Systems and methods are provided for high volume roll-to-roll direct coating of electrodes for silicon-dominant anode cells and may include applying a slurry to a current collector film, the slurry comprising silicon particles and a binder material; drying the slurry to form a precursor composite film; rolling the current collector film into a precursor composite roll; and applying a heat treatment to the precursor composite film and the current collector film in a nitrogen gas environment, wherein the heat treatment is configured for converting the precursor composite film to a pyrolyzed composite film. The heat treatment may include one or both of: applying the heat treatment to a roll comprising the precursor composite roll in whole; and applying the heat treatment to the current collector film as it is continuously fed from the precursor composite roll.

Systems and methods are provided for high volume roll-to-roll direct coating of electrodes for silicon-dominant anode cells and may include applying a slurry to a current collector film, the slurry comprising silicon particles and a binder material; drying the slurry to form a precursor composite film; rolling the current collector film into a precursor composite roll; and applying a heat treatment to the precursor composite film and the current collector film in a nitrogen gas environment, wherein the heat treatment is configured for converting the precursor composite film to a pyrolyzed composite film. The heat treatment may include one or both of: applying the heat treatment to a roll comprising the precursor composite roll in whole; and applying the heat treatment to the current collector film as it is continuously fed from the precursor composite roll.

The invention provides process for producing a stable Si or Ge electrode structure comprising cycling a Si or Ge nanowire electrode until a structure of the Si nanowires form a continuous porous network of Si or Ge ligaments.

The invention provides process for producing a stable Si or Ge electrode structure comprising cycling a Si or Ge nanowire electrode until a structure of the Si nanowires form a continuous porous network of Si or Ge ligaments.

A battery and a method of constructing a battery are disclosed in which a first conductive substrate portion has a first face and a second conductive substrate portion has a second face opposed to the first face. A first electrode material is disposed in electrical contact with the first face, an electrolyte material is disposed in contact with the first electrode material, a second electrode material is disposed in contact with the electrolyte material, and a conductive tab disposed in contact with the second electrode material. The first conductive substrate portion, the first electrode material, and the conductive tab extend outward beyond a particular edge of the second conductive substrate portion.

A battery and a method of constructing a battery are disclosed in which a first conductive substrate portion has a first face and a second conductive substrate portion has a second face opposed to the first face. A first electrode material is disposed in electrical contact with the first face, an electrolyte material is disposed in contact with the first electrode material, a second electrode material is disposed in contact with the electrolyte material, and a conductive tab disposed in contact with the second electrode material. The first conductive substrate portion, the first electrode material, and the conductive tab extend outward beyond a particular edge of the second conductive substrate portion.

A permeable composite material for making an electrode for an electrochemical cell, the composite material comprising: a support defining pores; and alkali metal deposited on the support within a plurality of said pores. An electrode comprising the composite material is also described, as are methods of making the material and cells and assemblies comprising the electrode.

A permeable composite material for making an electrode for an electrochemical cell, the composite material comprising: a support defining pores; and alkali metal deposited on the support within a plurality of said pores. An electrode comprising the composite material is also described, as are methods of making the material and cells and assemblies comprising the electrode.

A method for preparing an electrode for use in lithium batteries and the resulting electrodes are described The method comprises coating a slurry of silicon, sulfur doped graphene and polyacrylonitrile on a current collector followed by sluggish heat treatment.

Systems and methods for water based phenolic binders for silicon-dominant anodes may include an electrode coating layer on a current collector, where the electrode coating layer is formed from silicon and a pyrolyzed water-based phenolic binder. The water-based phenolic binder may include phenolic/resol type polymers crosslinked with poly(methyl vinyl ether-alt-maleic anhydride), poly(methyl vinyl ether-alt-maleic acid), and/or Poly(acrylamide-co-diallyldimethylammonium chloride) (PDADAM). The electrode coating layer may further include conductive additives. The current collector may comprise one or more of a copper, tungsten, stainless steel, and nickel foil in electrical contact with the electrode coating layer. The electrode coating layer may include more than 70% silicon. The electrode may be in electrical and physical contact with an electrolyte, where the electrolyte includes a liquid, solid, or gel. The battery electrode may be in a lithium ion battery.