Transfer lamination of electrodes in silicon-dominant anode cells

Systems and methods are provided for high volume roll-to-roll transfer lamination of electrodes for silicon-dominant anode cells.

Method And System For Silicon-Dominant Lithium-Ion Cells With Controlled Utilization of Silicon

Systems and methods for silicon-dominant lithium-ion cells with controlled utilization of silicon may include a cathode, an electrolyte, and an anode, where the anode has an active material comprising more than 50% silicon. The battery may be charged by lithiating silicon while not lithiating carbon. The active material may comprise more than 70% silicon. A voltage of the anode during discharge of the battery may remain above a minimum voltage at which silicon can be lithiated. The anode may have a specific capacity of greater than 3000 mAh/g. The battery may have a specific capacity of greater than 1000 mAh/g. The anode may have a greater than 90% initial Coulombic efficiency and may be polymer binder free. The battery may be charged at a 10 C rate or higher. The battery may be charged at temperatures below freezing without lithium plating. The electrolyte may comprise a liquid, solid, or gel. 1. A battery , the battery comprising:a cathode, an electrolyte, and an anode, the anode having an active material comprising more than 50% silicon, and wherein the battery is charged by lithiating silicon while lithiating less than 20% of carbon in the active material.2. The battery according to claim 1 , wherein the active material comprises more than 70% silicon.3. The battery according to claim 1 , wherein a voltage of the anode during discharge of the battery remains above a minimum voltage at which silicon can be lithiated.4. The battery according to claim 1 , wherein the anode has a specific capacity of greater than 3000 mAh/g.5. The battery according to claim 1 , wherein the battery has a specific capacity of greater than 1000 mAh/g.6. The battery according to claim 1 , wherein the anode has a greater than 90% initial Coulombic efficiency.7. The battery according to claim 1 , wherein the anode active material has no polymer binder.8. The battery according to claim 1 , wherein the battery is operable to be charged at a 10 C rate or higher while retaining at least 50% ...

METHOD AND SYSTEM FOR CONTINUOUS LAMINATION OF BATTERY ELECTRODES

Systems and methods for continuous lamination of battery electrodes may include a cathode, an electrolyte, and an anode, where the anode includes a current collector, a cathode, an electrolyte, and an anode, the anode comprising a polymeric adhesive layer coated onto the current collector, and an active material coated onto the polymeric adhesive layer such that the polymeric adhesive layer is arranged between the active material and the current collector, wherein the anode is subjected to a heat treatment to induce pyrolysis after application of the polymeric adhesive layer to the current collector and application of the active material to the polymeric adhesive layer, the heat being applied to the anode at a temperature between 500 and 850 degrees C.

Anisotropic Expansion of Silicon-Dominant Anodes

Systems and methods for anisotropic expansion of silicon-dominant anodes may include a cathode, an electrolyte, and an anode, where the anode may include a current collector and an active material on the current collector. An expansion of the anode during operation may be configured by a roughness and/or thickness of the current collector, a metal used for the current collector, and/or a lamination process that adheres the active material to the current collector. The expansion of the anode may be more anisotropic for thicker current collectors. A thicker current collector may be 10 μm thick or greater. The expansion of the anode may be more anisotropic for more rigid materials used for the current collector. A more rigid current collector may include nickel and a less rigid current collector may include copper. The expansion of the anode may be more anisotropic for a rougher surface current collector.

DIRECT COATING OF ELECTRODES IN SILICON-DOMINANT ANODE CELLS

Systems and methods are provided for high volume roll-to-roll direct coating of electrodes for silicon-dominant anode cells.

TRANSFER LAMINATION OF ELECTRODES IN SILICON-DOMINANT ANODE CELLS

Systems and methods are provided for high volume roll-to-roll transfer lamination of electrodes for silicon-dominant anode cells. 1. A system for continuous roll-to-roll electrode processing , the system comprising:a plurality of carrier films, wherein each carrier film of the plurality of carrier films has applied thereon at a start of electrode processing in the system, at least one precursor composite film;one or more heat treatment ovens, wherein each of the one or more heat treatment ovens is configured for applying pyrolysis to at least one carrier film of the plurality of carrier films, to convert a corresponding precursor composite film on the at least one carrier film to a pyrolyzed composite film; anda plurality of press rollers, wherein at least two of the plurality of press rollers are configured for pressing onto two sides of a current collector film, two pyrolyzed mixture films, with each one of the two pyrolyzed mixture films being applied from one of two corresponding different carrier films of the plurality of carrier films, to create a corresponding electrode composite film, wherein the two corresponding different carrier films of the plurality of carrier films are separated after the pressing.2. The system of claim 1 , wherein the at least one precursor composite film comprises silicon (Si).3. The system of claim 1 , comprising a plurality of moving rollers claim 1 , configured for moving the plurality of carrier films during the electrode processing in the system.4. The system of claim 1 , wherein each of the one or more heat treatment ovens is configured to apply the pyrolysis at a temperature >500° C.5. The system of claim 1 , wherein each of the one or more heat treatment ovens is configured to apply the pyrolysis in a reducing atmosphere.6. The system of claim 5 , wherein each of the one or more heat treatment ovens is configured to create reducing atmosphere related conditions claim 5 , the reducing atmosphere related conditions comprising ...

