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.

An electrochemical cell that converts chemical energy to electrical energy includes a cathode with an active material of fluorinated carbon on a perforated metal cathode current collector, a lithium anode on a perforated metal anode current collector, a stepped header, a stable electrolyte, and a separator. In various embodiments, an anode current collector design, a cathode current collector design, a stepped header design, a cathode formulation, an electrolyte formulation, a separator, and a battery incorporating the electrochemical cell are provided.

A cell, which is a non-aqueous electrolyte secondary battery, includes: an electrode assembly including a plurality of sheet-shaped positive electrodes and a plurality of sheet-shaped negative electrodes, the plurality of positive electrodes and the plurality of negative electrodes being alternately stacked with separators interposed therebetween; and a battery case that houses the electrode assembly. The electrode assembly includes: an outer layer including a positive electrode arranged on an outermost side of the electrode assembly, and a separator adjacent to the positive electrode; and an inner layer arranged on an inner side of the outer layer. The outer layer includes a fusing member configured to fuse due to heat generation in the electrode assembly caused by a short circuit in the electrode assembly. The inner layer does not include the fusing member.

Batteries and methods of using and making batteries are provided. A cell can include a housing; a cathode current collector, in the housing, including a cathode tab and a cathode plate. The cathode tab can include a tab area. The cathode plate can include a plate area and a peripheral edge that surrounds at least a portion of the plate area. The peripheral edge can include a plurality of partial perforations. The plate area can include a plurality of interior perforations. The cell can further include an anode current collector, in the housing, including an anode tab; an anode, in the housing, provided adjacent the anode current collector; and a cathode, in the housing, provided adjacent to the cathode current collector.

A process for preparing a cathode of a lithium battery, having the following steps: (a) Longitudinally punching a metal band to form irregular filamentous holes, horizontally stretching the metal band, and performing compaction to give the metal net irregular filamentous holes; (b) After the metal net is cleaned and dried, processing the metal net surface by a laser less than 5W, of 500-1000W, and of 10-100W sequentially; and (c) Coating the metal net, having the surface processed with lasers, with a prepared cathode paste, and drying, pressing, and cutting the metal net to obtain a battery cathode.

Disclosed herein are exemplary embodiments of improved electrode plate and separator assemblies (400) for lead acid batteries, improved lead acid cells or batteries incorporating the improved assemblies, systems or vehicles incorporating the improved assemblies (400) and/or batteries (100), and methods related thereto. The electrode plate (200, 201) may have a grid (202) of a stamped, cast, or expanded metal manufacturing process. The grid (202) may have a non-uniform application of active material (203). The separators (300) preferably provide a support structure for resisting or mitigating any plate warping or plate deflection.

An electrochemical cell that converts chemical energy to electrical energy includes a cathode with an active material of fluorinated carbon on a perforated metal cathode current collector, a lithium anode on a perforated metal anode current collector, a stepped header, a stable electrolyte, and a separator. In various embodiments, an anode current collector design, a cathode current collector design, a stepped header design, a cathode formulation, an electrolyte formulation, a separator, and a battery incorporating the electrochemical cell are provided.

The present invention provides carbon-nanotube (CNT)-polymer-metal composite substrate products, each product including a first current collector including at least one carbon nanotube (CNT) mat and a high conducting metallic element in electrical connection with a first tab, the high conducting metallic element bound to the at least one carbon nanotube mat, and optionally including a second current collector including a metallic conducting element in electrical connection with a second tab, a separator material separating between the first and second current collectors, an electrolyte solution disposed between the first collector and the second collector and a housing configured to house the first collector, second collector, separator material electrolyte solution and active material.

A lithium ion secondary battery that can operate in a high-temperature environment of 85° C. The lithium ion secondary battery includes a positive electrode active material that can store and release lithium ions Li.sup.|, a positive electrode binder that binds the positive electrode active material, a negative electrode active material that can store and release lithium ions Li.sup.+, a negative electrode binder that binds the negative electrode active material, and an electrolytic solution containing an organic solvent and an imide-based lithium salt. The negative electrode active material is previously doped with lithium ions. The positive electrode binder has a Hansen solubility parameter-based relative energy difference (RED) value of more than 1 with respect to the electrolytic solution.