Disclosed is a method for manufacturing a lithium metal secondary battery including a lithium metal electrode as a negative electrode, wherein the lithium metal electrode has a protective layer formed thereon, and the lithium metal secondary battery is discharged before its initial charge during an activation step of the lithium metal secondary battery so that stripping occurs on the surface of the lithium metal electrode.

A process for producing a cathode or anode material adapted for use in the manufacture of fast rechargeable ion batteries. The process may include the steps of Selecting an precursor material that, upon heating in a gas stream, releases volatile compounds to create porous materials to generate a material compound suitable for an electrode in an ion battery. Grinding the precursor material to produce a powder of particles with a first predetermined particle size distribution to form a precursor powder. Calcining the precursor powder in a flash calciner reactor segment with a first process gas at a first temperature to produce a porous particle material suitable for an electrode in an ion battery, and having the pore properties, surface area and nanoscale structures for applications in such batteries. Processing the hot precursor powder in a second calciner reactor segment with a second process gas to complete the calcination reaction, to anneal the material to optimise the particle strength, and to modify the oxidation state of the product for maximising the charge density when the particle is activated in a battery cell to form a second precursor powder. Quenching the second precursor powder. Activating the particles of the second precursor powder in an electrolytic cell by the initial charging steps to intercalate electrolyte ions in the particles.

Battery core packs employing minimum cell-face pressure containment devices and methods are disclosed for minimizing dendrite growth and increasing cycle life of metal and metal-ion battery cells.

Systems and methods for improved performance of silicon anode containing cells through formation may include a cathode, electrolyte, and silicon containing anode. The battery may be subjected to a formation process comprising one or more cycles of: charging the battery at a 1 C rate to 3.8 volts or greater until a current in the battery reaches C/20, and discharging the battery to 2.5 volts or less. The battery may comprise a lithium ion battery. The electrolyte may comprise a liquid, solid, or gel. The anode may comprise greater than 70% silicon. The battery may be discharged until the current reaches 0.2 C. The battery may be discharged at a 1 C rate or at a 0.2 C rate. The battery may be in a rest period between the charge and discharge.

Over-lithiated cathode materials for use in an electrochemical cell that cycles lithium ions, and methods of making and using the same, are provided. The over-lithiated cathode materials may include positive electroactive materials selected from the group consisting of: Li.sub.2Mn.sub.2O.sub.4, Li.sub.2MSiO.sub.4 (where M is Fe, Mn, Co, or Mn), Li.sub.2VOPO.sub.4, and combinations thereof. Methods for preparing the positive electroactive material may include charging an electrochemical cell at a first voltage window and discharging the electrochemical cell at a second a second voltage window that is less than the first voltage window. The electrochemical cell may include a positive electrode, including the positive electroactive material, and a negative electrode, including a volume-expanding negative electroactive material. During charging, lithium ions and electrons may move from the positive electrode to the negative electrode. During discharging, a portion of the lithium ions and electrons may remain at the negative electrode as a lithium reservoir.

In general, the present disclosure is directed to forming lithium ion battery (LIB) cells with structure and chemistry that achieves formation of a solid electrolyte interphase (SEI) layer that allows for operating in relatively high ambient temperature environments, e.g., up to and exceeding 60° C., while significantly reducing self-discharge amounts, e.g., relative to other LIB cells formed with SEI layers measuring about 1-2 nanometers in thickness. For example, one non-limiting embodiment of the present disclosure enables a self-discharge amount for a LIB cell of 10% or less over a four (4) week period of time when operating at an ambient temperature of 60 degrees Celsius.

A metal battery, such as a lithium battery, includes an anode, an anode current collector in electrical contact with the anode, a cathode, a cathode current collector in electrical contact with the cathode, a separator disposed between the anode and cathode, a liquid electrolyte, and an anode protection structure. The anode protection structure includes an anode protection layer disposed between the anode and the separator. The anode protection layer includes a matrix and domains within the matrix. One of the matrix and domains contains a first material and the other of the matrix and domains contains a second material. The first material is less permeable by the electrolyte than the second material.

A method for identifying a cell quality during cell formation includes: conducting a beginning of life cycling following an initial cell formation charge of multiple cells; collecting and preprocessing a discharge data set generated by one of the multiple cells during the beginning of life cycling; calculating a statistical variance from the discharge data set identifying an estimated probability of meeting a target cell usage time; and projecting a life span of the multiple cells.

Disclosed are methods, systems, and devices for battery formation. A first set of pulses, having a first frequency, and that carry a net zero charge, are applied to a battery. After the first set of pulses are applied to the battery, a second set of pulses that carry a net positive charge are applied to the battery. The second set of pulses are either applied after expiry of a particular time period following the application of the first set of pulses, or based on some battery measurements. After the second set of pulses are applied to the battery, a battery parameter is measured, and based on the measured battery parameter, a third set of pulses, having a second frequency, and that also carry a net zero charge, are applied to the battery.

A method of manufacturing a lithium secondary battery, which includes coating a slurry for forming a porous coating layer on a porous polymer substrate and drying the porous coating layer under a humidified condition to form a preliminary separator; forming an electrode assembly, wherein the preliminary separator is interposed between a positive electrode and a negative electrode, placing the electrode assembly into a battery case and injecting an electrolytic solution into the battery case; and thermally treating the electrode assembly. A lithium secondary battery manufactured by the method is also provided. Accordingly, the separator has significantly improved ionic conductivity compared to separators commonly used in the art.