Two-dimensional (2D) material-based metal or alloy catalysts synthesized on carbon materials (e.g., carbon nanotubes) prevent polysulfide shuttling and overcome technical challenges for developing practical lithium-sulfur (Li—S) batteries. Soluble lithium polysulfides (LiPSs) tend to shuttle during battery cycling and corrode a Li anode, leading to eventual performance fading in the Li—S battery. This shuttle effect can be reduced by accelerating the conversion of the dissolved polysulfides to the insoluble LiPSs and back to the sulfur. A 2D material-based alloy or 2D material synthesized on carbon materials can suppress polysulfide shuttling by catalyzing polysulfide reactions. 2D material-based alloys with 2H (semiconducting)-1T (metallic) mixed phase exhibit synergistic effects of accelerated electron transfer and catalytic performance as confirmed by the lower charge-transfer resistance of carbon nanotube (CNT)-S cathode and the high binding energy of LiPSs to the catalyst.

A technique of improving the performance of a secondary battery is provided. A secondary battery according to an embodiment includes a first electrode, a second electrode, a first layer disposed on the first electrode and including a first n-type oxide semiconductor, a second layer disposed on the first layer and including a second n-type oxide semiconductor material and a first insulating material, a third layer which is disposed on the second layer and is a solid electrolyte layer, and a fourth layer disposed on the third layer and including hexagonal Ni(OH)2 microcrystals.

A conductive current collector with modified surfaces can be included as a portion of a bipolar battery assembly. The fabrication process can include deposition or formation of a thin film layer such as metal silicide on a surface of the current collector. Metal silicides can be created by co-sputtering or by annealing after deposition of one or more of a silicon or a metal layer. Additional layers can be provided, such as to facilitate adhesion of an active material to a current collector.

A method of forming a layer of a cathode is provided. The method includes generating a plasma remote from one or more sputter targets, sputtering material from the target or targets using the plasma, and depositing the sputtered material on the substrate to which a bias voltage has been applied, thereby forming the layer of cathode.

In certain embodiments, a method includes forming a battery electrode on a substrate. Forming the battery electrode on the substrate includes depositing a first electrode active material layer on a first portion of a surface of the substrate and depositing, to form a current collector, a conductive material using a thin film deposition process on a surface of the first electrode active material layer. The conductive material is deposited over an edge of the first electrode active material layer and onto a second portion of the surface of the substrate, the second portion of the substrate being adjacent to the first portion of the substrate. The method includes removing the battery electrode from the substrate, the battery electrode including the first electrode active material layer and the current collector.

Embodiments described herein relate generally to devices, systems and methods of producing high energy density electrodes including a first electrode material disposed on a current collector and having a first porosity, and a second electrode material disposed on the first electrode material and having a second porosity less than the first porosity. In some embodiments, the second electrode material includes a mixture of an active material and a conductive material in a liquid electrolyte. In some embodiments, the first electrode materials can have a different composition than the second electrode material. In some embodiments, the first electrode material can include a high-capacity material such as tin, silicon antimony, aluminum, or titanium oxide. In some embodiments, a lithium-containing material can be disposed between the first electrode material and the second electrode material.

A method for forming a battery structure includes texturing an anode packaging material to form a first textured surface, depositing one or more metal layers including an anode metal on the first textured surface and forming a separator on the anode metal. It also includes texturing a cathode packaging material to form a second textured surface, depositing a cathode metal on the second textured surface, and forming an electrolyte binder paste on the cathode metal, which contacts the separator with any gap being filled with electrolyte.

A secondary battery includes: a first electrode configured to function as a p-type semiconductor; a second electrode configured to function as an n-type semiconductor; and a hole transfer member provided between the first electrode and the second electrode, the first electrode is a sputtered film or a vapor deposited film, the second electrode is a sputtered film or a vapor deposited film containing at least one of silicon and graphene, and the hole transfer member is a sputtered film or a vapor deposited film containing a dielectric material.

Provided is conducting network polymer-encapsulated phosphorus-based anode particulate or multiple particulates for a lithium or sodium ion battery, the particulate comprising: (A) a core comprising one or a plurality of phosphorus material particles or coating (e.g. on surfaces of graphitic material particles) having a diameter or thickness from 0.5 nm to 10 μm and is selected from red phosphorus, black phosphorus (including phosphorene), violet phosphorus, a metal phosphide, MPy, or a combination thereof, wherein M=Mn, V, Sn, Ni, Cu, Fe, Co, Zn, Ge, Se, Mo, Ga, In, or an alloy thereof, and y=1-4; and (B) an encapsulating shell that embraces or encapsulates the core, wherein the encapsulating shell comprises an electron- and/or ion-conducting network (cross-linked) polymer.

A negative electrode having a carbon-based thin film formed on at least one surface of a lithium metal layer, and a lithium secondary battery including the same. A carbon-based thin film formed on at least one surface of a lithium metal layer blocks side reactions caused by direct contact between the lithium metal layer and an electrolyte as well as increasing a specific surface area of a negative electrode, and thereby suppresses lithium dendrite formation, and by obtaining current density distribution uniformly, enhances cycle performance, reduces an overvoltage to improve electrochemical performance of a lithium secondary battery.