The present disclosure is directed to methods of securing battery tab structures to binderless, collectorless self-standing electrodes, comprising electrode active material and carbon nanotubes and no foil-based collector, and the resulting battery-tab secured electrodes. Such methods and the resulting battery tab-secured electrodes may facilitate the use of such composites in battery and power applications.

Provided are an electrodeposited copper foil, an electrode comprising the same, and a lithium-ion secondary battery comprising the same. The electrodeposited copper foil has a drum side and a deposited side opposing the drum side, wherein at least one of the drum side and the deposited side exhibits a void volume value (Vv) in the range of 0.17 μm.sup.3/μm.sup.2 to 1.17 μm.sup.3/μm.sup.2; and an absolute value of a difference between a maximum height (Sz) of the drum side and a Sz of the deposited side is in the range of less than 0.60 μm.

Embodiments of the invention include batteries and other charge-storage devices incorporating sheets and/or powders of silica fibers and methods for producing such devices. The silica fibers may be formed via electrospinning of a sol gel produced with a silicon alkoxide reagent, such as tetraethyl ortho silicate, alcohol solvent, and an acid catalyst.

Lithium ion batteries, electrodes, nanofibers, and methods for producing same are disclosed herein. Provided herein are batteries having (a) increased energy density; (b) decreased pulverization (structural disruption due to volume expansion during lithiation/de-lithiation processes); and/or (c) increased lifetime. In some embodiments described herein, using high throughput, water-based electrospinning process produces nanofibers of high energy capacity materials (e.g., ceramic) with nanostructures such as discrete crystal domains, mesopores, hollow cores, and the like; and such nanofibers providing reduced pulverization and increased charging rates when they are used in anodic or cathodic materials.

The present disclosure is directed to methods of securing battery tab structures to binderless, collectorless self-standing electrodes, comprising electrode active material and carbon nanotubes and no foil-based collector, and the resulting battery-tab secured electrodes. Such methods and the resulting battery tab-secured electrodes may facilitate the use of such composites in battery and power applications.

An energy storage device can include a cathode, an anode, and a separator between the cathode and the anode. At least one of the electrodes can include an electrode film prepared by a dry process. The electrode film, the electrode and/or the separator can comprise a salt, improved porosity, increased density, be prelithiated, and/or a foam. Process and apparatuses used for fabricating the electrode and/or electrode film are also described.

Embodiments of the invention include batteries and other charge-storage devices incorporating sheets and/or powders of silica fibers and methods for producing such devices. The silica fibers may be formed via electrospinning of a sol gel produced with a silicon alkoxide reagent, such as tetraethyl ortho silicate, alcohol solvent, and an acid catalyst.

A process is provided comprising submerging a substrate in an electrochemical deposit bath having at least a metal salt and saccharin. In embodiments, the film is further treated with anodization, and in other cases chemical vapor deposition. Films are also provided formed by the disclosed processes. The films are nanoporous on at least a portion of a surface of the films. Also disclosed are electronic devices having the films disclosed, including lithium-ion batteries, storage devices, supercapacitors, electrodes, semiconductors, fuel cells, and/or combinations thereof.

A process for delineating a population of electrode structures in a web includes laser ablating the web to form ablations in the web, each ablation being formed by removing a portion of an electrochemically active layer to thereby expose a portion of an electrically conductive layer. The process includes forming alignment features in the web that are formed at predetermined locations on the web. The process also includes laser machining the web to form weakened tear patterns in the web that delineate members of the electrode structure population, each of the delineated members being individually bounded, at least in part, by a member of the weakened tear patterns that is adapted to facilitate separation of delineated members, individually, from the web by an application of a force, the alignment features being used to aid in the formation of the weakened tear patterns.

A process for delineating a population of electrode structures in a web includes laser ablating the web to form ablations in the web, each ablation being formed by removing a portion of an electrochemically active layer to thereby expose a portion of an electrically conductive layer. The process includes forming alignment features in the web that are formed at predetermined locations on the web. The process also includes laser machining the web to form weakened tear patterns in the web that delineate members of the electrode structure population, each of the delineated members being individually bounded, at least in part, by a member of the weakened tear patterns that is adapted to facilitate separation of delineated members, individually, from the web by an application of a force, the alignment features being used to aid in the formation of the weakened tear patterns.