Method and system for continuous lamination of battery electrodes

Systems and methods for continuous lamination of battery electrodes may include a cathode, an electrolyte, and an anode, where the anode includes a current collector, a cathode, an electrolyte, and an anode, the anode comprising a polymeric adhesive layer coated onto the current collector, and an active material coated onto the polymeric adhesive layer such that the polymeric adhesive layer is arranged between the active material and the current collector, wherein the anode is subjected to a heat treatment to induce pyrolysis after application of the polymeric adhesive layer to the current collector and application of the active material to the polymeric adhesive layer, the heat being applied to the anode at a temperature between 500 and 850 degrees C.

CATALYSTS AND METHODS FOR LOWERING ELECTRODE PYROLYSIS TEMPERATURE

Systems and methods are disclosed that provide for pyrolysis reactions to be performed at reduced temperatures that convert non-conductive precursor polymers to conductive carbon suitable for use in electrode materials, which may be incorporated into a cathode, an electrolyte, and an anode, where the pyrolysis method may include one or more catalysts or reactive reagents.

CONTROL OF THERMAL TRANSFER DURING ELECTRODE PYROLYSIS BASED PROCESSING

Systems and methods are provided for control of thermal transfer during electrode pyrolysis based processing. A thermal rod may be used for processing battery electrodes, with the thermal rod being configured for engaging an electrode roll. At least a portion of the thermal rod is disposed within the electrode roll once it is engaged with the electrode roll, and the thermal rod is configured for providing thermal transfer into the electrode roll during processing of the electrode roll, with the processing including pyrolysis processing of the electrode roll. 1. An apparatus for processing battery electrodes , the apparatus comprising: [ the electrode roll comprises a sheet comprising electrode material applied on a current collector rolled to create concentric alternating layers of electrode material and current collector, and', 'at least a portion of the thermal rod is disposed within the electrode roll once engaged, with at least a portion of the thermal rod being disposed within the concentric alternating layers of electrode material and current collector; and, 'the thermal rod is configured for engaging an electrode roll, wherein, 'the thermal rod is configured for providing thermal transfer into the electrode roll during processing of the electrode roll, the processing comprising pyrolysis processing of the electrode roll., 'a thermal rod, wherein2. The apparatus of claim 1 , wherein the thermal rod is configured for providing one or both of cooling thermal transfer and heating thermal transfer.3. The apparatus of claim 2 , wherein the thermal rod is configured for providing cooling thermal transfer based on a predefined cooling model for the electrode roll.4. The apparatus of claim 1 , wherein the thermal rod is configured for engaging the electrode roll by insertion via an internal space within the electrode roll.5. The apparatus of claim 4 , wherein the electrode roll comprises a hollow cylindrical core creating a corresponding cylindrical space within the ...

Reaction barrier between electrode active material and current collector

Systems and methods are provided for a reaction barrier between an electrode active material and a current collector. An electrode may comprise an active material, a metal foil, and a polymer. The polymer (such as polyamide-imide (PAI)) may be configured to provide a carbonized barrier between the active material and the metal foil after pyrolysis.

Direct coating of electrodes in silicon-dominant anode cells

Systems and methods are provided for high volume roll-to-roll direct coating of electrodes for silicon-dominant anode cells and may include applying a slurry to a current collector film, the slurry comprising silicon particles and a binder material; drying the slurry to form a precursor composite film; rolling the current collector film into a precursor composite roll; and applying a heat treatment to the precursor composite film and the current collector film in a nitrogen gas environment, wherein the heat treatment is configured for converting the precursor composite film to a pyrolyzed composite film. The heat treatment may include one or both of: applying the heat treatment to a roll comprising the precursor composite roll in whole; and applying the heat treatment to the current collector film as it is continuously fed from the precursor composite roll.

TRANSFER LAMINATION OF ELECTRODES IN SILICON-DOMINANT ANODE CELLS

Systems and methods are provided for high volume roll-to-roll transfer lamination of electrodes for silicon-dominant anode cells.

