abstract: Methods of removing a passivation layer on a lithium-containing electrode and preparing a protective coating on the lithium-containing electrode by applying a graphene source are provided herein. A lithium-containing electrode with the protective coating including graphene and lithium-containing electrochemical cells including the same are also provided herein.

Abstract: An electrode including an electrode active material and a mesoporous film coating at least a portion of the electrode active material is provided. The mesoporous film coats at least a portion of the electrode active material and includes M2SiO3, MAlO2, M2O—Al2O3—SiO2, or combinations thereof, where M is lithium (Li), sodium (Na), or a combination thereof. Methods of fabricating the electrode are also provided.

Abstract: Lithiated electrodes, electrochemical cells including lithiated electrodes, and methods of making the same are provided. The method includes lithiating at least one electrode in an electrochemical cell by applying current across a first current collector of the at least one electrode to a second current collector of an auxiliary electrode. The electrochemical cell may be disposed within a battery packaging and the auxiliary electrode may be disposed within the battery packaging adjacent to an edge of the electrochemical cell. The at least one electrode may include a first electroactive layer disposed on or near one or more surfaces of the first current collector, and the auxiliary electrode may include a second electroactive layer disposed at or near one or more surfaces of the second current collector. The method may further include extracting the auxiliary electrode from the battery packaging and sealing the battery packaging, which includes the pre-lithiated electrochemical cell.

Abstract: Methods of making a solid-state electrochemical cell that cycles lithium ions are provided that include applying a liquid metal composition comprising gallium to a first major surface of either a solid-state electrolyte or a solid electrode (e.g., lithium metal) in the presence of an oxidant and in an environment substantially free of water to reduce surface tension of the liquid metal composition so that it forms a continuous layer over the first major surface. The first major surface having the continuous layer of liquid metal composition is contacted with a second major surface to form a continuous interfacial layer between the solid-state electrolyte and the solid electrode. Solid-state electrochemical cells formed by such methods are also provided, where the metal composition comprising gallium is a liquid in a temperature range of greater than or equal to about 20° C. to less than or equal to about 30° C.

Abstract: Methods of making negative electrode materials for an electrochemical cell that cycles lithium ions are provided. A surface of the electrode material formed of silicon, silicon-containing alloys, tin-containing alloys, or combinations thereof is treated with an oxidant at a first temperature of greater than or equal to about 100° C. to form a continuous intermediate layer comprising oxides. The method also includes pyrolyzing a carbon-containing precursor over the continuous intermediate layer at a second temperature of greater than or equal to about 600° C. to form a continuous carbon coating thereon. The intermediate layer oxides may be transformed to carbides. The continuous carbon coating comprises both graphitic carbon and amorphous carbon and may be a multilayered coating, where the inner layer predominantly includes amorphous carbon and the outer layer predominantly includes graphitic carbon.

Abstract: An electroactive material for use in an electrochemical cell, like a lithium ion battery, is provided. The electroactive material comprises silicon or tin and undergoes substantial expansion during operation of a lithium ion battery. A polymeric ultrathin conformal coating is formed over a surface of the electroactive material. The coating is flexible and is capable of reversibly elongating by at least 250% from a contracted state to an expanded state in at least one direction to minimize or prevent fracturing of the negative electrode material during lithium ion cycling. The coating may be applied by vapor precursors reacting in atomic layer deposition (ALD) to form conformal ultrathin layers over the electroactive materials. Methods for making such materials and using such materials in electrochemical cells are likewise provided.

Abstract: A method of manufacturing a silicon-carbon composite electrode assembly for an electrochemical cell includes forming an electrode by pyrolyzing at least a portion of a polymer in an assembly to form pyrolyzed carbon. The assembly includes an electrode precursor in electrical contact with a current collector. The electrode precursor includes a polymer and an electroactive material. The electroactive material includes silicon. The current collector includes an electrically-conductive material. The pyrolyzing includes directing an energy stream toward a surface of the electrode precursor. The surface is disposed opposite the current collector. The silicon-carbon composite electrode assembly includes the electrode and the current collector. In certain variations, the energy stream includes a laser beam or a plasma jet. In certain aspects, the electrode defines a concentration gradient between a first surface and a second surface.

Abstract: An electrode including an electrode active material including lithium (Li) and a polymer layer coating at least a portion of the electrode active material is provided. The polymer layer includes a polymerization product of a monomer having Formula I: where R1 and R2 are independently an aryl or a branched or unbranched C1-C10 alkyl and X1 and X2 are independently chlorine (Cl), bromine (Br), or iodine (I).

Abstract: An electrode including an electrode active material and a ceramic hydrofluoric acid (HF) scavenger is provided. The ceramic hydrofluoric acid (HF) scavenger includes M2SiO3, MAlO2, M2O—Al2O3—SiO2, or combinations thereof, where M is lithium (Li), sodium (Na), or combinations thereof. Methods of making the electrode are also provided.

Abstract: A method of modifying a carbonate layer formed on a surface of an electrochemical cell component is provided. The surface includes a ceramic oxide. The carbonate layer includes a carbonate and is substantially non-conductive to lithium ions and sodium ions. The method includes contacting the carbonate layer with a modifying agent to form a mixture and causing the modifying agent to incorporate into the carbonate layer and form a modified hybrid layer including a eutectic mixture of the modifying agent and the carbonate. The modified hybrid layer is conductive to lithium ions and sodium ions.

Abstract: Methods of forming a plurality of axial geometry carbon structures (e.g., carbon nanotubes or carbon fibers) in situ in an electrode of an electrochemical cell that cycles lithium ions are provided. Electroactive particles that undergo volumetric expansion are mixed with a polymer precursor and a plurality of catalytic nanoparticles comprising a metal selected from the group consisting of: iron, nickel, cobalt, alloys, and combinations thereof to form a substantially homogeneous slurry. The slurry is applied to a substrate and then heated in an environment having a temperature of ?about 1000° C. and in certain aspects, ?about 895° C. to pyrolyze the polymer precursor. The plurality of catalytic nanoparticles facilitates in situ precipitation of carbon to grow a plurality of axial geometry carbon structures. After the heating, the electrode includes an electrically conductive carbonaceous porous network comprising the plurality of electroactive particles and the plurality of axial geometry carbon structures.

Abstract: A porous separator for a lithium-containing electrochemical cell is provided herein. The porous separator includes a porous substrate and an active layer comprising lithium ion-exchanged zeolite particles. Methods of manufacturing the porous separator and lithium-containing electrochemical cells including the porous separator are also provided herein.