Systems and methods for space configurable battery structures for electrical assemblies incorporating ion exchange materials are described. One method to construct such a battery includes preparing a battery casing for a rechargeable battery. The preparing may further include placing one or more electrode materials into the casing. A monomer or a functionalized n-mer may be prepared for polymerization. The monomer or the functionalized n-mer may be polymerized to form an ion exchange material, which is then then cross-linked. The ion exchange material may be arranged to define an interpenetrating surface with at least a portion of at least one of the electrodes.

A lithium secondary battery includes a positive electrode, a negative electrode, a separator, and a nonaqueous electrolyte having lithium-ion conductivity. The positive electrode contains a positive electrode active material containing lithium. The negative electrode faces the positive electrode. The separator is disposed between the positive and negative electrodes. The negative electrode includes a negative electrode current collector. The negative electrode current collector includes a layer and protrusions. The layer has a first surface on which lithium metal is deposited during charge. The protrusions protrude from the first surface. At least one of the protrusions includes a conductive material and an insulative material.

A lithium metal anode electrode includes (a) a porous conductive layer including a current collector layer that is porous and has a plurality of first pores, at least parts of the first pores extending through the current collector layer; and a conduction loading layer composed of a porous material that does not alloy with lithium, disposed proximate to the current collector layer, and that having a plurality of second pores, at least parts of the second pores extending through the conduction loading layer; and (b) a lithium metal active material layer composed of lithium metal disposed proximate to the porous conductive layer. Parts of the first and second pores are connected and expose the lithium metal active material layer for electrochemical reactions. The first and second pores have respective surface areas that are adapted for lithium deposition so that a stable SEI layer can be formed thereon.

Described herein are current collectors comprising metal grids as well as electrodes and lithium-metal cells comprising such current collectors and methods of fabricating such current collectors, electrodes, and lithium-metal cells. A thin current collector comprises a polymer base and a metal layer positioned on, directly interfaces, and supported by one side of the polymer base. A thin current collector also comprises a metal grid, which directly interfaces and is supported by the edge of the polymer base. The metal grid is electrically coupled to the metal layer, e.g., by overlapping or at least forming an interface with the metal layer. In an electrode that further comprises an active material layer supported on the metal layer, the metal grid extends away from the active material layer. In an electrochemical cell, the metal grid can be connected to the metal grids of other electrodes and/or cell tabs.

Described herein are current collectors comprising metal grids as well as electrodes and lithium-metal cells comprising such current collectors and methods of fabricating such current collectors, electrodes, and lithium-metal cells. A thin current collector comprises a polymer base and a metal layer positioned on, directly interfaces, and supported by one side of the polymer base. A thin current collector also comprises a metal grid, which directly interfaces and is supported by the edge of the polymer base. The metal grid is electrically coupled to the metal layer, e.g., by overlapping or at least forming an interface with the metal layer. In an electrode that further comprises an active material layer supported on the metal layer, the metal grid extends away from the active material layer. In an electrochemical cell, the metal grid can be connected to the metal grids of other electrodes and/or cell tabs.

Provided are a non-woven fabric current collector and a method and system of fabricating a battery using the same. An electrode according to an embodiment of the present invention includes a non-woven fabric current collector including a conductive non-woven fabric sheet including a network of conductive fibers and pores for communication between a main surface and the interior thereof; and conductive patterns partially blocking the pores on the main surface of the conductive non-woven fabric sheet.

Provided are a non-woven fabric current collector and a method and system of fabricating a battery using the same. An electrode according to an embodiment of the present invention includes a non-woven fabric current collector including a conductive non-woven fabric sheet including a network of conductive fibers and pores for communication between a main surface and the interior thereof; and conductive patterns partially blocking the pores on the main surface of the conductive non-woven fabric sheet.

A battery grid pasting machine includes a support structure, a battery grid plate support for supporting a battery grid plate, a paste dispensing hopper, a height adjustment mechanism for adjusting the spacing between the hopper and the battery grid plate support and a control system. The height adjustment mechanism includes a hydraulic cylinder connected to the hopper and a position sensor for sensing the position of the hydraulic cylinder. The control system includes a first hydraulic pump and a first hydraulic valve associated with the first hydraulic pump for incrementally moving the hydraulic cylinder by a first specified distance and a second hydraulic pump and a second hydraulic valve associated with the second hydraulic pump for incrementally moving the hydraulic cylinder by a second specified distance.

A battery grid pasting machine includes a support structure, a battery grid plate support for supporting a battery grid plate, a paste dispensing hopper, a height adjustment mechanism for adjusting the spacing between the hopper and the battery grid plate support and a control system. The height adjustment mechanism includes a hydraulic cylinder connected to the hopper and a position sensor for sensing the position of the hydraulic cylinder. The control system includes a first hydraulic pump and a first hydraulic valve associated with the first hydraulic pump for incrementally moving the hydraulic cylinder by a first specified distance and a second hydraulic pump and a second hydraulic valve associated with the second hydraulic pump for incrementally moving the hydraulic cylinder by a second specified distance.

A battery structure including a positive electrode current collector layer; a plurality of battery modules on the positive electrode current collector layer and spaced apart from one another; and a negative electrode current collector layer on the battery modules, opposite to the positive electrode current collector layer, wherein each battery module of the plurality of battery modules includes a plurality of first positive active material layers which are in electrical contact with the positive electrode current collector layer and disposed in a direction protruding from the positive electrode current collector layer; a plurality of first negative active material layers which are in electrical contact with the negative electrode current collector layer and disposed in a direction protruding from the negative electrode current collector layer; and an electrolyte layer between the first positive active material layers and the first negative active material layers.