Method and system for silicon-dominant lithium-ion cells with controlled utilization of silicon

Systems and methods for silicon-dominant lithium-ion cells with controlled utilization of silicon may include a cathode, an electrolyte, and an anode, where the anode has an active material comprising more than 50% silicon. The battery may be charged by lithiating silicon while not lithiating carbon. The active material may comprise more than 70% silicon. A voltage of the anode during discharge of the battery may remain above a minimum voltage at which silicon can be lithiated. The anode may have a specific capacity of greater than 3000 mAh/g. The battery may have a specific capacity of greater than 1000 mAh/g. The anode may have a greater than 90% initial Coulombic efficiency and may be polymer binder free. The battery may be charged at a 10C rate or higher. The battery may be charged at temperatures below freezing without lithium plating. The electrolyte may comprise a liquid, solid, or gel.

Transfer lamination of electrodes in silicon-dominant anode cells

Systems and methods are provided for high volume roll-to-roll transfer lamination of electrodes for silicon-dominant anode cells.

Method And System For Collocated Gasoline Pumps And Charging Stations For Ultra-High Speed Charging

Systems and methods for collocated gasoline pumps and electric vehicle charging stations for ultra-high speed charging may include a fuel station having fuel pumps, electric vehicle supply equipment, and a charge buffer. The charge buffer may receive electric current from an electricity supply grid and supply current to the electric vehicle supply equipment. The electric vehicle supply equipment may be configured to control throttling down of maximum charging power based on a type of cell. The controlling may include delaying the throttling for a first type of cell relative to a second type of cell. The electric vehicle supply equipment may be configured to apply a voltage to batteries above their battery voltage limit when charging. The electric vehicle supply equipment may charge batteries at a rate greater than 4 C, 5.6 C, or 10 C. The electric vehicle supply equipment may supply greater than 120 kW.

Configuring anisotropic expansion of silicon-dominant anodes using particle size

Systems and methods for configuring anisotropic expansion of silicon-dominant anodes using particle size may include a cathode, an electrolyte, and an anode, where the anode may include a current collector and an active material on the current collector. An expansion of the anode during operation may be configured by utilizing a predetermined particle size distribution of silicon particles in the active material. The expansion of the anode may be greater for smaller particle size distributions, which may range from 1 to 10 μm. The expansion of the anode may be smaller for a rougher surface active material, which may be configured by utilizing larger particle size distributions that may range from 5 to 25 μm. The expansion may be configured to be more anisotropic using more rigid materials for the current collector, where a more rigid current collector may comprise nickel and a less rigid current collector may comprise copper.

CONFIGURING ANISOTROPIC EXPANSION OF SILICON-DOMINANT ANODES USING PARTICLE SIZE

Systems and methods for configuring anisotropic expansion of silicon-dominant anodes using particle size may include a cathode, an electrolyte, and an anode, where the anode may include a current collector and an active material on the current collector. An expansion of the anode during operation may be configured by utilizing a predetermined particle size distribution of silicon particles in the active material. The expansion of the anode may be greater for smaller particle size distributions, which may range from 1 to 10 μm. The expansion of the anode may be smaller for a rougher surface active material, which may be configured by utilizing larger particle size distributions that may range from 5 to 25 μm. The expansion may be configured to be more anisotropic using more rigid materials for the current collector, where a more rigid current collector may comprise nickel and a less rigid current collector may comprise copper. 1. A battery , the battery comprising: a current collector; and', 'an active material layer directly on the current collector without an adhesive layer between the active material layer and the current collector, wherein a lateral expansion of the anode during operation is configured to be less than 2% by utilizing a predetermined particle size distribution of silicon particles in the active material layer., 'a cathode, an electrolyte, and an anode, the anode comprising2. The battery according to claim 1 , wherein the expansion of the anode is greater for silicon particles with particle size distributions with peaks ranging from 1-10 μm as compared to the expansion of the anode with silicon particles with particle size distributions with peaks greater than 10 μm.3. The battery according to claim 2 , wherein the predetermined particle size distribution has a peak at 10 μm.4. The battery according to claim 1 , wherein the expansion of the anode is configured by a roughness of the active material layer.5. The battery according to claim 4 , wherein ...

CARBON ADDITIVES FOR DIRECT COATING OF SILICON-DOMINANT ANODES

Systems and methods are provided for carbon additives for direct coating of silicon-dominant anodes. An example composition for use in directly coated anodes may include a silicon-dominated anode active material, a carbon-based binder, and a carbon-based additive, with the composition being configured for low-temperature pyrolysis. The low-temperature pyrolysis may be conducted at <850° C. An anode may be formed using a direct coating process of the composition on a current collector. The anode active material may yield silicon constituting between 90% and 95% of weight of the formed anode after pyrolysis. The carbon-based additive may yield carbon constituting between 2% and 6% of weight of the formed anode after pyrolysis. The carbon-based additive may include carbon particles with surface area >65 m2/g.

