Various methods and apparatus relating to three-dimensional battery structures and methods of manufacturing them are disclosed and claimed. In certain embodiments, a three-dimensional battery comprises a battery enclosure, and a first structural layer within the battery enclosure, where the first structural layer has a first surface, and a first plurality of conductive protrusions extend from the first surface. A first plurality of electrodes is located within the battery enclosure, where the first plurality of electrodes includes a plurality of cathodes and a plurality of anodes, and wherein the first plurality of electrodes includes a second plurality of electrodes selected from the first plurality of electrodes, each of the second plurality of electrodes being in contact with the outer surface of one of said first plurality of conductive protrusions. Some embodiments relate to processes of manufacturing energy storage devices with or without the use of a backbone structure or layer.

A method for manufacturing an electrode having a porosity of between 20% and 60% by volume and pores with an average diameter of less than 50 nm. In the method, provision is made of a substrate and a colloidal suspension of aggregates or agglomerates of monodisperse primary nanoparticles of an active electrode material, having an average primary diameter D.sub.50 of between 2 and 100 nm, the aggregates or agglomerates having an average diameter D.sub.50 of between 50 nm and 300 nm. A layer is deposited from said colloidal suspension on the substrate. The deposited layer is then dried and consolidated to obtain a mesoporous layer. A coating of an electronically conductive material is then deposited on and inside the pores of the porous layer. Such a porous electrode can be used in lithium-ion microbatteries.

A method for producing an all-solid multilayer battery, and an all-solid multilayer battery. The all-solid multilayer battery may be produced by depositing, by electrophoresis without any binder, at least one anode layer, at least one electrolyte layer, and at least one cathode layer. The at least one electrolyte layer, and the at least one cathode layer are obtained from a colloidal suspension containing nanoparticles that are not agglomerated with each other to create clusters and remain isolated from each other. A layer of Ms bonding material is then deposited on a surface of the at least one electrolyte layer. Next, two layers from the at least one dense anode layer, the at least one dense electrolyte layer, and the at least one dense cathode layer, are stacked face-to-face to obtain the all-solid multilayer battery having an assembly of a plurality of elementary cells connected with one another in parallel.

A method for generating hydrogen and making graphenic carbon particles is disclosed comprising introducing an inert carrier gas and a hydrocarbon precursor material comprising a material capable of forming a two-carbon-fragment species and/or methane into a thermal zone, heating the hydrocarbon precursor material in the thermal zone to decompose the hydrocarbon precursor material and form the hydrogen and the graphenic carbon particles, and contacting the gaseous stream with a quench stream. Graphenic carbon particles having an average aspect ratio greater than 3:1, a B.E.T. specific surface area of from 70 to 1000 square meters per gram, and a Raman spectroscopy 2D/G peak ratio of at least 1:1.

A negative electrode for a lithium metal battery includes a metal current collector substrate. A lithium metal layer is formed on at least one surface of the metal current collector substrate. A pre-lithiation layer is formed on the lithium metal layer. The pre-lithiation layer includes a prelithiated active material.

A method for manufacturing a lithium-ion microbattery having a capacity not exceeding 1 mAh, implementing a method for manufacturing an assembly comprising a porous electrode and a porous separator comprising a porous layer deposited on a substrate having a porosity comprised between 20% and 60% by volume, and pores with an average diameter of less than 50 nm. The separator comprises a porous inorganic layer deposited on the electrode, the porous inorganic layer having a porosity comprised between 20% and 60% by volume, and pores with an average diameter of less than 50 nm.

Herein discussed is an electrode comprising a copper or copper oxide phase and a ceramic phase, wherein the copper or copper oxide phase and the ceramic phase are sintered and are inter-dispersed with one another. Further discussed herein is a method of making a copper-containing electrode comprising: (a) forming a dispersion comprising ceramic particles and copper or copper oxide particles; (b) depositing the dispersion onto a substrate to form a slice; and (c) sintering the slice using electromagnetic radiation.

A method of dry coating of surfaces of a carrier and/or of production of self-standing layers, especially for use in lithium ion batteries having improved properties, is proposed, wherein the coating is effected at least by means of a particle-comprising powder in the dry state, especially having a solvent content of less than 1% by weight, and alignment of the particles is conducted in order to reduce the ionic resistance of the powder layer. The alignment of the particles additionally comprises fluidization of the powder.

Electrodepositable compositions including an aqueous medium, an ionic resin and particles including thermally produced graphenic carbon nanoparticles are disclosed. The compositions may also include lithium-containing particles. Electrodeposited coatings comprising a cured ionic resin, thermally produced graphenic carbon nanoparticle and lithium-containing particles are also disclosed. The electrodeposited coatings may be used as coatings for lithium ion battery electrodes.

A method for manufacturing an electrochemical device, implementing a process for manufacturing a porous electrode having a porous layer deposited on a substrate, the porous layer having a porosity of between 20% and 60% by volume and pores with an average diameter of less than 50 nm. The method includes providing a substrate and a colloidal suspension including aggregates or agglomerates of monodisperse primary nanoparticles of an active electrode material, having an average primary diameter of between 2 and 60 nm, the aggregates or agglomerates having an average diameter of between 50 nm and 300 nm, then depositing a layer from the colloidal suspension on the substrate, then drying and consolidating the layer to obtain a mesoporous layer, and then depositing a coating of an electronically conductive material on and inside the pores of the layer.