Granules including an active material powder and a binder are prepared. The granules are supplied onto a surface of a roller. The granules are electrically charged. The granules are transferred from a first region to a second region by way of rotation of the roller. A first electric field is formed between the second region and a third region to allow the granules to fly from the second region toward the third region. A second electric field is formed between the third region and a substrate to allow the granules to fly from the third region toward the substrate.

A process is provided comprising submerging a substrate in an electrochemical deposit bath having at least a metal salt and saccharin. In embodiments, the film is further treated with anodization, and in other cases chemical vapor deposition. Films are also provided formed by the disclosed processes. The films are nanoporous on at least a portion of a surface of the films. Also disclosed are electronic devices having the films disclosed, including lithium-ion batteries, storage devices, supercapacitors, electrodes, semiconductors, fuel cells, and/or combinations thereof.

A solid electrolyte interface is formed on a silicon monoxide electrode in a battery cell. While the solid electrolyte interface is being formed on the silicon monoxide electrode, the battery cell is charged for one or more initial cycles.

The present disclosure is directed to methods of securing battery tab structures to binderless, collectorless self-standing electrodes, comprising electrode active material and carbon nanotubes and no foil-based collector, and the resulting battery-tab secured electrodes. Such methods and the resulting battery tab-secured electrodes may facilitate the use of such composites in battery and power applications.

An electrode, a lithium battery including the same, and a method of preparing the electrode are provided. The electrode includes an electrode active material layer including an electrode active material and a binder; and an electrode current collector at a portion of the electrode active material layer and at one side of the electrode active material layer, or at a portion of the electrode active material layer between opposing sides of the electrode active material layer, wherein the electrode active material layer includes a plurality of through-holes.

Embodiments of the invention include batteries and other charge-storage devices incorporating sheets and/or powders of silica fibers and methods for producing such devices. The silica fibers may be formed via electrospinning of a sol gel produced with a silicon alkoxide reagent, such as tetraethyl ortho silicate, alcohol solvent, and an acid catalyst.

A method for manufacturing an electrode for a lithium ion battery is provided. A powder layer is formed by using a squeegee roll to squeegee powder including an electrode active material and supplied onto a substrate, and then compacted on the substrate by means of a pair of press rolls while conveying the substrate vertically downward to form an electrode sheet. The method includes: supplying the powder onto the substrate; leveling the powder supplied onto the substrate to form the powder layer using the squeegee roll which is disposed in a position so that a squeegee angle formed by a vertical line passing through the rotating axis of one of the press rolls and a line passing through said rotating axis and the rotating axis of the squeegee roll is 0° to 60°; and compacting the powder layer on the substrate using the pair of press rolls.

A process for delineating a population of electrode structures in a web is disclosed. The web has a down-web direction, a cross-web direction, an electrochemically active layer, and an electrically conductive layer. The process includes laser machining the web in at least the cross-web direction to delineate members of the electrode structure population in the web without releasing the delineated members from the web and forming an alignment feature in the web that is adapted for locating each delineated member of the electrode structure population in the web.

A method for producing a porous aluminum foil of the present invention is characterized in that a porous aluminum film is formed on a surface of a substrate by electrolysis using a plating solution containing at least (1) a dialkyl sulfone, (2) an aluminum halide, and (3) a nitrogen-containing compound, and having a water content of 100 to 2000 ppm, and then the film is separated from the substrate. The nitrogen-containing compound is preferably at least one selected from the group consisting of an ammonium halide, a hydrogen halide salt of a primary amine, a hydrogen halide salt of a secondary amine, a hydrogen halide salt of a tertiary amine, and a quaternary ammonium salt represented by the general formula: R.sup.1R.sup.2R.sup.3R.sup.4N.X (R.sup.1 to R.sup.4 independently represent an alkyl group and are the same as or different from one another, and X represents a counteranion for the quaternary ammonium cation).

Lithium ion batteries, electrodes, nanofibers, and methods for producing same are disclosed herein. Provided herein are batteries having (a) increased energy density; (b) decreased pulverization (structural disruption due to volume expansion during lithiation/de-lithiation processes); and/or (c) increased lifetime. In some embodiments described herein, using high throughput, water-based electrospinning process produces nanofibers of high energy capacity materials (e.g., ceramic) with nanostructures such as discrete crystal domains, mesopores, hollow cores, and the like; and such nanofibers providing reduced pulverization and increased charging rates when they are used in anodic or cathodic materials.