An alkaline electrochemical cell includes a cathode; a gelled anode having an anode active material and an electrolyte; and a separator disposed between the cathode and the anode; wherein the separator includes a non-conductive, porous material having a mean pore size of about 1 micron to about 5 microns, a maximum pore size of about 19 microns, and an air permeability of about 0.5 cc/cm.sup.2/s to about 3.8 cc/cm.sup.2/s at 125 Pa.

In an aspect, a method for making a metal-containing material comprises steps of: forming a metal-containing hydrogel from an aqueous precursor mixture using a photopolymerization; wherein the aqueous precursor mixture comprises water, one or more aqueous photosensitive binders, and one or more aqueous metal salts; and thermally treating the metal-containing hydrogel to form the metal-containing material; wherein the metal-containing hydrogel is exposed to a thermal-treatment atmosphere during the step of thermally treating; wherein a composition of the metal-containing material is at least partially determined by a composition of the thermal-treatment atmosphere during the thermally treating step.

A method of manufacturing an electrochemical cell includes transferring an anode semi-solid suspension to an anode compartment defined at least in part by an anode current collector and an separator spaced apart from the anode collector. The method also includes transferring a cathode semi-solid suspension to a cathode compartment defined at least in part by a cathode current collector and the separator spaced apart from the cathode collector. The transferring of the anode semi-solid suspension to the anode compartment and the cathode semi-solid to the cathode compartment is such that a difference between a minimum distance and a maximum distance between the anode current collector and the separator is maintained within a predetermined tolerance. The method includes sealing the anode compartment and the cathode compartment.

Embodiments described herein relate generally to devices, systems and methods of producing high energy density batteries having a semi-solid cathode that is thicker than the anode. An electrochemical cell can include a positive electrode current collector, a negative electrode current collector and an ion-permeable membrane disposed between the positive electrode current collector and the negative electrode current collector. The ion-permeable membrane is spaced a first distance from the positive electrode current collector and at least partially defines a positive electroactive zone. The ion-permeable membrane is spaced a second distance from the negative electrode current collector and at least partially defines a negative electroactive zone. The second distance is less than the first distance. A semi-solid cathode that includes a suspension of an active material and a conductive material in a non-aqueous liquid electrolyte is disposed in the positive electroactive zone, and an anode is disposed in the negative electroactive zone.

An alkaline electrochemical cell includes a cathode; a gelled anode having an anode active material and an electrolyte; and a separator disposed between the cathode and the anode; wherein the separator includes a non-conductive, porous material having a mean pore size of about 1 micron to about 5 microns, a maximum pore size of about 19 microns, and an air permeability of about 0.5 cc/cm.sup.2/s to about 3.8 cc/cm.sup.2/s at 125 Pa.

A battery cathode material includes cathode material, ceramic material, and carbon-containing gel. The cathode material includes lithium nickel cobalt manganese oxide (NCM), lithium nickel cobalt aluminum oxide (NCA), lithium nickel manganese oxide (LNMO), lithium cobalt oxide (LCO), lithium iron phosphate (LFP), lithium nickel cobalt manganese aluminum oxide (NCMA), or combinations thereof. The ceramic material surrounds the cathode material, and includes gallium, aluminum, or tantalum doped lithium lanthanum zirconium oxide (LLZO), lithium zinc titanate (LZTO), lithium aluminum titanium phosphate (LATP), lithium-zirconium phosphate (LZPO), lithium zirconate (LZO), or combinations thereof. The carbon-containing gel wrapping the cathode material, and includes binder and carbon-containing conductive material, in which the binder includes polyvinylpyrrolidone, polyvinyl alcohol, sodium dodecyl sulfonate, sodium dodecylbenzenesulfonate, glucose, carboxymethyl cellulose, alginate, or combinations thereof, and the carbon-containing conductive material includes carbon nanotube.

The present disclosure provides a gel electrolyte precursor and use thereof. The gel electrolyte precursor comprises a gel matrix monomer, a flexible additive, a polymerization initiator, and a lithium salt. The gel matrix monomer comprises an acrylonitrile-based monomer. The use of same in a semisolid battery achieves good electrical performance, and also reduces the amount of an electrolyte used. An acrylonitrile-based polymer obtained by the in-situ polymerization and gelation of an acrylonitrile-based monomer has good flame retardant performance and high voltage resistance, improving the safety performance of a battery.

Nanoporous carbon-based scaffolds or structures, and specifically carbon aerogels and their manufacture and use thereof are provided. Embodiments include a silicon-doped anode material for a lithium-ion battery, where the anode material includes beads of polyimide-derived carbon aerogel. The carbon aerogel includes silicon particles and accommodates expansion of the silicon particles during lithiation. The anode material provides optimal properties for use within the lithium-ion battery.

A battery includes a substrate; a composite cathode disposed on the substrate; a solid-state electrolyte disposed on the composite cathode; and a lithium anode disposed on the solid-state electrolyte, such that the composite cathode comprises a gel polymer electrolyte layer and a porous cathode active material layer. A method of forming a cathode for a solid-state battery includes mixing an active cathode material, at least one of a conductive carbon component and an electronic conductive component, and a polymer binder to form a slurry; immersing the slurry in an alcohol reagent to form a porous disc structure by phase conversion; and immersing the porous disc structure in a liquid electrolyte to form the cathode.

An alkaline electrochemical cell includes a cathode, an anode which includes an anode active material, and a non-conductive separator disposed between the cathode and the anode, wherein from about 20% to about 50% by weight of the anode active material relative to a total amount of anode active material has a particle size of less than about 75 μm, and wherein the separator includes a unitary, cylindrical configuration having an open end, a side wall, and integrally formed closed end disposed distally to the open end.