The present invention relates to a mesh-shaped, porous electric current density distributor for use with an electrode, the current density distributor being adapted for providing electric current to an active layer of the electrode, which active layer is provided to contact a face of the current density distributor, wherein the current density distributor comprises a porous mesh having a plurality of electrically conductive paths, wherein at least part of the electrically conductive paths extend along a direction of major current flow over the current density distributor. The porous mesh comprises in a direction crosswise to the direction of major electric current flow, a plurality of first paths of an electric insulator. The current carrying capacity of the current density distributor in crosswise direction to the major current flow over the current density distributor is smaller than the current carrying capacity in the direction along the major current flow over the current density distributor.

A mixed material having a high expansion rate for producing a porous metallic sintered body including: a conventional mixed material for producing a porous metallic sintered body which is formed of a mixture including a composition of 0.05 to 10% by mass of a non-water-soluble hydrocarbon-based organic solvent having 5 to 8 carbon atoms, 0.5 to 20% by mass of a water-soluble resin binder, and 5 to 80% by mass of a metal powder having an average particle size within a range of 0.5 to 500 m, and water as the balance; and a gas, wherein the mixed material contains the gas so that the proportion of the gas is within a range of 2 to 50% by volume while the remainder is the conventional mixed material for producing a porous metallic sintered body.

This invention provides metal-foam electrodes for batteries and fuel cells. In some variations, an electrode includes a first metal layer disposed on a second metal layer, wherein the first metal layer comprises an electrically conductive, open-cell metal foam with an average cell diameter of about 25 m or less. The structure also includes smaller pores between the cells. The electrode forms a one piece monolithic structure and allows thicker electrodes than are possible with current electrode-fabrication techniques. These electrodes are formed from an all-fluidic plating solution. The disclosed structures increase energy density in batteries and power density in fuel cells.

A battery includes an anode, an electrolyte, and a cathode. The cathode includes a current collector formed from a mesh structure with an opening pattern. The opening pattern does not include any angles less than 90 degrees, and the current collector has a first surface and a second surface opposite the first surface. The cathode also includes a first material layer bonded to the first surface of the current collector, and a second material layer bonded to the second surface of the current collector and to the first material layer through the current collector.

Systems and methods are provided for managing anisotropic expansion of silicon-dominant anodes. An example battery may include a cathode, an electrolyte, and an anode, with the anode including a current collector and an active material on a surface of the current collector. One or more characteristics of the current collector may ensure meeting particular expansion criteria. The expansion criteria may include expanding less in one of x-y directions and z-direction while expanding more in other one of the x-y directions and the z-direction, the x-y directions being parallel to the surface of the current collector and perpendicular to a thickness of the active material. The one or more characteristics include at least material of the current collector.

An electrode/separator assembly for use in an electrochemical cell includes a current collector; a porous composite electrode layer adhered to the current collector, said electrode layer comprising at least electroactive particles and a binder; and a porous composite separator layer comprising inorganic particles substantially uniformly distributed in a polymer matrix to form nanopores and having a pore volume fraction of at least 25%, wherein the separator layer is secured to the electrode layer by a solvent weld at the interface between the two layers, said weld comprising a mixture of the binder and the polymer. Methods of making and using the assembly are also described.

A current collector including a first principal plane and a second principal plane with a roughness of a first principal plane and a roughness of a second principal plane being mutually different.

A current collector including a first principal plane and a second principal plane with a roughness of a first principal plane and a roughness of a second principal plane being mutually different.

A current collector including a first principal plane and a second principal plane. In the current collector, the roughness of the first principal plane and second principal plane being mutually different.

A method for manufacturing an anode electrode includes providing a first substrate, a second substrate, and an anode current collector. The method includes forming a first lithium metal layer on the first substrate and a second lithium metal layer on the second substrate. The method includes pressing the first lithium metal layer and the second lithium metal layer into the anode current collector to form an anode electrode.