Methods for making lead-carbon coupling, lead-carbon electrode sheets, and a lead-carbon battery are revealed. The coupling methods consist of steps of assembling the carbon material that contains oxygen functional groups or metal precursors and lead material in contact with each other and then heating the assembled lead-carbon pair to form lead oxides or metal carbides as a bridge to form coupled lead-carbon interface with high electrochemical and mechanical stability. This coupled lead-carbon structure is applied to form lead-carbon electrode sheets and is further used as electrode sheets of lead-carbon batteries by lead welding.

The performance of a lithium ion-cell where the cathode is a layered-layered lithium rich cathode material xLiMO.sub.2(1-x)Li.sub.2MNO.sub.3, M being a transition metal selected from the group consisting of Co, Ni, or Mn, is improved by coating the surface of the cathode with a sulfonyl-containing compound, such as poly(1,4-phenylene ether-ether-sulfone), inhibits the reactivity of the electrolyte with the oxidized electrode surface while allowing lithium ion conduction.

For making battery electrodes, a composite strip of a cast ribbon of an electrically conductive metal attached to and extending along an edge of a web of electrically conductive carbon fiber material, also called a carbon felt in some examples, with a plurality of spaced apart notches cast in the ribbon and opening to an edge of the ribbon spaced from the carbon fiber material. A rotatable drum with a mold cavity and a confronting casting shoe for supplying molten metal, such as liquid lead, to the cavity may be used in a casting machine to continuous cast the composite strip.

A method and system for forming lithium anode devices are provided. In one embodiment, the methods and systems form pre-lithiated Group-IV alloy-type nanoparticles (NP's), for example, Li—Z where Z is Ge, Si, or Sn. In another embodiment, the methods and systems synthesize Group-IV nanoparticles and alloy the Group-IV nanoparticles with lithium. The Group-IV nanoparticles can be made on demand and premixed with anode materials or coated on anode materials. In yet another embodiment, the methods and systems form lithium metal-free silver carbon (“Ag—C”) nanocomposites (NC's). In yet another embodiment, a method utilizing silver (PVD) and carbon (PECVD) co-deposition to make anode coatings that can regulate lithium nucleation energy to minimize dendrite formation is provided.

A method and apparatus for manufacturing a flexible layer stack, and to a flexible layer stack. Implementations of the present disclosure particularly relate to a method and apparatus for coating flexible substrates with a low melting temperature metal or metal alloy. In one implementation, a method is provided. The method includes delivering a transfer liquid to a quenching surface of a rotating casting drum. The method further includes forming a material layer stack over the rotating casting drum by delivering a molten metal or molten metal alloy toward the quenching surface of the rotating casting drum. The method further includes transferring the material layer stack from the rotating casting drum to a continuous flexible substrate, wherein the quenching surface of the rotating casting drum is cooled to a temperature at which the layers of the material layer stack solidify.

A method of making a porous film includes disposing a slurry on a substrate, solidifying the slurry to yield a film on the substrate, and subliming the organic sublimable material to yield the porous film on the substrate. The slurry includes an electrochemically active material, an electrically conductive material, and a binder dispersed in an organic sublimable material. The electrochemically active material and the electrically conductive material are different.

A slurry includes a solid component including an electrochemically active material, an electrically conductive material, and a binder; and a liquid component including an organic sublimable material, wherein the electrochemically active material and the electrically conductive material are different, and the solid component is dispersed in the liquid component.

A machine and process for making a composite battery electrode with a conductive lead cast ribbon extending along and attached to a portion of a carbon fiber material. A lead ribbon may be continuously cast along a longitudinally elongate strip of carbon fiber material. The ribbon may be cast along an edge or edges of a longitudinally elongate strip of carbon fiber material.

A method for forming a battery anode can include: forming a slurry including active material comprising silicon particles, wherein the silicon particles can be derived from silica fumes, depositing the slurry on an current collector, drying the deposited slurry to form a deposited film, and compacting the deposited film to form the battery anode.

A method and apparatus for manufacturing a flexible layer stack, and to a flexible layer stack. Implementations of the present disclosure particularly relate to a method and apparatus for coating flexible substrates with a low melting temperature metal or metal alloy. In one implementation, a method is provided. The method includes delivering a transfer liquid to a quenching surface of a rotating casting drum. The method further includes forming a material layer stack over the rotating casting drum by delivering a molten metal or molten metal alloy toward the quenching surface of the rotating casting drum. The method further includes transferring the material layer stack from the rotating casting drum to a continuous flexible substrate, wherein the quenching surface of the rotating casting drum is cooled to a temperature at which the layers of the material layer stack solidify.

Disclose are a cathode of an all-solid lithium battery, and a secondary battery system using the same. The cathode includes a lithium composite, and a method of manufacturing the lithium composite comprises: dispersing a solid electrolyte to be uniformly distributed in the pores of a mesoporous conductor to provide a solid electrolyte composite, and coating the solid electrolyte composite on the surface of a lithium compound including nonmetallic solids such as S, Se, and Te.