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.

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).

An electrode material, its manufacturing method, and its use as a cathode material in batteries are provided. The electrode material comprises a plurality of nanoparticles, each having a diameter of approximately 100-400 nm and comprising a core and a shell encapsulating the core. The shell comprises carbon and nitrogen, respectively having a mass fraction of approximately 70-90% and approximately 5-20% relative to a total mass of the shell. The core comprises sulfur, having a mass fraction of approximately 40-97% relative to a total mass of the core. The core has a mass fraction of approximately 50-90% relative to a total mass of each nanoparticle. The electrode material can be used in a cathode of a Li—S battery, which has a good energy storage capacity, a high electrochemical stability, and a low capacity decay.

Disclosed are an anisotropic collector for a lithium-ion battery, and a manufacturing method therefor and an application thereof. The collector is made of a resin material added with spherical metal particles. Conductive particles of the collector in an X-Y direction do not form a sufficient conductive network, but form a good conductive network in a Z direction. While a short circuit occurs, the collector is not easy to activate most of active materials in the X-Y direction so that thermal runaway is not easy to occur, but the collector may fully conduct electricity in the Z direction so that the battery may be normally charged and discharged, thereby improving battery safety.

An all-solid-state rechargeable battery and a stacked all-solid-state rechargeable battery capable of reducing surface unevenness are provided. The battery makes it more difficult to crack a current collecting unit and to cut the current collecting unit, and the battery may be easily manufactured. The all-solid-state rechargeable battery includes positive and negative electrode layers; solid electrolyte layers stacked between the positive and negative electrode layers; an insulating layer on a side end surface of the positive electrode layer that covers the positive electrode layer; and thin type positive and negative electrode current collecting units protruding laterally from the positive and negative electrode layers, respectively. The insulating layer supports the positive and negative electrode current collecting units from at least one side. Two conductive units electrically connecting each of the positive and negative electrode current collecting units to an external wiring are formed in the insulating layer.

Provided are printed electrochemical cells, which utilize zinc salts for ionic transfer, and methods of fabricating such cells. In some examples, a printed electrochemical cell comprises a positive electrode with a positive current collector having a two-dimensional shape and comprising an electrolyte-facing surface formed by the graphite. For example, the positive current collector may be a graphite foil or an aluminum foil with a graphite coating. The cell also comprises electrolyte comprising an electrolyte salt and an electrolyte solvent. For example, the electrolyte salt comprises a zinc salt with a concentration of at least 30% by weight in the electrolyte. The cell is fabricated by printing a positive active material layer over the positive current collector, printing one or more electrolyte layers on various cell components, and laminating a separator layer between the positive and negative electrodes while soaking the separator layer with the electrolyte.

Provided are a current collector, an electrode plate, a battery and an application of the current collector. The current collector includes an insulation layer and a conductive layer. The insulation layer is configured to bear the conductive layer, the conductive layer is configured to bear an electrode active material layer. A room temperature film resistance R.sub.S of the conductive layer meets a conditional expression: 0.016Ω/□≤R.sub.S≤420Ω/□. By the current collector of the present application, the short circuit resistance of the battery in case of an abnormal situation causing the short circuit can be greatly increased, and the short circuit current can be greatly reduced. Thus, influence of the short circuit damage on the battery is limited to a point range, and an interrupt in the current only occurs in a point range, without disrupting normal operation of the battery in a certain period time.

A positive-electrode core laminate of a portion of a positive-electrode core on which no positive-electrode active material layer is formed is bonded to a positive-electrode current collector by ultrasonic bonding. A core recess is formed in a bonding region of the positive-electrode core laminate bonded to the positive-electrode current collector by ultrasonic bonding, a region of the positive-electrode core laminate in which the core recess is formed includes a solid-state bonding layer and a central layer, the solid-state bonding layer being formed by solid-state bonding between layers of the positive-electrode core, the central layer being disposed between the solid-state bonding layers formed on both faces of the positive-electrode core, and the first average grain size of metal crystal grains constituting the solid-state bonding layer is smaller than the second average grain size of metal crystal grains constituting the central layer.

A sulfide-impregnated solid-state battery is provided. The battery comprises a cell core constructed by basic cell units. Each unit comprises a positive electrode comprising a cathode layer and a positive meshed current collector comprising a conductive material which is further coated by oxide-based solid-state electrolyte. The cell unit further comprises a negative electrode comprising an anode layer and a negative meshed current collector comprising a conductive material which is further coated by oxide-based solid-state electrolyte. The positive and negative electrodes are stacked together to form the cell unit. The two coated oxide-based solid electrolyte layers are disposed between the positive and negative electrode as dual separators. Such a cell unit may be repeated or connected in parallel or bipolar stacking to form the cell core to achieve a desired battery voltage, power and energy. The cell core comprises a sulfide-based solid-state electrolyte dispersed in the pore structures of cell core.

An electrochemical cell comprising a first electrode separated from a second electrode by a shutdown separator. The first electrode can comprise a first current collector substrate having a first active material composite layered thereon. The second electrode can comprise a second current collector substrate parallel to the first current collector substrate. The second current collector substrate can have a second active material composite layered thereon. The first current collector substrate can have a first current collector tab extending from the first current collector substrate at a position along an axis parallel to a plane defined by the first current collector substrate. The second current collector substrate can have a second current collector tab extending from the second current collector substrate at a same position along the axis as the first current collector tab. A battery including the electrochemical cell and methods for manufacturing the battery are also described.