Method And System For Collocated Gasoline Pumps And Charging Stations For Ultra-High Speed Charging

Systems and methods for collocated gasoline pumps and electric vehicle charging stations for ultra-high speed charging may include a fuel station having fuel pumps, electric vehicle supply equipment, and a charge buffer. The charge buffer may receive electric current from an electricity supply grid and supply current to the electric vehicle supply equipment. The electric vehicle supply equipment may charge batteries at a rate greater than 4 C, 5.6 C, or 10 C. The electric vehicle supply equipment may be configured to charge batteries with silicon-dominant anodes including active material of 50% or more silicon. The charge buffer may be located in an underground former fuel tank. The electric vehicle supply equipment may supply greater than 120 kW. The charge buffer may include an array of capacitors and/or an array of batteries. The electric vehicle supply equipment may be configured to apply a voltage to batteries above their battery voltage limit when charging.

METHODS OF FORMING CARBON-SILICON COMPOSITE MATERIAL ON A CURRENT COLLECTOR

Methods of forming electrodes are described. In some embodiments, the method can include providing a current collector. The method can also include providing a mixture on the current collector. The mixture can include a precursor and silicon particles. The method can further include pyrolysing the mixture on the current collector to convert the precursor into one or more types of carbon phases to form a composite material and to adhere the composite material to the current collector. The one or more types of carbon phases can be a substantially continuous phase with the silicon particles distributed throughout the composite material.

DIRECT COATING OF ELECTRODES IN SILICON-DOMINANT ANODE CELLS

Systems and methods are provided for high volume roll-to-roll direct coating of electrodes for silicon-dominant anode cells. A slurry that includes silicon particles and a binder material may be applied to a current collector film, and the slurry may be processed to form a precursor composite film coated on the current collector film. The current collector film with the coated precursor composite film may be rolled into a precursor composite roll. A heat treatment may be applied to the current collector film with the coated precursor composite film in an environment including nitrogen gas, to convert the coated precursor composite film to a pyrolyzed composite film coated on the current collector film. The heat treatment may include applying the heat treatment to the precursor composite roll in whole and/or applying the heat treatment to the current collector film with the coated precursor composite film as it is continuously fed.

DIRECT COATING OF ELECTRODES IN SILICON-DOMINANT ANODE CELLS

Systems and methods are provided for high volume roll-to-roll direct coating of electrodes for silicon-dominant anode cells and may include applying a slurry to a current collector film, the slurry comprising silicon particles and a binder material; drying the slurry to form a precursor composite film; rolling the current collector film into a precursor composite roll; and applying a heat treatment to the precursor composite film and the current collector film in a nitrogen gas environment, wherein the heat treatment is configured for converting the precursor composite film to a pyrolyzed composite film. The heat treatment may include one or both of: applying the heat treatment to a roll comprising the precursor composite roll in whole; and applying the heat treatment to the current collector film as it is continuously fed from the precursor composite roll.

Anisotropic Expansion of Silicon-Dominant Anodes

Systems and methods for anisotropic expansion of silicon-dominant anodes may include a cathode, an electrolyte, and an anode, where the anode may include a current collector and an active material on the current collector. An expansion of the anode during operation may be configured by a metal used for the current collector, and/or a lamination process that adheres the active material to the current collector. The expansion of the anode may be more anisotropic for thicker current collectors. A thicker current collector may be 10 μm thick or greater. The expansion of the anode may be more anisotropic for more rigid materials used for the current collector. A more rigid current collector may include nickel and a less rigid current collector may include copper. The expansion of the anode may be more anisotropic for a rougher surface current collector.

ANISOTROPIC EXPANSION OF SILICON-DOMINANT ANODES

Systems and methods for anisotropic expansion of silicon-dominant anodes may include forming an anode by pyrolyzing an active material layer comprising a binder and silicon particles in a temperature range of 600 to 800° C.; and forming a battery cell comprising a cathode, an electrolyte, and the anode, where the anode comprises the pyrolyzed active material layer on a current collector. A lateral expansion of the anode during operation may be less than 2%, less than 1%, or less than 0.6%. The active material layer may be pyrolyzed on the current collector or may be pyrolyzed on a substrate before laminating on the current collector. The anode active material layer may be pyrolyzed using a 1 hour dwell time or less or using a 2 hour dwell time or less. The active material layer may be pyrolyzed in a temperature range of 650 to 800° C.

