In an embodiment, a Li-ion battery cell comprises an anode electrode with an electrode coating that (1) comprises Si-comprising active material particles, (2) exhibits an areal capacity loading in the range of about 3 mAh/cm.sup.2 to about 12 mAh/cm.sup.2, (3) exhibits a volumetric capacity in the range from about 600 mAh/cc to about 1800 mAh/cc in a charged state of the cell, (4) comprises conductive additive material particles, and (5) comprises a polymer binder that is configured to bind the Si-comprising active material particles and the conductive additive material particles together to stabilize the anode electrode against volume expansion during the one or more charge-discharge cycles of the battery cell while maintaining the electrical connection between the metal current collector and the Si-comprising active material particles.

An electrode structure for a battery includes a middle layer made of an electrically conductive perforated mesh having a top surface, a bottom surface, a plurality of interconnected electrically conductive segments and a plurality of perforations among adjacent ones of the interconnected segments. A top layer of an electrode material is disposed on the top surface, and a bottom layer of the electrode material is disposed on the bottom surface, such that the top and bottom layers are disposed in physical contact with each other through the perforations in the middle layer. A method of manufacturing the electrode structure includes providing the layer of perforated mesh, applying the top and bottom layers of electrode material to the top and bottom surfaces, and curing the top and bottom layers of electrode material using one or more of heat, electromagnetic radiation and convection to produce a layer of cured electrode structure.

Aspects of the disclosure include an electrode coating having a spatially varied porosity and a method of forming the same by using a porous current collector. An exemplary method can include forming a porous current collector having a bulk material and a plurality of voids. The porous current collector can be coated, infused, or otherwise saturated with an electrode coating having an active electrode material. The porous current collector and the electrode coating can be compressed in a calendering process to define the electrode film. The distribution of the plurality of voids in the porous current collector provides for regions of different calendering pressures during the calendering process. The regions of different calendering pressures leads to regions of higher and lower porosity in the resultant electrode film. In other words, an electrode film having a spatially varied porosity.

An electrode, a battery laminate, a battery and methods of providing the electrode, laminate or battery, where the electrode has an electrode layer and a current collector both having through-going bores of a size allowing liquid transport through the current collector and the electrode layer. The bores are provided by providing elongate slits or weakened portions and deforming the electrode. The current collector also has channels therein allowing liquid to travel along a plane of the current collector. In this manner, the drying of and introduction of electrolyte therein is made much faster.

An alkaline electrochemical cell has a central cathode having a corresponding cathode current collector electrically connected with a positive terminal of the electrochemical cell. The cathode current collector has a tubular shape, such as a cylindrical shape or rectangular shape, extending parallel with the length of the central cathode. The cathode current collector is embedded within the central cathode, such as at a medial point of a radius of the central cathode, thereby minimizing the distance between the cathode current collector and any portion of the central cathode, thereby increasing the mechanical strength of the cathode and facilitating charge transfer to the cathode current collector.

An object of the present invention is to provide an aluminum foil and an aluminum member for electrodes having good adhesiveness to an electrode material and high conductivity with the electrode material. Provided is an aluminum foil having through holes including an aluminum oxide film having a thickness of 25 nm or less on a surface of the aluminum foil, and further a hydrophilic layer on a part of a surface of the aluminum oxide film.

An electrode and a method of manufacturing an electrode for a lithium secondary battery comprising a perforated current collector. The perforated current collector is capable of allowing active materials to be bonded through perforations of the perforated current collector, and at the same time, improving the energy density of the battery by reducing the weight even if the wet process and the electrically conductive material and binder, which are essential components of the existing electrode mixture, are excluded. The electrode for the lithium secondary battery comprises a first electrode active material layer; a second electrode active material layer; and a perforated current collector interposed between the first electrode active material layer and the second electrode active material layer and is characterized in that the first electrode active material layer and the second electrode active material layer are combined through perforations of the current collector.

In a method of manufacturing an electrochemical cell, a porous or non-porous metal substrate may be provided. A precursor solution may be applied to a surface of the metal substrate. The precursor solution may comprise a chalcogen donor compound dissolved in a solvent. The precursor solution may be applied to the surface of the metal substrate such that the chalcogen donor compound reacts with the metal substrate and forms a conformal metal chalcogenide layer on the surface of the metal substrate. A conformal lithium metal layer may be formed on the surface of the metal substrate over the metal chalcogenide layer.

Electrical storage devices (10,38) are provided with pasted negative electrodes (12) and pasted positive electrodes (15) with porous separators (18) between them, with current collectors (20,22) disposed between the separator (18) and the negative and positive pastes (13,16), respectively.

Alkali metal secondary batteries that include anodes constructed from alkali metal foil applied to only one side of a porous current collector metal foil. Openings in the porous current collectors permit alkali metal accessibility on both sides of the anode structure. Such anode constructions enable the utilization of lower-cost and more commonly available alkali metal foil thickness, while still achieving high cell cycle life at a significantly reduced cost. Aspects of the present disclosure also include batteries with porous current collectors having increased volumetric and gravimetric energy densities, and methods of manufacturing anodes with porous current collectors.