Self healing lithium-ion battery negative electrodes, product including same, and methods of making and using same

1. A product comprising:

a positive electrode;

a negative electrode comprising an alloy that reacts with lithium, said alloy having a melting point below about 150 degrees Celsius and comprising at least two metals, at least one of which being a metal that can react with lithium, wherein said melting point is above an operating temperature for said negative electrode the negative electrode being constructed and arranged to self-heal by periodically warming to a temperature near said melting point to substantially remove any cracks in said negative electrode.

2. The product of claim 1 , wherein said alloy comprises Sn alloyed to at least one of Bi or In.

3. The product of claim 2 , wherein said alloy comprises an alloy composition of approximately 42 atomic percent Bi and 58 atomic percent Sn.

4. The product of claim 2 , wherein said alloy comprises approximately 50 atomic percent In and 50 atomic percent Sn.

5. The product of claim 2 , wherein alloy comprises approximately 9 atomic percent Bi, approximately 64 atomic percent Sn, and approximately 27 atomic percent In.

6. The product of claim 1 further comprising:

a separator coupled between said positive electrode and said negative electrode to form an electrode assembly.

7. A method comprising:

providing a lithium-ion battery system comprising a negative electrode comprising an alloy that reacts with lithium composition, wherein said alloy has a melting point below about 150 degrees Celsius and above a normal operating temperature of said lithium-ion battery system;

heating said negative electrode for a sufficient period of time to substantially remove any cracks in said negative electrode; and

cooling said negative electrode.

8. The method of claim 7 , wherein said alloy comprises Sn alloyed to at least one of Bi and In.

9. The method of claim 7 , wherein heating said negative electrode comprises:

heating said negative electrode outside of the battery system to a temperature near or slightly above said melting point for a sufficient period of time to substantially remove any cracks in said negative electrode.

10. The method of claim 7 , wherein heating said negative electrode comprises:

heating said negative electrode inside the battery system to a temperature near or slightly above said melting point for a sufficient period of time to substantially remove any cracks in said negative electrode.

11. The method of claim 7 , wherein the heating said negative electrode and cooling said negative electrode comprises:

introducing a current through said negative electrode to raise a temperature of said negative electrode near or above said melting point for a sufficient period of time to substantially remove any cracks in said negative electrode; and

removing said current from said negative electrode.

12. A method for increasing the cycle life of a cell enclosure-type lithium-ion battery system used in a product, the method comprising:

providing the cell enclosure-type lithium-ion battery system including at least one negative electrode and at least one positive electrode, wherein said at least one negative electrode comprises an alloy, wherein said alloy has a melting point below about 150 degrees Celsius and above a normal operating temperature of the cell enclosure-type lithium-ion battery system;

periodically warming said at least one negative electrode to a temperature near said melting point for a period of time sufficient to substantially remove any cracks in said at least one negative electrode; and

cooling said at least one negative electrode to a temperature below said melting point.

13. The method of claim 12 , wherein periodically warming said at least one negative electrode comprises:

heating said at least one negative electrode outside of the battery system from said normal operating temperature to a temperature near said melting point for a sufficient period of time to melt said at least one negative electrode to substantially repair said cracks in said negative electrode.

14. The method of claim 12 , wherein periodically warming said at least one negative electrode comprises:

coupling an electric bus to said at least one negative electrode; and

introducing an electrical current from said electric bus through said at least one negative electrode;

maintaining said electrical current for a period of time sufficient to substantially heal any cracks in said negative electrode; and

uncoupling said electric bus from said at least one negative electrode.

15. The method of claim 12 , further comprising:

determining one or more alloys of at least two metals, at least one of which having the ability to react with lithium, having a melting point below about 150 degrees Celsius;

determining which of said one or more alloys has a desired blend of lithium-ion absorbing capabilities and low melting point at a particular size and shape for use as a negative electrode in the product;

forming a negative electrode having said determined alloy content; and

introducing at least one of said negative electrodes within an interior portion of the battery system.

16. The method of claim 15 , wherein said at least two lithium-absorbing metals comprises Sn alloyed to at least one of Bi or In.

17. The method of claim 15 , wherein said at least two lithium-absorbing metals comprises approximately 42 atomic percent Bi and 58 atomic percent Sn.

18. The method of claim 15 , wherein said at least two lithium-absorbing metals comprises approximately 50 atomic percent In and 50 atomic percent Sn.

19. The method of claim 15 , wherein said at least two lithium-absorbing metals comprises approximately 9 atomic percent Bi, approximately 64 atomic percent Sn, and approximately 27 atomic percent In.