METHOD AND SYSTEM FOR SILICON DOMINANT LITHIUM-ION CELLS WITH CONTROLLED LITHIATION OF SILICON

Systems and methods for silicon dominant lithium-ion cells with controlled lithiation of silicon may include a cathode, an electrolyte, and an anode. The anode may include silicon lithiated at a level after discharge that is configured to be above a minimum threshold level, where the minimum threshold lithiation is 3% silicon lithiation. The lithiation level of the silicon after charging the battery may range between 30% and 95% silicon lithiation, between 30% and 75% silicon lithiation, between 30% and 65% silicon lithiation, or between 30% and 50% silicon lithiation. The lithiation level of the silicon after discharging the battery may range between 3% and 50% silicon lithiation, between 3% and 30% silicon lithiation, or between 3% and 10% silicon lithiation. The minimum threshold level may be a lithiation level below which a cycle life of the battery degrades. The electrolyte may include a liquid, solid, or gel. 1. A battery , the battery comprising:a cathode, an electrolyte, and an anode, the anode comprising silicon lithiated at a level after discharge that is configured to be above a minimum threshold level, wherein the minimum threshold lithiation is 3% silicon lithiation.2. The battery according to claim 1 , wherein the silicon lithiation level after discharge is configured by a discharge voltage of the anode.3. The battery according to claim 1 , wherein the silicon lithiation level after discharge is ensured to be above the minimum threshold level by a prelithiation of the silicon.4. The battery according to claim 1 , wherein the silicon lithiation level after discharge is configured by an irreversible discharge capacity of the cathode.5. The battery according to claim 1 , wherein the lithiation level of the silicon after charging the battery ranges between 30% and 95% silicon lithiation.6. The battery according to claim 1 , wherein the lithiation level of the silicon after charging the battery ranges between 30% and 75% silicon lithiation.7. The battery ...

TRANSFER LAMINATION OF ELECTRODES IN SILICON-DOMINANT ANODE CELLS

Systems and methods are provided for high volume roll-to-roll transfer lamination of electrodes for silicon-dominant anode cells. 1. A system for continuous roll-to-roll electrode processing with multiple lanes , the system comprising:a heat treatment oven configured for applying pyrolysis concurrently to a plurality of carrier films, to convert a corresponding precursor composite film on each carrier film to a pyrolyzed composite film; and each pair of press rollers is configured to press two pyrolyzed mixture films onto two sides of a current collector film from the plurality of current collector films,', 'the two pyrolyzed mixture films are applied from two different carrier films from the plurality of carrier films, and', 'the two different carrier films of the plurality of carrier films are separated after the pressing., 'a plurality of press rollers arranged in pairs configured for pressing pyrolyzed mixture films onto a plurality of current collector films, wherein2. The system of claim 1 , wherein the at least one precursor composite film comprises silicon (Si).3. The system of claim 1 , comprising a plurality of moving rollers claim 1 , configured for moving the plurality of carrier films during the electrode processing in the system.4. The system of claim 1 , wherein each of the one or more heat treatment ovens is configured to apply the pyrolysis at a temperature >500° C.5. The system of claim 1 , wherein each of the one or more heat treatment ovens is configured to apply the pyrolysis in a reducing atmosphere.6. The system of claim 5 , wherein each of the one or more heat treatment ovens is configured to create reducing atmosphere related conditions claim 5 , the reducing atmosphere related conditions comprising at least one of an inert atmosphere claim 5 , a vacuum claim 5 , or flowing of one or more reducing gases.7. The system of claim 1 , comprising at least one cleaning and inspection component configured for cleaning and inspecting electrode ...

Anisotropic expansion of silicon-dominant anodes

Systems and methods for anisotropic expansion of silicon-dominant anodes may include a cathode, an electrolyte, and an anode, where the anode may include a current collector and an active material on the current collector. An expansion of the anode during operation may be configured by a thickness of the current collector. The expansion of the anode may be more anisotropic for thicker current collectors. A thicker current collector may be 10 μm thick or greater. The expansion of the anode may be more anisotropic for more rigid materials used for the current collector. A more rigid current collector may include nickel and a less rigid current collector may include copper. The expansion of the anode may be more anisotropic for a rougher surface current collector.

Anisotropic expansion of silicon-dominant anodes

Systems and methods for anisotropic expansion of silicon-dominant anodes may include a cathode, an electrolyte, and an anode, where the anode may include a current collector and an active material on the current collector. An expansion of the anode during operation may be configured by a metal used for the current collector, and/or a lamination process that adheres the active material to the current collector. The expansion of the anode may be more anisotropic for thicker current collectors. A thicker current collector may be 10 μm thick or greater. The expansion of the anode may be more anisotropic for more rigid materials used for the current collector. A more rigid current collector may include nickel and a less rigid current collector may include copper. The expansion of the anode may be more anisotropic for a rougher surface current collector.

