A lithium- or sodium-ion battery anode layer, comprising a phosphorus material embedded in pores of a solid graphene foam composed of multiple pores and pore walls, wherein (a) the pore walls contain a pristine graphene or a non-pristine graphene material; (b) the phosphorus material contains particles or coating of P or MP.sub.y (M=transition metal and 1≤y≤4) and is in an amount from 20% to 99% by weight based on the total weight of the graphene foam and the phosphorus material combined, and (c) the multiple pores are lodged with particles or coating of the phosphorus material. Preferably, the solid graphene foam has a density from 0.01 to 1.7 g/cm.sup.3, a specific surface area from 50 to 2,000 m.sup.2/g, a thermal conductivity of at least 100 W/mK per unit of specific gravity, and/or an electrical conductivity no less than 1,000 S/cm per unit of specific gravity.

A secondary battery electrode includes: a current collector made of a porous metal material; and an electrode material mixture with which the current collector is filled. The current collector includes a material mixture-filled segment that is filled with the electrode material mixture, and a material mixture-unfilled segment that is unfilled with the electrode material mixture. The material mixture-unfilled segment includes a current-collecting tab which is thinner than the material mixture-filled segment and in which the porous metal material is present at a higher density than in the material mixture-filled segment, and a tab convergence portion via which the material mixture-filled segment is coupled to the current-collecting tab. The tab convergence portion is provided with at least one rib extending from a side adjacent to the material mixture-filled segment toward the current-collecting tab.

To provide a solid-state battery that can improve layout by allowing a current collecting position to be optionally disposed and that can suppress the occurrence of short circuits. A solid-state battery includes a positive electrode, a negative electrode, and a solid electrolyte layer disposed between the positive electrode and the negative electrode. A first electrode selected from one of the positive electrode and the negative electrode includes a material mixture filled portion including a metal porous body filled with an electrode material mixture. The solid electrolyte layer is disposed so as to cover a periphery of the material mixture filled portion. A second electrode selected from the other of the positive electrode and the negative electrode is disposed so as to cover the solid electrolyte layer.

This invention relates in general to electroactive materials and a process for the preparation thereof. The electroactive particles comprise a comprise a porous particle framework, wherein the total pore volume of pores having pore diameter in the range from 3.5 to 100 nm is in the range from 0.3 to 2.4 cm3 per gram of the porous particle framework. The pores of the porous particle are at least partially occupied by a multilayer coating that is disposed on the internal pore surfaces of the porous particle framework. The multilayer coating comprises at least a first electroactive material layer, a second electroactive material layer, and a first interlayer material disposed between the first and second electroactive material layers.

The present disclosure provides a solid-state bipolar battery that includes negative and positive electrodes having thicknesses between about 100 μm and about 3000 μm, and a solid-state electrolyte layer disposed between the negative electrode and the positive electrode and having a thickness between about 5 μm and about 100 μm. The first electrode includes a plurality of negative solid-state electroactive particles embedded on or disposed within a first porous material. The second electrode includes plurality of positive solid-state electroactive particles embedded on or disposed within a second porous material that is the same or different from the first porous material. The solid-state bipolar battery includes a first current collector foil disposed on the first porous material, and a second current collector foil disposed on the second porous material. The first and second current collector foils may each have a thickness less than or equal to about 10 μm.

An electrode includes a soft substrate, a metal layer in direct contact with the soft substrate, and a lithium layer formed directly on the metal layer, wherein the metal layer comprises wrinkles. The wrinkles are of a substantially uniform height, and the height is in a range of 100 nm to 20 μm. The wrinkles are typically separated by a substantially uniform distance, and the distance is in a range of 100 nm to 1000 μm. The wrinkles may be one dimensional or two dimensional. Fabricating an electrode includes forming a metal layer on a soft substrate, and forming a lithium layer on the metal layer. Forming the lithium layer on the metal layer yields uniform wrinkles in the metal layer. A battery may include the electrode as described.

A current collector may comprise a strength enhancement layer and a current collecting layer, wherein the current collecting layer may be stacked and bonded with the strength enhancement layer, and the current collecting layer may comprise a foam metal portion and a solid metal portion.

The present application provides a current collector and a preparation method therefor, a secondary battery, a battery module, a battery pack and a power consuming device. The current collector may comprise a strength enhancement layer and a current collecting layer. The current collecting layer may comprise a first foam metal layer that may be stacked and bonded with the strength enhancement layer and a second foam metal layer that may be provided on the side of the first foam metal layer away from the strength enhancement layer and may be stacked with the first foam metal layer, the second foam metal layer having a porosity greater than that of the first foam metal layer.

A secondary battery negative electrode according to the invention includes: a three-dimensional current collector formed of a self-supporting sponge-like structure of carbon nanotubes; a metal active material contained inside the three-dimensional current collector; and a plurality of seed particles contained inside the three-dimensional current collector and made of a material different from the metal active material, in which the secondary battery negative electrode does not include a foil of the metal active material.

Battery electrodes using VACNT forests to create 3D electrode nanostructures, and methods of making, are described. The VACNTs are electrically and mechanically attached to the anode or cathode substrates, providing a large area of 3D surfaces for coating with active materials and high-conductivity electron pathways to the cell current collectors. A number of different active materials suitable for anodes and cathodes in lithium-ion batteries may be used to coat the individual carbon nanotubes. The high surface area provided by the VACNT forest and the nano-dimensions of the coated active materials enable both high energy-density and high power-density to be achieved with the same battery. Complete conformal coating of the individual CNTs may be achieved by a number of different methods, and coating with multiple active materials may be used to create nanolaminate coatings having improved electrochemical characteristics over single materials.