A high-capacity and long-life negative electrode hydrogen storage material of La—Mg—Ni type for secondary rechargeable nickel-metal hydride battery and a method for preparing the same are provided in the present invention. A chemical formula of the negative electrode hydrogen storage material of La—Mg—Ni type is La.sub.1-x-yRe.sub.xMg.sub.y(Ni.sub.1-a-bAl.sub.aM.sub.b).sub.z, wherein Re is at least one of Ce, Pr, Nd, Sm, Y, and M is at least one of Ti, Cr, Mo, Nb, Ga, V, Si, Zn, Sn; 0≤x≤0.10, 0.3≤y≤0.5, 0<a≤0.05, 0≤b≤0.02, 2.3≤z<3.0. The negative electrode hydrogen storage material of La—Mg—Ni type in the present invention has excellent charge-discharge capacity and cycle life. The negative electrode hydrogen storage material of La—Mg—Ni type can be applied in both common secondary rechargeable nickel-metal hydride battery and secondary rechargeable nickel-metal hydride battery with ultra-low self-discharge and long-term storage performance.

A lithium-sulfur battery cathode including conductive porous carbon particles vacuum infused with sulfur and a conductive collector substrate to which the sulfur infused porous carbon particles are deposited. The sulfur infused carbon particles are encapsulated by an encapsulation polymer, the encapsulation polymer having ionic conductivity, electronic conductivity, polysulfide affinity, or combinations thereof. A lithium-sulfur battery including the lithium-sulfur battery cathode, a lithium anode and an electrolyte disposed between the sulfur cathode and the lithium anode is also provided. Methods of producing the sulfur cathode for use in a lithium-sulfur battery by a hybrid vacuum-and-melt method are also provided.

A nonaqueous electrolyte battery includes: a positive electrode containing a positive electrode active material made of a compound represented by a compositional formula of LiMn.sub.1-x-yFe.sub.xA.sub.yPO.sub.4 (wherein A is at least one selected from the group consisting of Mg, Ca, Al, Ti, Zn and Zr, 0≤x≤0.3, and 0≤y≤0.1); a negative electrode containing a negative electrode active material made from a titanium composite oxide; and a nonaqueous electrolyte, wherein a ratio (I.sub.P—F/I.sub.P—O) of a peak intensity (I.sub.P—F) of a P—F bond to a peak intensity (I.sub.P—O) of a P—O bond on the surface of the positive electrode, which are measured by X-ray photoelectron spectroscopic analysis, is 0.4 or more and 0.8 or less.

An electrode assembly for a secondary battery and method are provided. The electrode assembly comprises a population of unit cells and a constraint system. The electrode assembly comprises a population of electrode structures, a population of counter-electrode structures, and an electrically insulating separator material. The constraint system comprises (i) first and second primary growth constraints separated in the longitudinal direction, (ii) first and second connecting members separated in the vertical direction that connect the first and second primary growth constraints and a subset of the members of the electrode or counter-electrode population. The first and second connecting members are adhered to the subset by an electrically-insulating, thermoplastic, hot-melt adhesive having (i) a melting temperature in the range of 75° C. to 130° C., and (ii) a melt index value as measured according to ASTM D1238 in a range of at least 20 to no more than 350.

A web coating platform for depositing molten metal on flexible substrates is provided. The web coating platform can be used for manufacturing solid lithium anodes for use in energy storage devices, for example, rechargeable batteries. The coating platform can be designed for double-sided coating of a continuous flexible substrate (e.g., a copper foil) with molten lithium followed by double-sided lamination or passivation. The coating platform integrates novel coating elements unique to handling and processing molten metals. For example, some implementations of the present disclosure incorporate double-sided molten metal coating elements, which include at least one of a molten metal application assembly (e.g., kiss roller, slot-die, Meyer bar, and/or gravure roller), a primary melt pool assembly, a secondary melt pool assembly, and an engagement mechanism.

A method for forming a battery anode can include: forming a slurry including active material comprising silicon particles, wherein the silicon particles can be derived from silica fumes, depositing the slurry on an current collector, drying the deposited slurry to form a deposited film, and compacting the deposited film to form the battery anode.

A three-dimensional metallic foam is fabricated with an active oxide material for use as an anode for lithium batteries. The porous metal foam, which can be fabricated by a freeze-casting process, is used as the anode current collector of the lithium battery. The porous metal foam can be heat-treated to form an active oxide material to form on the surface of the metal foam. The oxide material acts as the three-dimensional active material that reacts with lithium ions during charging and discharging.

A method of forming an electrode in an electrochemical battery. The method forms the electrode by sacrificial casting, wherein a reticulated foam is used to form a model of the electrode.

A hydrogen storing alloy containing only a few impurities leading to a short circuit where the yield can be maintained even when the alloy is subjected to magnetic separation treatment. A hydrogen storing alloy includes a matrix phase having an AB5 type crystal structure, the alloy having a misch metal (referred to as “Mm”) in an A-site in an ABx composition and having any one or at least one of Ni, Al, Mn, and Co in a B-site in the ABx composition, wherein the ratio (referred to as “ABx”) of the total number of moles of elements comprising the B site to the total number of moles of elements comprising the A site is 5.00<ABx≦5.40; the content of Co is more than 0.0 mol % and less than 0.7 mol %; and residual magnetization is more than 0 emu/g and 0.020 emu/g or less.

Disclosed are electrochemical devices, such as lithium ion battery electrodes, lithium ion conducting solid-state electrolytes, and solid-state lithium ion batteries including these electrodes and solid-state electrolytes. Also disclosed are methods for making such electrochemical devices. In particular, a segmented cell architecture disclosed herein enables solid state batteries to be flexible and capable of assuming a rolled or folded stack structure.