CATALYSTS AND METHODS FOR LOWERING ELECTRODE PYROLYSIS TEMPERATURE

Systems and methods are disclosed that provide for pyrolysis reactions to be performed at reduced temperatures that convert non-conductive precursor polymers to conductive carbon suitable for use in electrode materials, which may be incorporated into a cathode, an electrolyte, and an anode, where the pyrolysis method may include one or more catalysts or reactive reagents.

Anisotropic Expansion of Silicon-Dominant Anodes

Systems and methods for anisotropic expansion of silicon-dominant anodes may include a cathode, an electrolyte, and an anode, where the anode may include a current collector and an active material on the current collector. An expansion of the anode during operation may be configured by a thickness of the current collector. The expansion of the anode may be more anisotropic for thicker current collectors. A thicker current collector may be 10 μm thick or greater. The expansion of the anode may be more anisotropic for more rigid materials used for the current collector. A more rigid current collector may include nickel and a less rigid current collector may include copper. The expansion of the anode may be more anisotropic for a rougher surface current collector.

CONFIGURING ANISOTROPIC EXPANSION OF SILICON-DOMINANT ANODES USING PARTICLE SIZE

Systems and methods for configuring anisotropic expansion of silicon-dominant anodes using particle size may include a cathode, an electrolyte, and an anode, where the anode may include a current collector and an active material on the current collector. An expansion of the anode during operation may be configured by utilizing a predetermined particle size distribution of silicon particles in the active material. The expansion of the anode may be greater for smaller particle size distributions, which may range from 1 to 10 μm. The expansion of the anode may be smaller for a rougher surface active material, which may be configured by utilizing larger particle size distributions that may range from 5 to 25 μm. The expansion may be configured to be more anisotropic using more rigid materials for the current collector, where a more rigid current collector may comprise nickel and a less rigid current collector may comprise copper.

Reaction barrier between electrode active material and current collector

Systems and methods are provided for a reaction barrier between an electrode active material and a current collector. An electrode may comprise an active material, a metal foil, and a polymer. The polymer (such as polyamide-imide (PAI)) may be configured to provide a carbonized barrier between the active material and the metal foil after pyrolysis.

Anisotropic expansion of silicon-dominant anodes

Systems and methods for anisotropic expansion of silicon-dominant anodes may include forming an anode by pyrolyzing an active material layer comprising a binder and silicon particles in a temperature range of 600 to 800C; and forming a battery cell comprising a cathode, an electrolyte, and the anode, where the anode comprises the pyrolyzed active material layer on a current collector. A lateral expansion of the anode during operation may be less than 2%, less than 1%, or less than 0.6%. The active material layer may be pyrolyzed on the current collector or may be pyrolyzed on a substrate before laminating on the current collector. The anode active material layer may be pyrolyzed using a 1 hour dwell time or less or using a 2 hour dwell time or less. The active material layer may be pyrolyzed in a temperature range of 650 to 800C.

Method and system for collocated gasoline pumps and charging stations for ultra-high speed charging

Direct coating of electrodes in silicon-dominant anode cells

Systems and methods are provided for high volume roll-to-roll direct coating of electrodes for silicon-dominant anode cells.

Direct coating of electrodes in silicon-dominant anode cells

Systems and methods are provided for high volume roll-to-roll direct coating of electrodes for silicon-dominant anode cells.

Carbon additives for direct coating of silicon-dominant anodes

Anisotropic expansion of silicon-dominant anodes

Systems and methods for anisotropic expansion of silicon-dominant anodes may include a cathode, an electrolyte, and an anode, where the anode may include a current collector and an active material on the current collector. An expansion of the anode during operation may be configured by a roughness and/or thickness of the current collector, a metal used for the current collector, and/or a lamination process that adheres the active material to the current collector. The expansion of the anode may be more anisotropic for thicker current collectors. A thicker current collector may be 10 m thick or greater. The expansion of the anode may be more anisotropic for more rigid materials used for the current collector. A more rigid current collector may include nickel and a less rigid current collector may include copper. The expansion of the anode may be more anisotropic for a rougher surface current collector.

