An anode for an energy storage device includes a current collector. The current collector includes: i) an electrically conductive substrate including a first electrically conductive material; ii) a plurality of electrically conductive structures in electrical communication with the electrically conductive substrate, wherein each electrically conductive structure includes a second electrically conductive material; and iii) a metal oxide coating. The metal oxide coating includes one or both of: a) a first metal oxide material in contact with the electrically conductive substrate; or b) a second metal oxide material in contact with the electrically conductive structures; or both (a) and (b). The anode further includes lithium storage coating overlaying the metal oxide coating, the lithium storage layer including a total content of silicon, germanium, or a combination thereof, of at least 40 atomic %. The electrically conductive structures are at least partially embedded within the lithium storage coating.

A non-aqueous electrolyte secondary battery disclosed herein includes a positive electrode, a negative electrode, and a non-aqueous electrolyte. The positive electrode includes a positive electrode current collector, and a positive electrode active material layer, an insulating layer, and a boundary layer which are provided on the positive electrode current collector. The boundary layer is positioned between the positive electrode active material layer and the insulating layer, and is in contact with the positive electrode active material layer and the insulating layer. The positive electrode active material layer contains a positive electrode active material. The insulating layer contains an inorganic filler. The boundary layer contains the positive electrode active material contained in the positive electrode active material layer and the inorganic filler contained in the insulating layer. The boundary layer contains hydrated alumina. The non-aqueous electrolyte contains lithium fluorosulfonate.

Methods for forming anode structures are provided and include transferring a flexible substrate a first deposition chamber arranged downstream from a first spool chamber, the first deposition chamber containing a first coating drum capable of guiding the flexible substrate past a first plurality of deposition units, and guiding the flexible substrate past the first plurality of deposition units while depositing a lithium metal film on the flexible substrate via the first plurality of deposition units. The method also includes transferring the flexible substrate from the first deposition chamber to a second deposition chamber, the second deposition chamber containing a second coating drum capable of guiding the flexible substrate past a second deposition unit containing a crucible capable of depositing ceramic on the lithium metal film, and guiding the flexible substrate past the crucible while depositing a ceramic protective film on the lithium metal film via the evaporation crucible.

An electrochemical device, which is a non-aqueous electrochemical device, comprising a polymer (P) enclosed in an inside of the electrochemical device, wherein the polymer (P) is a polymer having a molecular structure containing a unit (P) represented by the following formula (P), the polymer (P) having a weight-average molecular weight of greater than 50,000, as well as an electrode for an electrochemical device, a coating liquid for an electrochemical device, an insulating layer for an electrochemical device, an undercoat layer for an electrochemical device, and an electrolytic solution for an electrochemical device including the polymer (P) and other ingredients:

##STR00001## in the formula (P), R.sup.P is a group of 1 to 20 carbon atoms.

A method of manufacturing a free-standing electrode film includes preparing a mixture including an electrode active material, a binder, and an additive solution or conductive paste, the additive solution or conductive paste being in an amount less than 5% by weight of the mixture and including a polymer additive and a liquid carrier, as well as a conductive material in the case of a conductive paste. The mixture may have total solid contents greater than 95% by weight. Preparing the mixture may include mixing the additive solution or conductive paste with the electrode active material to lubricate the electrode active material and subsequently adding and mixing in the binder. The method may further include subjecting the mixture to a shear force and, after the mixture has been subjected to the shear force, pressing the mixture into a free-standing film.

A negative electrode for a non-aqueous electrolyte secondary battery includes a negative electrode current collector, and a negative electrode mixture layer supported on the negative electrode current collector. The negative electrode mixture layer includes a negative electrode active material capable of electrochemically absorbing and releasing lithium ions, a binder, and a conductive agent. The negative electrode active material includes flaky silicon particles, and the binder includes a silicate.

Systems and methods for all-conductive battery electrodes may include an electrode coating layer on a current collector, where the electrode coating layer comprises more than 50% silicon, and where each material in the electrode has a resistivity of less than 100 Ω-cm. The silicon may have a resistivity of less than 10 Ω-cm, less than 1 Ω-cm, or less than 1 mΩ-cm. The electrode coating layer may comprise pyrolyzed carbon and/or conductive additives. The current collector comprises a metal foil. The metal current collector may comprise one or more of a copper, tungsten, stainless steel, and nickel foil in electrical contact with the electrode coating layer. The electrode coating layer comprises more than 70% silicon. The electrode may be in electrical and physical contact with an electrolyte. The electrolyte may comprise a liquid, solid, or gel. The battery electrode may be in a lithium ion battery.

An electrochemical cell is provided, which includes a cathode comprising a three dimensional (3D) porous cathode structure, an anode, an electrolyte separator, comprised of a ceramic material, located between the cathode and the anode, and a cathode current collector, wherein the cathode is located between the cathode current collector and the electrolyte separator. The 3D porous cathode structure includes ionically conducting electrolyte strands extending through the cathode from the cathode current collector to the electrolyte separator, pores extending through the cathode from the cathode current collector to the electrolyte separator, and an electronically conducting network extending on sidewall surfaces of the pores from the cathode current collector to the electrolyte separator.

A current collector is disclosed and comprises a conductive material and an elemental metal of a group 6 metal contacting the conductive material. Also disclosed are an electrochemical cell comprising a current collector, a cathode adjacent to the current collector, and an alkali metal-based electrolyte between the current collector and the cathode, with the cathode separated from the group 6 metal by the alkali metal-based electrolyte. A method of operating the electrochemical cell is also disclosed.

An aluminum foil comprising an aluminum foil substrate that has a porous region, wherein the porous region is formed throughout the entirety of the aluminum foil substrate in the thickness direction thereof.