A powder comprising pillared particles for use as an active component of a metal ion battery, the pillared particles comprising a particle core and a plurality of pillars extending from the particle core, wherein the pillared particles are formed from a starting material powder wherein at least 10% of the total volume of the starting material powder is made up of starting material particles having a particle size of no more than 10 microns.

A method for making nanoporous nickel composite material comprises: providing a cathode plate and a copper-containing anode plate, electroplating a copper material layer a surface of the cathode plate; laying a carbon nanotube layer on the copper material layer, and forming an overlapped structure of the copper material layer and the carbon nanotube laye; the cathode plate and the overlapped structure are used as a cathode, and a nickel-containing anode plate is used as an anode, plating a nickel material layer on the overlapped structure to form sandwich structure; repeating steps S1 to S3 to obtain a carbon nanotube-reinforced copper-nickel alloy; rolling and annealing the carbon nanotube-reinforced copper-nickel alloy; and etching the carbon nanotube-reinforced copper-nickel alloy to form the nanoporous nickel composite material.

One variation of a battery unit includes: a substrate including silicon and defining a cell, wherein the cell includes a base encompassed by a continuous wall and a set of posts extending normal to the base; an electrolyte material coating vertical surfaces of each post, in the set of posts, and vertical surfaces of the continuous wall in the cell; a cathode material filling the cell over the electrolyte material, between posts in the set of posts, and between the set of posts and the continuous wall; a seal extending along a top of the continuous wall; and a cathode current collector bonded to the seal, electrically coupled to the cathode material, and cooperating with the substrate to enclose the cell to form a single-cell battery.

A lithium ion battery including an electrolyte and a lithium titanate negative electrode is provided. The lithium titanate negative electrode includes structures of a lithium titanate core and a conformal layer surrounding each lithium titanate core. The conformal layer either includes titanium oxide with substantially no lithium or has a concentration of lithium ranging from a lower concentration at a surface portion of the layer to a higher concentration at an interior portion of the layer adjacent to the lithium titanate core. A method of preparing the lithium titanate structures and a method of preparing an electrode for a lithium ion battery, wherein the electrode includes lithium titanate structures, are also provided.

A method for forming a battery element includes etching trenches into a substrate and crystal orientation dependent etching of the trenches. Further, the method includes forming solid state battery structures within the trenches.

A process for etching a substrate comprising polycrystalline silicon to form silicon nanostructures includes depositing metal on top of the substrate and contacting the metallized substrate with an etchant aqueous solution comprising about 2 to about 49 weight percent HF and an oxidizing agent.

The present disclosure is directed to providing improved processability by forming a protective film on the surface of lithium metal used as an electrode layer through a simple process, and to improving the cycle characteristics of a lithium metal secondary battery by forming a stable protective film. The present disclosure provides a method for manufacturing a negative electrode, including the steps of: (S1) preparing lithium metal; and (S2) dipping the lithium metal in an acid solution for 60-120 seconds to form a LiF film on the surface of lithium metal.

Electrodes, production methods and mono-cell batteries are provided, which comprise active material particles embedded in electrically conductive metallic porous structure, dry-etched anode structures and battery structures with thick anodes and cathodes that have spatially uniform resistance. The metallic porous structure provides electric conductivity, a large volume that supports good ionic conductivity, that in turn reduces directional elongation of the particles during operation, and may enable reduction or removal of binders, conductive additives and/or current collectors to yield electrodes with higher structural stability, lower resistance, possibly higher energy density and longer cycling lifetime. Dry etching treatments may be used to reduce oxidized surfaces of the active material particles, thereby simplifying production methods and enhancing porosity and ionic conductivity of the electrodes. Electrodes may be made thick and used to form mono-cell batteries which are simple to produce and yield high performance.

A negative electrode for an accumulator functions based on the ion insertion and deinsertion principle and/or based on the alloy formation and dealloying principle. A first layer comprises an active material deposited on a first face of a current collector. A second layer comprises an active material deposited on a second face of a current collector, the first face being opposite the second face. The negative electrode extends lengthwise in an electrode longitudinal direction. Each of the first and second layers is partly coated with an assembly of strips of a metal, the cations of the metal are those involved in the ion insertion and deinsertion process and/or in the alloy formation and dealloying process in the active material of the first and second layers, the strips being separated along the electrode longitudinal direction and each extend lengthwise along a strip longitudinal direction substantially perpendicular to the electrode longitudinal direction.

A process for etching a substrate comprising polycrystalline silicon to form silicon nanostructures includes depositing metal on top of the substrate and contacting the metallized substrate with an etchant aqueous solution comprising about 2 to about 49 weight percent HF and an oxidizing agent.