Control of thermal transfer during electrode pyrolysis based processing

Systems and methods are provided for control of thermal transfer during electrode pyrolysis based processing. An apparatus for processing battery electrodes may include a core configured for use in forming an electrode roll and a thermal rod. The core is configured to engage a sheet including electrode material applied on a current collector, specifically by rolling the sheet on the core to create concentric alternating layers of electrode material and current collector around an internal space formed by the core. The thermal rod is configured for engaging the electrode roll via the internal space of the core such that, once engaged, at least a portion of the thermal rod is disposed within the concentric alternating layers of electrode material and current collector. The thermal rod is configured to provide thermal transfer into the electrode roll via the core during processing of the electrode roll, with the processing including applying pyrolysis.

Catalysts and methods for lowering electrode pyrolysis temperature

Systems and methods are disclosed that provide for pyrolysis reactions to be performed at reduced temperatures that convert non-conductive precursor polymers to conductive carbon suitable for use in electrode materials, which may be incorporated into a cathode, an electrolyte, and an anode, where the pyrolysis method may include one or more catalysts or reactive reagents.

Catalysts and methods for lowering electrode pyrolysis temperature

Catalysts and methods for lowering electrode pyrolysis temperature

Systems and methods are disclosed that provide for pyrolysis reactions to be performed at reduced temperatures that convert non-conductive precursor polymers to conductive carbon suitable for use in electrode materials, which may be incorporated into a cathode, an electrolyte, and an anode, where the pyrolysis method may include one or more catalysts or reactive reagents.

Method And System For Silicon-Dominant Lithium-Ion Cells With Controlled Utilization of Silicon

Systems and methods for silicon-dominant lithium-ion cells with controlled utilization of silicon may include a cathode, an electrolyte, and an anode, where the anode has an active material comprising more than 50% silicon. The battery may be charged by lithiating silicon while not lithiating carbon. The active material may comprise more than 70% silicon. A voltage of the anode during discharge of the battery may remain above a minimum voltage at which silicon can be lithiated. The anode may have a specific capacity of greater than 3000 mAh/g. The battery may have a specific capacity of greater than 1000 mAh/g. The anode may have a greater than 90% initial Coulombic efficiency and may be polymer binder free. The battery may be charged at a 10 C rate or higher. The battery may be charged at temperatures below freezing without lithium plating. The electrolyte may comprise a liquid, solid, or gel.

Method and system for silicon-dominant lithium-ion cells with controlled utilization of silicon

Systems and methods for silicon-dominant lithium-ion cells with controlled utilization of silicon may include a cathode, an electrolyte, and an anode, where the anode has an active material comprising more than 50% silicon. The battery may be charged by lithiating silicon while not lithiating carbon. The active material may comprise more than 70% silicon. A voltage of the anode during discharge of the battery may remain above a minimum voltage at which silicon can be lithiated. The anode may have a specific capacity of greater than 3000 mAh/g. The battery may have a specific capacity of greater than 1000 mAh/g. The anode may have a greater than 90% initial Coulombic efficiency and may be polymer binder free. The battery may be charged at a 10C rate or higher. The battery may be charged at temperatures below freezing without lithium plating. The electrolyte may comprise a liquid, solid, or gel.

Method and system for silicon-dominant lithium-ion cells with controlled utilization of silicon

Systems and methods for silicon-dominant lithium-ion cells with controlled utilization of silicon may include a cathode, an electrolyte, and an anode, where the anode has an active material comprising more than 50% silicon. The battery may be charged by lithiating silicon while not lithiating carbon. The active material may comprise more than 70% silicon. A voltage of the anode during discharge of the battery may remain above a minimum voltage at which silicon can be lithiated. The anode may have a specific capacity of greater than 3000 mAh/g. The battery may have a specific capacity of greater than 1000 mAh/g. The anode may have a greater than 90% initial Coulombic efficiency and may be polymer binder free. The battery may be charged at a 10C rate or higher. The battery may be charged at temperatures below freezing without lithium plating. The electrolyte may comprise a liquid, solid, or gel.

Anisotropic expansion of silicon-dominant anodes

Systems and methods for anisotropic expansion of silicon-dominant anodes may include a cathode, an electrolyte, and an anode, where the anode may include a current collector and an active material on the current collector. An expansion of the anode during operation may be configured by a roughness and/or thickness of the current collector, a metal used for the current collector, and/or a lamination process that adheres the active material to the current collector. The expansion of the anode may be more anisotropic for thicker current collectors. A thicker current collector may be 10 μm thick or greater. The expansion of the anode may be more anisotropic for more rigid materials used for the current collector. A more rigid current collector may include nickel and a less rigid current collector may include copper. The expansion of the anode may be more anisotropic for a rougher surface current collector.

