An electrode including an electrode active material and a ceramic hydrofluoric acid (HF) scavenger is provided. The ceramic hydrofluoric acid (HF) scavenger includes M.sub.2SiO.sub.3, MAlO.sub.2, M.sub.2OAl.sub.2O.sub.3SiO.sub.2, or combinations thereof, where M is lithium (Li), sodium (Na), or combinations thereof. Methods of making the electrode are also 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 web coating platform for depositing molten metal on flexible substrates is provided. The web coating platform can be used for manufacturing solid lithium anodes for use in energy storage devices, for example, rechargeable batteries. The coating platform can be designed for double-sided coating of a continuous flexible substrate (e.g., a copper foil) with molten lithium followed by double-sided lamination or passivation. The coating platform integrates novel coating elements unique to handling and processing molten metals. For example, some implementations of the present disclosure incorporate double-sided molten metal coating elements, which include at least one of a molten metal application assembly (e.g., kiss roller, slot-die, Meyer bar, and/or gravure roller), a primary melt pool assembly, a secondary melt pool assembly, and an engagement mechanism.

An electrode for the use of an advanced lithium battery is fabricated using three-dimensionally structured metal foam coated with an active material. The metal foam is porous metal foam that can be used as an anode current collector of a lithium-ion battery and is coated with an anode active material, such as tin, through a sonication-assisted electroless plating method. Additionally, the coated metal foam is heat-treated at an appropriate temperature in order to improve the integrity of the coating layer and hence, the cyclic performance of the lithium-ion battery.

A high-capacity and long-life negative electrode hydrogen storage material of LaMgNi type for secondary rechargeable nickel-metal hydride battery and a method for preparing the same are provided in the present invention. A chemical formula of the negative electrode hydrogen storage material of LaMgNi type is La.sub.1-x-yRe.sub.xMg.sub.y(Ni.sub.1-a-bAl.sub.aM.sub.b).sub.z, wherein Re is at least one of Ce, Pr, Nd, Sm, Y, and M is at least one of Ti, Cr, Mo, Nb, Ga, V, Si, Zn, Sn; 0x0.10, 0.3y0.5, 0<a0.05, 0b0.02, 2.3z<3.0. The negative electrode hydrogen storage material of LaMgNi type in the present invention has excellent charge-discharge capacity and cycle life. The negative electrode hydrogen storage material of LaMgNi type can be applied in both common secondary rechargeable nickel-metal hydride battery and secondary rechargeable nickel-metal hydride battery with ultra-low self-discharge and long-term storage performance.

Systems and methods are provided for producing an electrode comprising a current collector and an active material. The active material is tape cast and laminated to the current collector. This electrode may be used as the anode and/or cathode of a lithium-ion battery. The tape casting may be performed by coating a device with a slurry and allowing the slurry to dry. The device may be, for example, a stainless steel drum or a belt having a low adhesion. The slurry may be pealed from the device as a laminate layer. One or more laminate layers may be adhered to the current collector that is subsequently pyrolyzed.

A nonaqueous electrolyte battery includes: a positive electrode containing a positive electrode active material made of a compound represented by a compositional formula of LiMn.sub.1-x-yFe.sub.xA.sub.yPO.sub.4 (wherein A is at least one selected from the group consisting of Mg, Ca, Al, Ti, Zn and Zr, 0x0.3, and 0y0.1); a negative electrode containing a negative electrode active material made from a titanium composite oxide; and a nonaqueous electrolyte, wherein a ratio (I.sub.P-F/I.sub.P-O) of a peak intensity (I.sub.P-F) of a P-F bond to a peak intensity (I.sub.P-O) of a P-O bond on the surface of the positive electrode, which are measured by X-ray photoelectron spectroscopic analysis, is 0.4 or more and 0.8 or less.

Cast components can improve the effectiveness of current state-of-the-art in thermal battery processing technology in terms of cost, labor, materials usage, and flexibility. Cast components can include cast cathodes, anodes, and separators.

Disclosed herein are multiphase metal anodes useful in non-aqueous batteries. The anodes include at least one active metal and at least one conductive metal.

Described herein is a process for the production of moldings made of porous material impregnated with polysulfide, the process including the following steps:

(a) insertion of the porous material into a mold;

(b) introduction of liquid polysulfide into the mold at a flow rate within the porous material in the range from 0.5 to 200 cm/s;

(c) cooling of the polysulfide to a temperature below the melting point of the polysulfide; and

(d) removal of the porous material impregnated with the polysulfide.