Systems and methods for electrode lamination using overlapped irregular shaped active material may include a battery having a cathode, an electrolyte, and an anode, with the anode including an active material on a metal current collector. The active material may include a plurality of irregularly shaped pieces bonded to the metal current collector, and may include silicon, carbon, and a pyrolyzed polymer. The active material may include more than 50% silicon by weight. The plurality of irregularly shaped pieces may be roll press laminated to the metal current collector. Gaps may remain between some of the irregularly shaped pieces of active material. The gaps may absorb strain in the active material during lithiation of the anode. The metal current collector may include a copper or nickel foil. Portions of the metal current collector not covered by active material may be protected by an adhesive or inorganic layer.

Systems and methods for electrode lamination using overlapped irregular shaped active material may include a battery having a cathode, an electrolyte, and an anode, with the anode including an active material on a metal current collector. The active material may include a plurality of irregularly shaped pieces bonded to the metal current collector, and may include silicon, carbon, and a pyrolyzed polymer. The active material may include more than 50% silicon by weight. The plurality of irregularly shaped pieces may be roll press laminated to the metal current collector. Gaps may remain between some of the irregularly shaped pieces of active material. The gaps may absorb strain in the active material during lithiation of the anode. The metal current collector may include a copper or nickel foil. Portions of the metal current collector not covered by active material may be protected by an adhesive or inorganic layer.

A metal battery, such as a lithium battery, includes an anode, an anode current collector in electrical contact with the anode, a cathode, a cathode current collector in electrical contact with the cathode, a separator disposed between the anode and cathode, a liquid electrolyte, and an anode protection structure. The anode protection structure includes an anode protection layer disposed between the anode and the separator. The anode protection layer includes a matrix and domains within the matrix. One of the matrix and domains contains a first material and the other of the matrix and domains contains a second material. The first material is less permeable by the electrolyte than the second material.

In an embodiment, a Li-ion battery electrode comprises a conductive interlayer arranged between a current collector and an electrode active material layer. The conductive interlayer comprises first conductive additives and a first polymer binder, and the electrode active material layer comprises a plurality of active material particles mixed with a second polymer binder (which may be the same as or different from the first polymer binder) and second conductive additives (which may be the same as or different from the first conductive additives). In a further embodiment, the Li-ion battery electrode may be fabricated via application of successive slurry formulations onto the current collector, with the resultant product then being calendared (or densified).

A method of manufacturing a lithium metal negative electrode, a lithium metal negative electrode manufactured thereby, and a lithium-sulfur battery including the same is disclosed. The method of manufacturing a lithium metal negative electrode includes the steps of (a) applying lithium nitride powder on at least one surface of a lithium metal layer including lithium metal; and (b) rolling the applied powder to form a lithium nitride protective layer of a powder bed on at least one surface of the lithium metal layer.

A method of manufacturing a lithium metal negative electrode, a lithium metal negative electrode manufactured thereby, and a lithium-sulfur battery including the same is disclosed. The method of manufacturing a lithium metal negative electrode includes the steps of (a) applying lithium nitride powder on at least one surface of a lithium metal layer including lithium metal; and (b) rolling the applied powder to form a lithium nitride protective layer of a powder bed on at least one surface of the lithium metal layer.

A lithium metal negative electrode for an electrochemical cell for a secondary lithium metal battery includes a polycrystalline metal substrate having a major facing surface with a defined crystallographic texture. An epitaxial lithium metal layer is formed on the major facing surface of the polycrystalline metal substrate. The epitaxial lithium metal layer exhibits a predominant crystal orientation. The predominant crystal orientation of the epitaxial lithium metal layer is derived from the defined crystallographic texture of the major facing surface of the polycrystalline metal substrate.

A lithium metal negative electrode for an electrochemical cell for a secondary lithium metal battery includes a polycrystalline metal substrate having a major facing surface with a defined crystallographic texture. An epitaxial lithium metal layer is formed on the major facing surface of the polycrystalline metal substrate. The epitaxial lithium metal layer exhibits a predominant crystal orientation. The predominant crystal orientation of the epitaxial lithium metal layer is derived from the defined crystallographic texture of the major facing surface of the polycrystalline metal substrate.

The present disclosure relates to a method of making carbon nanotube supported self-standing electrodes embedded in a polymer based battery packaging material. The present disclosure further relates to a method of continuously making carbon nanotube supported self-standing electrodes embedded in a polymer based battery packaging material. The resulting self-standing electrodes may be used in a wearable and flexible battery.

The present disclosure relates to a method of making carbon nanotube supported self-standing electrodes embedded in a polymer based battery packaging material. The present disclosure further relates to a method of continuously making carbon nanotube supported self-standing electrodes embedded in a polymer based battery packaging material. The resulting self-standing electrodes may be used in a wearable and flexible battery.