A method for manufacturing an electrode comprising a polymer matrix trapping an electrolyte, the method comprising the following steps: a) a step of preparing a composition comprising the ingredients intended to be included in the constitution of the electrode; b) a step of forming the electrode, from the composition, on a support; wherein the composition prepared in step a) is a composition in paste form having a dynamic viscosity greater than 5000. Pa.Math.s measured at a shear gradient of 0.1 s-1 and at ambient temperature; and wherein the preparation step consists in introducing the ingredients intended to be included in the constitution of the electrode into a mixer with two co-rotating interpenetrating screws rotating in a closed sleeve, and mixing the ingredients therein, the preparation step being implemented at a temperature less than 100° C.

The present invention relates to an electrochemical device comprising a) a positive electrode, b) a negative electrode, c) a separator, and d) a liquid electrolyte, wherein at least one of said positive electrode and said negative electrode is a gelled electrode comprising an electronic conductive substrate and directly adhered onto the electronic conductive substrate, at least one layer of a gelled electrode-forming composition, and wherein the d) liquid electrolyte comprises at least one organic carbonate and/or at least one ionic liquid, and at least one metal salt. The present invention also relates to a process for manufacturing an electrochemical device comprising at least one gelled electrode.

Embodiments described herein relate generally to devices, systems and methods of producing high energy density batteries having a semi-solid cathode that is thicker than the anode. An electrochemical cell can include a positive electrode current collector, a negative electrode current collector and an ion-permeable membrane disposed between the positive electrode current collector and the negative electrode current collector. The ion-permeable membrane is spaced a first distance from the positive electrode current collector and at least partially defines a positive electroactive zone. The ion-permeable membrane is spaced a second distance from the negative electrode current collector and at least partially defines a negative electroactive zone. The second distance is less than the first distance. A semi-solid cathode that includes a suspension of an active material and a conductive material in a non-aqueous liquid electrolyte is disposed in the positive electroactive zone, and an anode is disposed in the negative electroactive zone.

The present invention relates to a silicon-nanographite aerogel for use as an anode in a battery, such as a lithium ion battery, comprising a matrix of nanographite flakes consisting of a mixture of graphene, multilayer graphene and graphite nanoplatelets, and silicon nanoparticles having a diameter between 1 nm and 100 nm, whereby the aerogel has a three-dimensional structure with pores between the flakes, whereby the specific surface area accommodates a volume expansion of the silicon nanoparticles of at least 400% during lithiation, and wherein the surfaces of the nanographite flakes are for 10 to 90% covered with nanoparticles of silicon or wherein the aerogel has a specific surface area between 10 and 500 m.sup.2/g as measured using a BET (Braunauer-Emmett-Teller). The invention also relates to a method of making the aerogel and an electrode comprising the aerogel.

Nanoporous carbon-based scaffolds or structures, and specifically carbon aerogels and their manufacture and use thereof are provided. Embodiments include a silicon-doped anode material for a lithium-ion battery, where the anode material includes beads of polyimide-derived carbon aerogel. The carbon aerogel includes silicon particles and accommodates expansion of the silicon particles during lithiation. The anode material provides optimal properties for use within the lithium-ion battery.

Implementations described herein generally relate to metal electrodes, more specifically, lithium-containing anodes, high performance electrochemical devices, such as secondary batteries, including the aforementioned lithium-containing electrodes, and methods for fabricating the same. In one implementation, a rechargeable battery is provided. The rechargeable battery comprises a cathode film including a lithium transition metal oxide, a separator film coupled to the cathode film and capable of conducting ions, a solid electrolyte interphase film coupled to the separator, wherein the solid electrolyte interphase film is a lithium fluoride film or a lithium carbonate film, a lithium metal film coupled to the solid electrolyte interphase film and an anode current collector coupled to the lithium metal film.

An alkaline electrochemical cell includes a cathode, an anode which includes an anode active material, and a non-conductive separator disposed between the cathode and the anode, wherein from about 20% to about 50% by weight of the anode active material relative to a total amount of anode active material has a particle size of less than about 75 μm, and wherein the separator includes a unitary, cylindrical configuration having an open end, a side wall, and integrally formed closed end disposed distally to the open end.

Disclosed is a metal-air fuel cell based on a solid oxide electrolyte employing metal nanoparticles as fuel. The metal-air fuel cell includes an anode, a cathode, a solid oxide electrolyte and a metal fuel, wherein the metal fuel comprises metal nanoparticles having an average particle diameter ranging from 1 nm to 100 nm. The metal nanoparticles have a low melting point and provide high reactivity. Thus, the metal-air fuel cell forms a metal molten phase at a relatively low temperature thereby improving contactability and has improved reactivity to promote oxidation, thereby enabling highly efficient power generation.

Various embodiments are directed to an electrochemical cell having a non-homogeneous anode. The electrochemical cell includes a container, a cathode forming a hollow cylinder within the container, an anode positioned within the hollow cylinder of the cathode, and a separator between the cathode and the anode. The anode comprises at least two concentric anode portions, defined by different anode characteristics. For example, the two anode portions may contain different surfactant types, which provides the two anode portions with different charge transfer resistance characteristics. By lowering the charge transfer resistance of a portion of an anode located proximate the current collector of the cell (and away from the separator) relative to an anode portion located adjacent the separator, improved cell discharge performance may be obtained.

An electrochemical cell includes an anode, a semi-solid cathode, and a separator disposed therebetween. The semi-solid cathode includes a porous current collector and a suspension of an active material and a conductive material disposed in a non-aqueous liquid electrolyte. The porous current collector is at least partially disposed within the suspension such that the suspension substantially encapsulates the porous current collector.