The invention relates to a process for the preparation of carbon-deposited alkali metal oxyanion and the use thereof as cathode material in lithium secondary batteries wherein the process comprises synthesis of partially reacted alkali metal oxyanion, a wet-based nanomilling step, a drying step and a subsequent carbon deposition step performed by a thermal CND process. The invention also relates to carbon deposited alkali metal oxyanion with less than 80 ppm of sulfur impurities for the preparation of a cathode of lithium secondary batteries with exceptional high-temperature electrochemical properties.

High-performance flexible batteries are promising energy storage devices for portable and wearable electronics. The major obstacle to develop flexible batteries is the shortage of flexible electrodes with excellent electrochemical performance. Another challenge is the limited progress in the flexible batteries beyond Li-ion because of safety concerns for the Li-based electrochemical system. Accordingly, a self-supported tin sulfide (SnS) porous film (PF) was fabricated as a flexible cathode material in Al-ion battery, which delivers a high specific capacity of 406 mAh/g. A capacity decay rate of 0.03% per cycle was achieved, indicating a good stability. The self-supported and flexible SnS film also shows an outstanding electrochemical performance and stability during dynamic and static bending tests. Microscopic images demonstrated that the porous structure of SnS is beneficial for minimizing the volume expansion during charge/discharge. This leads to an improved structural stability and superior long-term cyclability.

A method of electroplating (or electrodeposition) carbon to coat anode and cathode active materials used in Li-ion batteries (LIBs) for improving their cycle life. The electroplating of the carbon coating from the carbon source is ultrafast, preferably taking less than 10 seconds. The carbon source can be comprised of an acetonitrile, methanol, ethanol, acetonitrile, nitromethane, nitroethane or N,N-dimethylformamide (DMF) solution. The protective carbon coating may be used also in gas sensors, biological cell sensors, supercapacitors, catalysts for fuel cells and metal air batteries, nano and optoelectronic devices, filtration devices, structural components, and energy storage devices.

Lithium-ion batteries are provided that variously comprise anode and cathode electrodes, an electrolyte, a separator, and, in some designs, a protective layer. In some designs, at least one of the electrodes may comprise a composite of (i) Li2S and (ii) conductive carbon that is embedded in the core of the composite. In some designs, the protective layer may be disposed on at least one of the electrodes via electrolyte decomposition. Various methods of fabrication for lithium-ion battery electrodes and particles are also provided.

Lithium-ion batteries are provided that variously comprise anode and cathode electrodes, an electrolyte, a separator, and, in some designs, a protective layer. In some designs, at least one of the electrodes may comprise a composite of (i) Li2S and (ii) conductive carbon that is embedded in the core of the composite. In some designs, the protective layer may be disposed on at least one of the electrodes via electrolyte decomposition. Various methods of fabrication for lithium-ion battery electrodes and particles are also provided.

A lithium battery as a secondary battery has a battery cell including a first current collector which has a first face and a second face, a positive electrode active material particle which pierces the first current collector and is exposed from the first face and the second face, an electrolyte layer which covers the positive electrode active material particle exposed from the first face and the second face of the first current collector, a negative electrode as an electrode which is in contact with the electrolyte layer, and a second current collector which is in contact with the negative electrode. The battery cell is hermetically enclosed in a package in a state where one end portion which is a portion of the first current collector is exposed.

A lithium battery as a secondary battery has a battery cell including a first current collector which has a first face and a second face, a positive electrode active material particle which pierces the first current collector and is exposed from the first face and the second face, an electrolyte layer which covers the positive electrode active material particle exposed from the first face and the second face of the first current collector, a negative electrode as an electrode which is in contact with the electrolyte layer, and a second current collector which is in contact with the negative electrode. The battery cell is hermetically enclosed in a package in a state where one end portion which is a portion of the first current collector is exposed.

A method of producing a structured composite material is described. A porous media is provided, an electrically conductive material is deposited on surfaces or within pores of the plurality of porous media particles, and an active material is deposited on the surfaces or within the pores of the plurality of porous media particles coated with the electrically conductive material to coalesce the plurality of porous media particles together and form the structured composite material.

Provided are various embodiments of a positive electrode for a secondary battery, which in one embodiment includes a first positive electrode material mixture layer formed on a positive electrode collector, and a second positive electrode material mixture layer formed on the first positive electrode material mixture layer, wherein the first positive electrode material mixture layer has an operating voltage of 4.25 V to 6.0 V and includes an active material for overcharge which generates lithium and gas during charge; a method of preparing such a positive electrode for a secondary battery; and a lithium secondary battery including such a positive electrode.

Process for fabrication of all-solid-state thin film batteries, said batteries comprising a film of anode materials, a film of solid electrolyte materials and a film of cathode materials, in which: each of these three films is deposited using an electrophoresis process, the anode film and the cathode film are each deposited on a conducting substrate, preferably a thin metal sheet or band, or a metalized insulating sheet or band or film, said conducting substrates or their conducting elements being useable as battery current collectors, the electrolyte film is deposited on the anode and/or cathode film,
and in which said process also comprises at least one step in which said sheets or bands are stacked so as to form at least one battery with a collector/anode/electrolyte/cathode/collector type of stacked structure.