Embodiments of the present disclosure generally relate to battery technology, and more specifically, methods and systems for preparing lithium anodes. In one or more embodiments, a method for producing a lithium intercalated anode includes introducing a sacrificial substrate containing lithium films and an anode substrate containing graphite into a processing region within a chamber. The method also includes combining the sacrificial and anode substrates overlapping one another around a rewinder roller, rotating the rewinder roller to wind the sacrificial and anode substrates together to produce a rolled anode-sacrificial substrate bundle during a winding process. The method also includes heating the sacrificial substrate, the anode substrate, and/or the rolled anode-sacrificial substrate bundle while rotating the rewinder roller and applying a force to the rolled anode-sacrificial substrate bundle via an idle roller during the winding process.

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.

Cathode active materials for alkaline cells are disclosed. In particular, the cathode structures encompass conductive carbons introduced to the cathode so as to have a specific spatial orientation and/or a multi-carbon structure. The overall intent is to leverage the conductor(s) provided to the cathode structure to improve electronic and ionic conductance and, by extension, improve battery discharge performance.

Disclosed are electrochemical devices, such as lithium ion battery electrodes, lithium ion conducting solid-state electrolytes, and solid-state lithium ion batteries including these electrodes and solid-state electrolytes. Also disclosed are methods for making such electrochemical devices. Also disclosed are composite electrodes for solid state electrochemical devices. The composite electrodes include one or more separate phases within the electrode that provide electronic and ionic conduction pathways in the electrode active material phase.

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.

An aluminum electrode can include gel polymer as the binder, which can be combined with a carbon electrode to form a dual-ion battery.

New aluminum electrode alloys and methods of making the same are disclosed. In one embodiment, a method comprises, casting an aluminum alloy into an as-cast product, wherein the aluminum alloy comprises from 0.005 wt. % to 0.06 wt. % Fe, and forming the as-cast product into an aluminum electrode alloy. The casting step may comprise solidifying at a solidification rate. The solidification rate may be at or above a threshold solidification rate. The threshold solidification rate is sufficient to achieve not greater than 0.04 vol. % of Fe particles.

Provided herein are electrochemical cells (e.g., sodium batteries), as well as methods of making and using thereof. The electrochemical cells can employ an anode-free design that includes a nucleation layer (e.g., a carbon nucleation layer) disposed on a current collector (e.g., an aluminum current collector). Electrochemical studies show that the modified current collectors can provide highly stable and efficient plating and stripping of sodium metal over a range of currents and sodium loadings with long-term durability. Further, full cells constructed using these modified current collectors can achieve energy densities of greater than 400 Wh/kg, far surpassing recent reports for sodium-ion batteries and even the theoretical maximum for lithium ion battery technology while still relying on naturally abundant raw materials and cost-effective aqueous processing.

A method for patterning a lithium metal surface, including the steps of (S1) forming an intaglio or relief pattern having a predetermined size on a patterning substrate; (S2) either (a) compressing lithium metal physically to a surface of the patterning substrate having the pattern formed thereon to form the predetermined pattern on the surface of the lithium metal, or (b) applying liquid lithium to the surface of the patterning substrate having the pattern formed thereon and solidifying the liquid lithium to form the predetermined pattern on the surface of the lithium metal; and (S3) separating the lithium metal having the predetermined pattern formed thereon from the patterning substrate, wherein the patterning substrate is at least one selected from a silicon wafer or polycarbonate substrate.

A negative electrode includes a lithium-alkaline earth metal alloy, and can be used in a lithium-sulfur battery. Furthermore, a method to obtain said negative electrode, and a lithium-sulfur battery containing the negative electrode.