A zinc-air battery cell assembly comprising: a layer of anode material; one or more layers of cathode material; a separator directly between and engaging both the layer of anode material and the layer of cathode material that acts as both an electronic insulator and an ion conductive path between the layer of anode material and the layer of cathode material; and a diffusion member directly engaging the layer of cathode material.

A zinc-air battery cell assembly comprising: a layer of anode material; one or more layers of cathode material; a separator directly between and engaging both the layer of anode material and the layer of cathode material that acts as both an electronic insulator and an ion conductive path between the layer of anode material and the layer of cathode material; and a diffusion member directly engaging the layer of cathode material.

A battery cell includes a first electrode formed from at least one of a metal foil, a metal mesh or a metal layer on a substrate. A second electrode can be formed from at least partially oxidized material in a form of at least one of a metal foil, a metal layer on a substrate, a metal mesh, or a battery electrode that includes plurality of particles on current collector. A layer of an ion exchange material can be positioned between the first and second electrodes, with the ion exchange material capable of acting as an electrolyte in some embodiments.

A negative electrode of a lithium ion electrochemical cell, the negative electrode including an active electrode material that includes a first component and a second component. The first component may include graphene, silicon, or a combination thereof. The second component may include silicon. The active electrode material may include particles in which the second component is encapsulated by the first component. The negative electrode may have an internal porosity of between 40 to 60 percent.

A negative electrode of a lithium ion electrochemical cell, the negative electrode including an active electrode material that includes a first component and a second component. The first component may include graphene, silicon, or a combination thereof. The second component may include silicon. The active electrode material may include particles in which the second component is encapsulated by the first component. The negative electrode may have an internal porosity of between 40 to 60 percent.

A membraneless battery comprising a cathode comprising a cathode electroactive material; an anode comprising an anode electroactive material; a catholyte in contact with the cathode, wherein the catholyte is not in contact with the anode; an anolyte in contact with the anode, wherein the anolyte is not in contact with the cathode; and one or more buffer interlayers disposed between the anolyte and the catholyte. The catholyte has a pH of less than 4, and the anolyte has a pH of greater than 10. The one or more buffer interlayers regulate a pH in the battery. The anode electroactive material comprises a Zn electroactive material. At least one of the one or more buffer interlayers comprises a weak acid and its conjugate base; and/or at least one of the one or more buffer interlayers comprises a weak base and its conjugate acid.

A membraneless battery comprising a cathode comprising a cathode electroactive material; an anode comprising an anode electroactive material; a catholyte in contact with the cathode, wherein the catholyte is not in contact with the anode; an anolyte in contact with the anode, wherein the anolyte is not in contact with the cathode; and one or more buffer interlayers disposed between the anolyte and the catholyte. The catholyte has a pH of less than 4, and the anolyte has a pH of greater than 10. The one or more buffer interlayers regulate a pH in the battery. The anode electroactive material comprises a Zn electroactive material. At least one of the one or more buffer interlayers comprises a weak acid and its conjugate base; and/or at least one of the one or more buffer interlayers comprises a weak base and its conjugate acid.

Provided are electrochemical cells and methods of manufacturing these cells. An electrochemical cell comprises a positive electrode and an electrolyte layer, printed over the positive electrode. In some examples, each of the positive electrode, electrolyte layer, and negative electrode comprises an ionic liquid enabling ionic transfer. The negative electrode comprises a negative active material layer (e.g., comprising zinc), printed over and directly interfacing the electrolyte layer. The negative electrode also comprises a negative current collector (e.g., copper foil) and a conductive pressure sensitive adhesive layer. The conductive pressure sensitive adhesive layer is disposed between and adhered to, directly interfaces, and provides electronic conductivity between the negative active material layer and the negative current collector. In some examples, the conductive pressure sensitive adhesive layer comprises carbon and/or metal particles (e.g., nickel, copper, indium, and/or silver). Furthermore, the conductive pressure sensitive adhesive layer may comprise an acrylic polymer, encapsulating these particles.

An alkaline electrochemical cell includes a cathode; a gelled anode having an anode active material and an electrolyte; and a separator disposed between the cathode and the anode; wherein the separator includes a non-conductive, porous material having a mean pore size of about 1 micron to about 5 microns, a maximum pore size of about 19 microns, and an air permeability of about 0.5 cc/cm.sup.2/s to about 3.8 cc/cm.sup.2/s at 125 Pa.

An alkaline electrochemical cell includes a cathode; a gelled anode having an anode active material and an electrolyte; and a separator disposed between the cathode and the anode; wherein the separator includes a non-conductive, porous material having a mean pore size of about 1 micron to about 5 microns, a maximum pore size of about 19 microns, and an air permeability of about 0.5 cc/cm.sup.2/s to about 3.8 cc/cm.sup.2/s at 125 Pa.