Disclosed herein are embodiments of a method and system for producing powders for lithium ion batteries utilizing plasma processing during the manufacture of the powders. Advantageously, embodiments of the disclosed methods can significantly reduce the manufacturing time, the overall number of steps, and the harmful byproducts of conventional lithium ion battery processing.

A process for delineating a population of electrode structures in a web includes laser ablating the web to form ablations in the web, each ablation being formed by removing a portion of an electrochemically active layer to thereby expose a portion of an electrically conductive layer. The process includes forming alignment features in the web that are formed at predetermined locations on the web. The process also includes laser machining the web to form weakened tear patterns in the web that delineate members of the electrode structure population, each of the delineated members being individually bounded, at least in part, by a member of the weakened tear patterns that is adapted to facilitate separation of delineated members, individually, from the web by an application of a force, the alignment features being used to aid in the formation of the weakened tear patterns.

Electrodeposited copper foils having properties suitable for use as current collectors in lithium-ion secondary batteries are disclosed. The electrodeposited copper foils include a drum side and a deposited side. At least one of the deposited side or the drum side exhibits a void volume (Vv) value in the range of 0.17 to 1.17 m.sup.3/m.sup.2.

A lithium ion conducting membrane and methods of making the same. The membrane includes a polymeric matrix and a plurality of ion-conducting particles disposed within the polymeric matrix. An inorganic coating deposited in the polymeric matrix.

Electrodeposited copper foils having properties suitable for use as negative electrode current collectors in lithium-ion secondary batteries are disclosed. The copper foil has a yield strength in the range of 11 to 45 kg/mm.sup.2, and a difference in residual stress between the drum side and the deposited side of at most 95 MPa. Negative electrode current collectors for lithium-ion secondary battery, a lithium-ion secondary battery incorporating the negative electrode, and batteries containing the negative electrode current collector are also disclosed.

Embodiments of the invention include batteries and other charge-storage devices incorporating sheets and/or powders of silica fibers and methods for producing such devices. The silica fibers may be formed via electrospinning of a sol gel produced with a silicon alkoxide reagent, such as tetraethyl ortho silicate, alcohol solvent, and an acid catalyst.

A solid electrolyte interface is formed on a silicon monoxide electrode in a battery cell. While the solid electrolyte interface is being formed on the silicon monoxide electrode, the battery cell is charged for one or more initial cycles.

A method for producing a copper composite structure is disclosed. The method for producing a copper composite structure includes a first step of forming a copper pillar structure; and a second step of annealing the copper pillar structure under a nitrogen atmosphere.

A method for manufacturing an electrode for a lithium ion battery is provided. A powder layer is formed by using a squeegee roll to squeegee powder including an electrode active material and supplied onto a substrate, and then compacted on the substrate by means of a pair of press rolls while conveying the substrate vertically downward to form an electrode sheet. The method includes: supplying the powder onto the substrate; leveling the powder supplied onto the substrate to form the powder layer using the squeegee roll which is disposed in a position so that a squeegee angle formed by a vertical line passing through the rotating axis of one of the press rolls and a line passing through said rotating axis and the rotating axis of the squeegee roll is 0 to 60; and compacting the powder layer on the substrate using the pair of press rolls.

A method for reusing components of a battery (used battery assembly), such as a bipolar battery, to form another battery (reused battery assembly). The method may find use in allowing for a battery to be used, disassembled, recycled or reprocessed, assembled, and reused all within a single facility. A method for preparing a reused battery assembly including: a) disassembling a used battery assembly; b) salvaging one or more used components from the used battery assembly to provide for one or more reused components; and c) assembling a reused battery assembly with the one or more reused components.