# US 12,218,303 B2 · Prelithiated hybridized energy storage device > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,218,303 B2 - Document ID: US12218303B2 - Status: Granted - Kind: B2 - Application number: 18/396,497 - Filed: 2023-12-26 - Published: 2024-10-24 - Granted: 2025-02-04 - Earliest claimed: 2017-02-21 - Assignees: Tesla, Inc. - Applicants: Tesla, Inc. - Inventors: Hieu Minh Duong; Porter Mitchell; Mohammed-Yazid Saidi; Joon Ho Shin; Haim Feigenbaum - Web page: https://patentgrep.com/patent/US12218303B2 ## CPC - H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries - H01M 4/043: {involving compressing or compaction} - H01M 4/133: Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx - H01M 4/134: Electrodes based on metals, Si or alloys - H01M 4/1393: of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx - H01M 4/1395: of electrodes based on metals, Si or alloys - H01M 4/364: {as mixtures} - H01M 4/382: {Lithium (H01M4/405 takes precedence)} - H01M 4/587: for inserting or intercalating light metals - H01M 4/622: {being polymers} - H01M 4/625: {Carbon or graphite} - H01M 4/628: {Inhibitors, e.g. gassing inhibitors, corrosion inhibitors} - Y02E 60/10: Energy storage using batteries - Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract An energy storage device can include a first electrode, a second electrode and a separator between the first electrode and the second electrode wherein the first electrode includes an electrochemically active material and a porous carbon material, and the second electrode includes elemental lithium metal and carbon particles. A method for fabricating an energy storage device can include forming a first electrode and a second electrode, and inserting a separator between the first electrode and the second electrode, where forming the first electrode includes combining an electrochemically active material and a porous carbon material, and forming the second electrode includes combining elemental lithium metal and a plurality of carbon particles. ## Claims ### Claim 1 An electrode film comprising: lithium-intercalating carbon particles; elemental lithium metal; and a fibrillized binder; wherein at least some of the lithium-intercalating carbon particles and the elemental lithium metal form lithium-carbon composite particles or lithium-intercalating carbon particles coated with elemental lithium metal; and wherein the electrode film is a free-standing electrode film and is absent of solvent residues; and wherein the electrode film is homogeneous, and free of holes and metal smearing. ### Claim 2 (depends on 1) The electrode film of claim 1, wherein the lithium-carbon composite particles comprise pores, and wherein at least some of the elemental lithium metal particles are situated within the pores. ### Claim 3 (depends on 1) The electrode film of claim 1, wherein the electrode film further comprises first porous carbon particles. ### Claim 4 (depends on 3) The electrode film of claim 3, wherein the first porous carbon particles comprise conductive carbon. ### Claim 5 (depends on 1) The electrode film of claim 1, wherein the elemental lithium metal is untreated lithium metal. ### Claim 6 (depends on 1) The electrode film of claim 1, wherein the free-standing electrode film comprises a structural matrix of binder fibrils. ### Claim 7 (depends on 1) The electrode film of claim 1, wherein the lithium-intercalating carbon particles are selected from the group consisting of graphite particles, porous carbon particles, activated carbon particles, hierarchically structured carbon particles and combinations thereof. ### Claim 8 (depends on 1) The electrode film of claim 1, wherein the fibrillized binder comprises polytetrafluoroethylene (PTFE). ### Claim 9 (depends on 1) An assembly comprising: a first electrode comprising an electrochemically active material and second porous carbon particles; a second electrode comprising the electrode film of claim 1; and a separator between the first and second electrodes. ### Claim 10 (depends on 9) An energy storage device comprising the assembly of claim 9, an electrolyte and a housing. ### Claim 11 (depends on 10) The energy storage device of claim 10, wherein the energy storage device is a battery. ### Claim 12 A method for fabricating an electrode film, comprising: combining elemental lithium metal, a plurality of lithium-intercalating carbon particles and a fibrillizable binder to form an electrode film mixture; processing the lithium-intercalating carbon particles and the elemental lithium metal such that at least some of the lithium-intercalating carbon particles and the elemental lithium metal form lithium-carbon composite particles or lithium-intercalating carbon particles coated with elemental lithium metal; and forming an electrode film from the electrode film mixture; wherein the electrode film is a free-standing electrode film and is absent of solvent residues; and wherein the electrode film is homogeneous, and free of holes and metal smearing. ### Claim 13 (depends on 12) The method of claim 12, further comprising: forming an electrode by laminating the electrode film to a current collector. ### Claim 14 (depends on 13) A method of fabricating an energy storage device, comprising the method of claim 13, and placing the electrode in a housing to form an energy storage device. ### Claim 15 (depends on 12) The method of claim 12, wherein the method does not utilize solvent. ### Claim 16 (depends on 12) The method of claim 12, wherein the elemental lithium metal comprises a plurality of elemental lithium metal particles. ### Claim 17 (depends on 16) The method of claim 16, further comprising providing bulk elemental lithium metal, and reducing a size of the bulk elemental lithium metal to form the plurality of elemental lithium metal particles. ### Claim 18 (depends on 16) The method of claim 16, wherein the elemental lithium metal particles are untreated elemental lithium metal particles. ### Claim 19 (depends on 12) The method of claim 12, wherein combining the elemental lithium metal and the lithium-intercalating carbon particles comprises combining dry elemental lithium metal and dry carbon particles to form a dry electrode film mixture. ### Claim 20 (depends on 12) The method of claim 12, wherein processing is selected from the group consisting of high sheer mixing, heating, exposure to carbonate vapor, exposure to carbonate liquid, and combinations thereof. ### Claim 21 (depends on 12) The method of claim 12, wherein the method does not utilize solvents.