The adhesion between metal foil serving as a current collector and a negative electrode active material is increased to enable long-term reliability. An electrode active material layer (including a negative electrode active material or a positive electrode active material) is formed over a base, a metal film is formed over the electrode active material layer by sputtering, and then the base and the electrode active material layer are separated at the interface therebetween; thus, an electrode is formed. The electrode active material particles in contact with the metal film are bonded by being covered with the metal film formed by the sputtering. The electrode active material is used for at least one of a pair of electrodes (a negative electrode or a positive electrode) in a lithium-ion secondary battery.

A method of making a positive electrode includes forming a slurry of particles using an electrode formulation, a diluent, and oxalic acid, coating the slurry on a collector and drying the coating on the collector to form the positive electrode. The electrode formulation includes an electrode active material, a conductive carbon source, an organic polymeric binder, and a water soluble polymer. The diluent consists essentially of water.

The adhesion between metal foil serving as a current collector and a negative electrode active material is increased to enable long-term reliability. An electrode active material layer (including a negative electrode active material or a positive electrode active material) is formed over a base, a metal film is formed over the electrode active material layer by sputtering, and then the base and the electrode active material layer are separated at the interface therebetween; thus, an electrode is formed. The electrode active material particles in contact with the metal film are bonded by being covered with the metal film formed by the sputtering. The electrode active material is used for at least one of a pair of electrodes (a negative electrode or a positive electrode) in a lithium-ion secondary battery.

A power system adapted for supplying power in a high temperature environment is disclosed. The power system includes a rechargeable energy storage that is operable in a temperature range of between about seventy degrees Celsius and about two hundred and fifty degrees Celsius coupled to a circuit for at least one of supplying power from the energy storage and charging the energy storage; wherein the energy storage is configured to store between about one one hundredth (0.01) of a joule and about one hundred megajoules of energy, and to provide peak power of between about one one hundredth (0.01) of a watt and about one hundred megawatts, for at least two charge-discharge cycles. Methods of use and fabrication are provided. Embodiments of additional features of the power supply are included.

The present disclosure is directed towards the design of electrochemical cells for use in high pressure or high differential pressure operations. The electrochemical cells of the present disclosure have non-circular external pressure boundaries, i.e., the cells have non-circular profiles. In such cells, the internal fluid pressure during operation is balanced by the axial tensile forces developed in the bipolar plates, which prevent the external pressure boundaries of the cells from flexing or deforming. That is, the bipolar plates are configured to function as tension members during operation of the cells. To function as an effective tension member, the thickness of a particular bipolar plate is determined based on the yield strength of the material selected for fabricating the bipolar plate, the internal fluid pressure in the flow structure adjacent to the bipolar plate, and the thickness of the adjacent flow structure.

A method for using an integrated battery and device structure includes using two or more stacked electrochemical cells integrated with each other formed overlying a surface of a substrate. The two or more stacked electrochemical cells include related two or more different electrochemistries with one or more devices formed using one or more sequential deposition processes. The one or more devices are integrated with the two or more stacked electrochemical cells to form the integrated battery and device structure as a unified structure overlying the surface of the substrate. The one or more stacked electrochemical cells and the one or more devices are integrated as the unified structure using the one or more sequential deposition processes. The integrated battery and device structure is configured such that the two or more stacked electrochemical cells and one or more devices are in electrical, chemical, and thermal conduction with each other.

A clamping device for an electrochemical cell stack is provided. The clamping device can include a first plate and a second plate. The second plate can be positionable relative to the first plate such that a space between the first plate and the second plate can be sized to receive an electrochemical cell stack. The device also can include a coupling member coupling the first plate to the second plate. At least one of the first and second plates can be movable away from the other plate. The coupling member can have a first end portion and a second end portion. The device further can include an elastic member disposed between the first end portion and the second end portion.

Separator systems for electrochemical systems providing electronic, mechanical and chemical properties useful for applications including electrochemical storage and conversion. Separator systems include structural, physical and electrostatic attributes useful for managing and controlling dendrite formation and for improving the cycle life and rate capability of electrochemical cells including silicon anode based batteries, air cathode based batteries, redox flow batteries, solid electrolyte based systems, fuel cells, flow batteries and semisolid batteries. Separators include multilayer, porous geometries supporting excellent ion transport properties, providing a barrier to prevent dendrite initiated mechanical failure, shorting or thermal runaway, or providing improved electrode conductivity and improved electric field uniformity, as well as composite solid electrolytes with supporting mesh or fiber systems providing solid electrolyte hardness and safety with supporting mesh or fiber toughness and long life required for thin solid electrolytes without fabrication pinholes or operationally created cracks.

A battery assembly can be formed on a base layer provided on a substrate, with a thin film battery stack including an anode layer, a cathode layer, and an electrolyte layer between the anode and cathode layers. The thin film battery stack can be attached to a pattern film layer with holes for electrical connection to the anode and cathode layers.

A battery comprises at least one layer with anode material. For each layer with anode material, the battery comprises at least one layer with cathode material. Between each layer with anode material and each layer with cathode material there lies at least one separator as a separating layer. The battery also comprises a housing with an interior space. The housing is arranged such that it surrounds the layers, in each case such that each layer with anode material and each layer with cathode material is completely accommodated in it. The housing is substantially of a material that has no, or negligible, electrical conductivity. The housing is preferably of a nonconductor, with preference of plastic. The invention also relates to a method for producing the battery according to the invention, and to a use of the same.