Methods of forming a composite material film can include providing a layer comprising a carbon precursor and silicon particles on a sacrificial substrate. The methods can also include pyrolysing the carbon precursor to convert the precursor into one or more types of carbon phases to form the composite material film, whereby the sacrificial substrate has a char yield of about 10% or less.

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.

Composite cathode-separator laminations (CSL) include a current collector with sulfur-based host material applied thereto, a coated separator comprising an electrolyte membrane separator with a carbonaceous coating, and a porous, polymer-based interfacial layer (PBIL) forming a binding interface between the carbonaceous coating and the host material. The host material includes less than about 6% polymeric binder, and less than about 40% electrically conductive carbon, with the balance comprising one or more sulfur compounds. The PBIL can have a thickness of less than about 5 μm and a porosity of about 5% to about 40%. The host material can comprise less than about 40% conductive carbon (e.g., graphene) and have a porosity of less than about 40%. The carbonaceous coating (e.g., graphene) can have a thickness of about 1 μm to about 5 μm. The CSL can be disposed with an anode within an electrolyte to form a lithium-sulfur battery cell.

A solid-state battery includes a third active material layer, a first solid electrolyte layer, a first active material layer, a first current collector layer, a second active material layer, a second solid electrolyte layer and a fourth active material layer in the order mentioned, wherein both the first and second active layers are anode or cathode active material layers. When both the first and second active layers are anode layers, both the third and fourth active layers are cathode layers. When both the first and second active layers are cathode layers, both the third and fourth active layers are anode layers, at least the first current collector layer extends to an outer side than the third and fourth active layers, and an insulating resin layer continuously across a surface of the extending part on one side, a side face and a surface of the extending part on the other side.

Provided is a positive electrode structure for a secondary battery. This positive electrode structure includes: a positive electrode current collector composed of a tabular nickel foam and having a tabular coated portion and an uncoated portion extending from an outer peripheral portion of the coated portion; and a positive electrode active material containing nickel hydroxide and/or nickel oxyhydroxide incorporated into the coated portion of the positive electrode current collector. The positive electrode active material is not present in the uncoated portion of the positive electrode current collector, and the nickel foam constituting the uncoated portion is compressed so as to have a thickness of 0.10 times or more and less than 0.8 times a thickness of the nickel foam constituting the coated portion.

Provided is a slurry composition for a secondary battery electrode that has excellent fibrous carbon nanomaterial dispersibility and is capable of forming an electrode mixed material layer having excellent close adherence to a current collector. The slurry composition is obtained using a conductive material paste composition for a secondary battery electrode that contains a fibrous carbon nanomaterial, a binder, and a solvent. The binder includes a first copolymer that includes an alkylene structural unit and a nitrile group-containing monomer unit and has a weight average molecular weight of at least 170,000 and less than 1,500,000.

A lithium secondary battery including a positive electrode, a negative electrode, a separator disposed between the positive electrode and the negative electrode, and a nonaqueous electrolyte having lithium-ion conductivity. At the negative electrode, lithium metal deposits during charging, and the lithium metal dissolves during discharging. The negative electrode has a porous resin substrate, and a lithium metal layer laminated with the porous resin substrate. The porous resin substrate has a porous region in which the lithium metal layer is not packed.

A current collector has a pore-forming functional coating layer, an electrode sheet and a battery. The current collector having a pore-forming functional coating layer comprises an electrically conductive substrate layer and a functional coating layer applied on at least one surface of the substrate layer, wherein the functional coating layer comprises a gas-generating compound which has a decomposition temperature of 250° C. or less and is capable of producing gas. A compound capable of generating gas by decomposition is applied in the functional layer of the current collector. Hence, through holes extending through the coating layer can be produced by decomposing the pore-forming compound at the bottom of the active coating layer to generate gas with no need to change the existing coating process, thereby improving the kinetic performance of battery products. The method is simple, practicable, cost efficient, suitable for popularization, and has high application value.

A current collector, an electrode, and a non-aqueous electrolyte battery are provided. The current collector includes a conductive body having a three-dimensional porous structure. The current collector has an air permeability of 0.1 to 600 cc/cm.sup.2/sec and a thickness of less than 100 μm. Also, the electrode includes the current collector and an electrode material layer disposed on at least one surface of the current collector. The non-aqueous electrolyte battery includes the electrode.

This application provides a current collector and a preparation method thereof, a secondary battery containing such current collector, a battery module, a battery pack, and an electric apparatus. The current collector in this application includes a support layer, a binder layer, and a metal layer, where the binder layer is arranged between the support layer and the metal layer, the binder layer includes an organic binder and inorganic particles, a thickness D.sub.0 of the binder layer is 1.0-5.0 μm, optionally 1.0-3.0 μm; and the inorganic particles include large particles with a median particle size D.sub.50large and small particles with a median particle size D.sub.50small, and the median particle sizes of the large particles and the small particles satisfy the following relationships: D.sub.50large>D.sub.50small; D.sub.50large=(0.5-0.9)×D.sub.0; and D.sub.50small=(0.1-0.4)×D.sub.0.