A battery with many cavities that form tiny reaction zones having voids. A concave-shaped anode and convex shaped cathode is inserted into each of the cavities as layers. During charging, lithium metal forms in each cavity on the anode current collector. The formation of lithium metal in each of the many thousands of small cavities that are isolated from each other prevents the buildup of significant quantities of lithium metal in one location. The combination of tiny reaction zones and voids allows lithium metal to form without stressing the structure of the battery cell.

An electrically conductive holder (1′) for holding a tablet electrode (4) of a button battery (11′) pressed into the holder. The holder includes a bottom portion (3) and at least three supports (20) protruding outward from the bottom portion, the supports being positioned along the circumference of the holder so that the holder is supported by the supports. A wall portion (2) rises upward from the circumference of the bottom portion with the supports protruding from the bottom portion in the direction opposite the wall portion. Also, an assembly including the holder (1′) and a battery electrode tablet (4) pressed into the holder, and to a button battery (11′) including the assembly, and a method for producing a holder/tablet assembly by a compression process that uses a stamp (6′) provided with depressions (22) configured for deforming the bottom portion (3) of the holder during the compression process.

An electrically conductive holder (1′) for holding a tablet electrode (4) of a button battery (11′) pressed into the holder. The holder includes a bottom portion (3) and at least three supports (20) protruding outward from the bottom portion, the supports being positioned along the circumference of the holder so that the holder is supported by the supports. A wall portion (2) rises upward from the circumference of the bottom portion with the supports protruding from the bottom portion in the direction opposite the wall portion. Also, an assembly including the holder (1′) and a battery electrode tablet (4) pressed into the holder, and to a button battery (11′) including the assembly, and a method for producing a holder/tablet assembly by a compression process that uses a stamp (6′) provided with depressions (22) configured for deforming the bottom portion (3) of the holder during the compression process.

Embodiments described herein relate to electrodes containing yolk-sell electroactive materials. In some aspects, an anode can include a carbon shell having an outer surface and an inner volume, the carbon shell including a plurality of pinholes on the outer surface. The anode particle is disposed in the inner volume of the carbon shell, such that a portion of the inner volume includes a void space. The anode further includes a plurality of graphene flakes disposed on the outer surface of the carbon shell, the plurality of graphene flakes covering at least a portion of the pinholes. In some embodiments, at least about 50% of the inner volume of the carbon shell can include void space. In some embodiments, the plurality of graphene flakes can cover at least about 90% of the pinholes.

Embodiments described herein relate to electrodes containing yolk-sell electroactive materials. In some aspects, an anode can include a carbon shell having an outer surface and an inner volume, the carbon shell including a plurality of pinholes on the outer surface. The anode particle is disposed in the inner volume of the carbon shell, such that a portion of the inner volume includes a void space. The anode further includes a plurality of graphene flakes disposed on the outer surface of the carbon shell, the plurality of graphene flakes covering at least a portion of the pinholes. In some embodiments, at least about 50% of the inner volume of the carbon shell can include void space. In some embodiments, the plurality of graphene flakes can cover at least about 90% of the pinholes.

Embodiments of the invention provide batteries, electrodes, and methods of making the same. According to one embodiment, a battery may include a positive plate having a grid pasted with a lead oxide material, a negative plate having a grid pasted with a lead based material, a separator separating the positive plate and the negative plate, and an electrolyte. A nonwoven glass mat may be in contact with a surface of either or both the positive plate or the negative plate to reinforce the plate. The nonwoven glass mat may include a plurality of first coarse fibers having fiber diameters between about 6 μm and 11 μm and a plurality of second coarse fibers having fiber diameters between about 10 μm and 20 μm.

An electrochemical cell includes an anode, a semi-solid cathode, and a separator disposed therebetween. The semi-solid cathode includes a porous current collector and a suspension of an active material and a conductive material disposed in a non-aqueous liquid electrolyte. The porous current collector is at least partially disposed within the suspension such that the suspension substantially encapsulates the porous current collector.

An electrochemical cell includes an anode, a semi-solid cathode, and a separator disposed therebetween. The semi-solid cathode includes a porous current collector and a suspension of an active material and a conductive material disposed in a non-aqueous liquid electrolyte. The porous current collector is at least partially disposed within the suspension such that the suspension substantially encapsulates the porous current collector.

An electrically conductive porous composite composed of an expanded microsphere matrix binding a material composition having electrical conductivity properties to form an electrically conductive porous composite is disclosed herein. An energy storage device incorporating the electrically conductive porous composite is also disclosed herein.

A lithium metal electrode includes a current collector having a surface irregularity structure, a lithium metal layer disposed outside of the surface irregularity structure except the uppermost surface of the surface irregularity structure in the current collector, an electron-insulating protective layer disposed outside of the lithium metal layer, and a lithium ion-isolating layer disposed (1) on the uppermost surface of the surface irregularity structure of the current collector, or (2) on the uppermost surface of the surface irregularity structure of the current collector, on the uppermost surface of the lithium metal layer, and on the uppermost surface of the electron-insulating protective layer, wherein the electron-insulating protective layer includes a non-porous layer transporting lithium ions and having no pores, and a polymer porous layer disposed outside thereof. A lithium secondary battery and flexible secondary battery including the lithium metal electrode are also provided.