Disclosed herein are a method of manufacturing dry binders for electrodes usable in a dry electrode method by using a mixture of polymer powder containing a hydroxyl group (—OH) and polytetrafluoroethylene, and a method of manufacturing dry electrodes including dry binders.

A method of preparing a lithium metal electrode, wherein the method includes providing a lithium metal strip, and providing a lubricant composition including a fluorine-based solvent and a fluorine-based compound on the lithium metal strip to obtain a coated lithium metal strip; and rolling the coated lithium metal strip to obtain the lithium metal electrode.

An electrode structure for a battery includes a middle layer made of an electrically conductive perforated mesh having a top surface, a bottom surface, a plurality of interconnected electrically conductive segments and a plurality of perforations among adjacent ones of the interconnected segments. A top layer of an electrode material is disposed on the top surface, and a bottom layer of the electrode material is disposed on the bottom surface, such that the top and bottom layers are disposed in physical contact with each other through the perforations in the middle layer. A method of manufacturing the electrode structure includes providing the layer of perforated mesh, applying the top and bottom layers of electrode material to the top and bottom surfaces, and curing the top and bottom layers of electrode material using one or more of heat, electromagnetic radiation and convection to produce a layer of cured electrode structure.

An electrode sheet manufacturing method includes preparing a wet powder that contains an active material and a volatile liquid, and of which a BET specific surface area is 50 cm.sup.2/g or more, performing film formation of an active material sheet by spreading the wet powder, and manufacturing an electrode sheet by disposing the active material sheet on a surface of a backing material.

A negative electrode for a lithium metal battery includes a metal current collector substrate. A lithium metal layer is formed on at least one surface of the metal current collector substrate. A pre-lithiation layer is formed on the lithium metal layer. The pre-lithiation layer includes a prelithiated active material.

Aspects of the disclosure include an electrode coating having a spatially varied porosity and a method of forming the same by using a porous current collector. An exemplary method can include forming a porous current collector having a bulk material and a plurality of voids. The porous current collector can be coated, infused, or otherwise saturated with an electrode coating having an active electrode material. The porous current collector and the electrode coating can be compressed in a calendering process to define the electrode film. The distribution of the plurality of voids in the porous current collector provides for regions of different calendering pressures during the calendering process. The regions of different calendering pressures leads to regions of higher and lower porosity in the resultant electrode film. In other words, an electrode film having a spatially varied porosity.

A system for fabricating an electrode film for a secondary battery includes a powder film fabrication unit configured to form mixture powder with active material powder, binder powder, and conductive material powder, and fabricating a powder film roll by fibrillating the mixture powder, a base material film fabrication unit configured to form a mixture solution with carbon-based powder, the binder powder, and organic solvent, and form a base material film roll by patterning the mixture solution on a base material film, and an electrode film fabrication unit configured to dispose the base material film roll between two powder film rolls, and form an electrode film roll by overlapping and bonding the powder film and the base material film.

Granules including an active material powder and a binder are prepared. The granules are supplied onto a surface of a roller. The granules are electrically charged. The granules are transferred from a first region to a second region by way of rotation of the roller. A first electric field is formed between the second region and a third region to allow the granules to fly from the second region toward the third region. A second electric field is formed between the third region and a substrate to allow the granules to fly from the third region toward the substrate.

A method of manufacturing a negative electrode includes styrene butadiene rubber on at least one surface of a negative electrode current collector, applying a second slurry including a negative electrode active material and a polyacrylic acid-based binder onto the first slurry, and drying and rolling the negative electrode current collector to which the first slurry and the second slurry are applied. The negative electrode active material includes a silicon-based negative electrode active material. According to the present disclosure, expansion and contraction of a silicon-based negative electrode active material during charging and discharging may be alleviated, and electrode flexibility may be improved, resulting in a significant improvement in lifespan properties of a secondary battery.

A method of forming a lithium or sodium foil for use as an electrode involves imposing a surface texturing that is predominately the {110} or {100} crystallographic orientation. For a Li {110} foil, a raw foil with a thickness of about 600 μm is heated to about 90° C. to randomize the crystallographic orientation and the foil is rolled to about 300 μm upon cooling. The rolled film is then scraped of about 50 μm of the lithium surface and heated to about 75° C. and rolled a second time to about 200 μm, and again cooled to room temperature. The cooled foil can be shaped into the electrode. The electrode can be employed in a battery to greatly extend the life of the battery relative to a lithium battery with a lithium anode that lacks the surface texturing. The alkali metal can be lithium electrochemically deposited on 3D scaffold such as carbon cloth with the deposited alkali metal maintaining the {110} texture.