Direct coating of electrodes in silicon-dominant anode cells

Methods of forming carbon-silicon composite material on a current collector

Methods of forming electrodes are described. In some embodiments, the method can include providing a current collector. The method can also include providing a first carbon precursor on the current collector and providing a mixture on the first carbon precursor. The mixture can include a second carbon precursor and silicon particles. The method can further include pyrolysing the second carbon precursor to convert the second carbon precursor into one or more types of carbon phases to form a composite material. The one or more types of carbon phases can be a substantially continuous phase with the silicon particles distributed throughout the composite material. The method can also include pyrolysing the first carbon precursor to adhere the composite material to the current collector.

Configuring anisotropic expansion of silicon-dominant anodes using particle size

Systems and methods for configuring anisotropic expansion of silicon-dominant anodes using particle size may include a cathode, an electrolyte, and an anode, where the anode may include a current collector and an active material on the current collector. An expansion of the anode during operation may be configured by utilizing a predetermined particle size distribution of silicon particles in the active material. The expansion of the anode may be greater for smaller particle size distributions, which may range from 1 to 10 pm. The expansion of the anode may be smaller for a rougher surface active material, which may be configured by utilizing larger particle size distributions that may range from 5 to 25 μm. The expansion may be configured to be more anisotropic using more rigid materials for the current collector, where a more rigid current collector may comprise nickel and a less rigid current collector may comprise copper.

Carbon additives for direct coating of silicon-dominant anodes

Systems and methods are provided for carbon additives for direct coating of silicon-dominant anodes. An example composition for use in directly coated anodes may include a silicon-dominated anode active material, a carbon-based binder, and a carbon-based additive, with the composition being configured for low-temperature pyrolysis. The low-temperature pyrolysis may be conducted at < 850C. An anode may be formed using a direct coating process of the composition on a current collector. The anode active material may yield silicon constituting between 90% and 95% of weight of the formed anode after pyrolysis. The carbon-based additive may yield carbon constituting between 2% and 6% of weight of the formed anode after pyrolysis. The carbon-based additive may include carbon particles with surface area > 65 m2/g.

Method and system for use of nitrogen as a stabilization gas of polyacrylonitrile (pan)

Methods of forming carbon-silicon composite material on a current collector

Methods of forming electrodes are described. In some embodiments, the method can include providing a current collector. The method can also include providing a first carbon precursor on the current collector and providing a mixture on the first carbon precursor. The mixture can include a second carbon precursor and silicon particles. The method can further include pyrolysing the second carbon precursor to convert the second carbon precursor into one or more types of carbon phases to form a composite material. The one or more types of carbon phases can be a substantially continuous phase with the silicon particles distributed throughout the composite material. The method can also include pyrolysing the first carbon precursor to adhere the composite material to the current collector.

Configuring anisotropic expansion of silicon-dominant anodes using particle size

Systems and methods for configuring anisotropic expansion of silicon-dominant anodes using particle size may include a cathode, an electrolyte, and an anode, where the anode may include a current collector and an active material on the current collector. An expansion of the anode during operation may be configured by utilizing a predetermined particle size distribution of silicon particles in the active material. The expansion of the anode may be greater for smaller particle size distributions, which may range from 1 to 10 pm. The expansion of the anode may be smaller for a rougher surface active material, which may be configured by utilizing larger particle size distributions that may range from 5 to 25 μm. The expansion may be configured to be more anisotropic using more rigid materials for the current collector, where a more rigid current collector may comprise nickel and a less rigid current collector may comprise copper.

Configuring anisotropic expansion of silicon-dominant anodes using particle size

Reaction barrier between electrode active material and current collector

Systems and methods are provided for a reaction barrier between an electrode active material and a current collector. An electrode may comprise an active material, a metal foil, and a polymer. The polymer (such as polyamide-imide (PAI)) may be configured to provide a carbonized barrier between the active material and the metal foil after pyrolysis.

Anisotropic expansion of silicon-dominant anodes

Method and system for silicon dominant lithium-ion cells with controlled lithiation of silicon

Direct coating of electrodes in silicon-dominant anode cells

Systems and methods are provided for high volume roll-to-roll direct coating of electrodes for silicon-dominant anode cells. A slurry that includes silicon particles and a binder material may be applied to a current collector film, and the slurry may be processed to form a precursor composite film coated on the current collector film. The current collector film with the coated precursor composite film may be rolled into a precursor composite roll. A heat treatment may be applied to the current collector film with the coated precursor composite film in an environment including nitrogen gas, to convert the coated precursor composite film to a pyrolyzed composite film coated on the current collector film. The heat treatment may include applying the heat treatment to the precursor composite roll in whole and/or applying the heat treatment to the current collector film with the coated precursor composite film as it is continuously fed.