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.

The invention discloses a lithium battery structure and the electrode layer thereof. The lithium battery structure includes two battery units with the two negative active material layers being disposed in face-to-face arrangement. The negative current collector includes a conductive substrate with a plurality of through holes and an isolation layer. The isolation layer is covered on one surface of the conductive substrate and extended along the through holes to another surface to cover the edge of the openings of the through holes. It can be effectively avoided the lithium dendrites depositing near the openings of the through holes on the conductive substrate. Also, the face-to-face arrangement of the negative active material layers is effectively control the locations of the plated lithium dendrites. Therefore, the safety of the battery and the cycle life of the battery is greatly improved.

A method for producing a cathode for a lithium-ion battery includes providing a cathode collector carrier film and applying a coating compound onto at least one main surface of the cathode collector carrier film. The coating compound contains a particulate auxiliary material. The coating compound is subsequently compressed to form a cathode film on the cathode collector carrier film. During the compression of the coating compound, the cathode collector carrier film is perforated. A lithium-ion battery is also described.

Provided is a stacked electrode assembly including: a lowermost electrode arranged on a lowermost portion of the stacked electrode assembly; an uppermost electrode arranged on an uppermost portion of the stacked electrode assembly; at least one unit stacked body arranged between the lowermost electrode and the uppermost electrode and including a positive electrode, a negative electrode, and a separator, the separator being arranged between the positive electrode and the negative electrode; and a separator arranged between the lowermost electrode and the at least one unit stacked body, and between the at least one unit stacked body and the uppermost electrode. A capacity and energy density of a lithium battery may be improved by employing an electrode including a mesh electrode current collector as the lowermost electrode or the uppermost electrode of the stacked electrode assembly.

A fuel electrode incorporates a first and second corrugated portion that are attached to each other at offset angles respect to their corrugation axis and therefore reinforce each other. A first corrugated portion may extend orthogonally with respect to a second corrugated portion. The first and second corrugated portions may be formed from metal wire and may therefore have a very high volumetric void fraction and a high surface area to volume ratio (sa/vol). In addition, the strands of the wire may be selected to enable high conductivity to the current collectors while maximizing the sa/vol. In addition, the shape of the corrugation, including the period distance, amplitude and geometry may be selected with respect to the stiffness requirements and electrochemical cell application factors. The first and second corrugated portions may be calendared or crushed to reduce thickness of the fuel electrode.

A negative electrode for an electrochemical cell of a lithium metal battery may be manufactured by welding together a lithium metal layer and a metallic current collector layer. The lithium metal layer and the current collector layer may be arranged adjacent one another and in an at least partially lapped configuration such that faying surfaces of the layers confront one another and establish a faying interface therebetween at a weld site. A laser beam may be directed at an outer surface of the current collector layer at the weld site to melt a portion of the lithium metal layer adjacent the faying surface of the current collector layer and produce a lithium metal molten weld pool. The laser beam may be terminated to solidify the molten weld pool into a solid weld joint that physically bonds the lithium metal layer and the current collector layer together at the weld site.

Using the generally used coating method of an active material paste to a metal foil on a 3DF made the electrode properties instable due to residual air inside of the 3DF, and had the risk of causing micro short circuit of the battery due to metal fine powder and the like adhered to the 3DF and the 3DF exposed to the electrode surface. To solve the above-mentioned, the coating of the active material paste to the 3DF was made into a two-step coating process as shown below. Step one removes the air and fills the paste at the same time by applying the paste flow from one side of the 3DF (the first step coating process). Step two coats a new paste onto the surface of the electrode obtained by step one (the second step coating process). This electrode obtained by the two-step coating process hardly has remaining air amount, can uniformly confine metallic power dust or the 3DF itself inside the electrode (the first step coating process), and in addition to this, has the capability of Li ions freely moving between the electrode surface and the depth portion of the electrode through the opening portion formed on the tip portion of the innumerable protrusions of the 3DF, the micro short circuit of the battery due to Li dendrite was prevented even in repeated charge and discharge.

Disclosed are an electrode including a perforated current collector, and a lithium secondary battery including the same, and according to the present disclosure, precipitation and elimination reactions of lithium metal are induced inside a perforation of a negative electrode current collector, and therefore, volume expansion of a cell is suppressed and battery performance is enhanced therefrom.

In an embodiment, a Li-ion battery cell comprises an anode electrode with an electrode coating that (1) comprises Si-comprising active material particles, (2) exhibits an areal capacity loading in the range of about 3 mAh/cm.sup.2 to about 12 mAh/cm.sup.2, (3) exhibits a volumetric capacity in the range from about 600 mAh/cc to about 1800 mAh/cc in a charged state of the cell, (4) comprises conductive additive material particles, and (5) comprises a polymer binder that is configured to bind the Si-comprising active material particles and the conductive additive material particles together to stabilize the anode electrode against volume expansion during the one or more charge-discharge cycles of the battery cell while maintaining the electrical connection between the metal current collector and the Si-comprising active material particles.

Provided herein are three-dimensional ion transport networks and current collectors for electrodes of electrochemical cells. Exemplary electrodes include interconnected layers and channels including an electrolyte to facilitate ion transport. Exemplary electrodes also include three dimensional current collectors, such as current collectors having electronically conducting rods, electronically conducting layers or a combination thereof.