The present invention pertains to a process for manufacturing a film, said process comprising: (i) providing a composition [composition (C)] comprising, preferably consisting of: —at least one fluoropolymer [polymer (F)] comprising recurring units derived from at least one fluorinated monomer comprising a —SO 3 M functional group, wherein M is an alkaline metal [monomer (FM)] and—a liquid medium [medium (L)] comprising at least 50% by weight, based on the total weight of said medium (L), of at least one alkyl carbonate; (ii) processing the composition (C) provided in step (i) into a film; and (iii) drying the film provided in step (ii). The present invention further pertains to use of said film in a process for manufacturing a lithium electrode and to use of said lithium electrode in a process for manufacturing a lithium-sulphur battery.

Among other things, the present disclosure provides a particle comprising a form of sulfur and/or lithium sulfide (Li.sub.2S) that is doped with a group VIA element, such as selenium (e.g. Se34), tellurium (e.g. Te52), or polonium (e.g. Po84). The present disclosure also provides a cell comprising a negative electrode, a separator, and a positive electrode comprising the particles of the present disclosure.

Electrodes and methods of preparing electrodes with a porous electroactive region are generally described herein.

The present invention relates to the application of a force to enhance the performance of an electrochemical cell. The force may comprise, in some instances, an anisotropic force with a component normal to an active surface of the anode of the electrochemical cell. In the embodiments described herein, electrochemical cells (e.g., rechargeable batteries) may undergo a charge/discharge cycle involving deposition of metal (e.g., lithium metal) on a surface of the anode upon charging and reaction of the metal on the anode surface, wherein the metal diffuses from the anode surface, upon discharging. The uniformity with which the metal is deposited on the anode may affect cell performance. For example, when lithium metal is redeposited on an anode, it may, in some cases, deposit unevenly forming a rough surface. The roughened surface may increase the amount of lithium metal available for undesired chemical reactions which may result in decreased cycling lifetime and/or poor cell performance. The application of force to the electrochemical cell has been found, in accordance with the invention, to reduce such behavior and to improve the cycling lifetime and/or performance of the cell.

A method for manufacturing an electrochemical device that may be selected from the group consisting of: lithium ion batteries with a capacity greater than 1 mAh, capacitors, supercapacitors, resistors, inductors, transistors, photovoltaic cells, fuel cells, implementing a method for manufacturing an assembly comprising a porous electrode and a porous separator comprising a porous layer deposited on a substrate having a porosity comprised between 20% and 60% by volume, and pores with an average diameter of less than 50 nm.

An immobilized chalcogen system or body includes an element of chalcogen, an electrically conductive material, and a hydrophilic membrane gate. The hydrophilic membrane gate may be used to isolate hydrophobic regions, one related to polychalcogenide ion(s) and another related to a hydrophobic electrolyte system. The hydrophilic membrane gate may prevent polychalcogenide from forming, and may provide control of undesirable parasitic mass transport and undesirable electron transport inside a chalcogen-based battery, and thereby allow the battery to cycle at a high specific capacity with a long cycling life. If desired, the immobilized chalcogen system or body may be employed in a cathode of a rechargeable battery.

The present invention relates to the application of a force to enhance the performance of an electrochemical cell. The force may comprise, in some instances, an anisotropic force with a component normal to an active surface of the anode of the electrochemical cell. In the embodiments described herein, electrochemical cells (e.g., rechargeable batteries) may undergo a charge/discharge cycle involving deposition of metal (e.g., lithium metal) on a surface of the anode upon charging and reaction of the metal on the anode surface, wherein the metal diffuses from the anode surface, upon discharging. The uniformity with which the metal is deposited on the anode may affect cell performance. For example, when lithium metal is redeposited on an anode, it may, in some cases, deposit unevenly forming a rough surface. The roughened surface may increase the amount of lithium metal available for undesired chemical reactions which may result in decreased cycling lifetime and/or poor cell performance. The application of force to the electrochemical cell has been found, in accordance with the invention, to reduce such behavior and to improve the cycling lifetime and/or performance of the cell.

An immobilized chalcogen system or body includes a mixture or combination of chalcogen and carbon. The carbon can be in the form of a carbon skeleton. The chalcogen can include oxygen, sulfur, selenium, or tellurium, or a combination of any two or more of oxygen, sulfur, selenium, and tellurium. The activation energy for chalcogen to escape the immobilized chalcogen system or body is ≥96 kJ/mole.

Methods of making a sintered electrode comprise forming a slurry including 40 wt % to 75 wt % of a powder comprising a chalcogenide and at least one of an alkali metal or an alkaline earth metal, 1 wt % to 10 wt % of a binder, and 30 wt % to 50 wt % of a solvent. Methods include casting the slurry into a green tape. Methods include drying the green tape to form a dried green tape by removing at least a portion of the solvent. The dried green tape includes at most 10 wt % of organic material in the dried green tape. Methods include sintering the dried green tape at a temperature from 500° C. to 1350° C. for no more than 60 minutes to form the sintered electrode.

An anode for use in an energy storage device is provided. The anode includes a current collector having an electrically conductive substrate and a surface layer overlaying a first side of the electrically conductive substrate. The surface layer may include a metal oxide or a metal chalcogenide. The anode may also include a lithium storage layer overlaying the surface layer. The lithium storage layer may have a total content of silicon, germanium, or a combination thereof of at least 40 atomic %. The lithium storage layer may include less than 10 atomic % carbon. The anode may also include a plurality of lithium storage filamentary structures in contact with a second side of the electrically conductive substrate. The second side is opposite the first side. The plurality of lithium storage filamentary structures may include silicon, germanium, tin, or a combination thereof.