Abstract: A composition-of-matter is described herein, comprising a first layer and third layer separated by a second layer. The first and third layers each comprise a thermoplastic polymer and a substance capable of reversibly releasing lithium or a delithiated form of the substance. The second layer comprises a thermoplastic polymer and is capable of conducting lithium ions. Further described herein is an electrochemical system comprising the composition-of-matter, wherein the first and third layers are each a lithium-based electrode, and batteries and supercapacitors comprising such an electrochemical system, as well as methods for preparing the composition-of-matter or the electrochemical system.

Abstract: The present invention provides a method for concurrent electrophoretic deposition (EPD) of a membrane-electrode assembly (MEA) comprising a first MEA electrode and a second MEA electrode. The method comprises electrophoretically depositing the first MEA electrode from a suspension comprising a first precursor on a first surface of an ion permeable membrane and electrophoretically depositing the second MEA electrode from a second suspension comprising a second precursor on a second surface of the ion permeable membrane, wherein the first precursor is physically separated from and ionically connected to the second precursor by the membrane.

Abstract: A composition-of-matter comprising a plurality of particles is disclosed herein, the particles comprising a substance reversibly releasing an alkali metal while decreasing in volume and absorbing the alkali metal while increasing in volume. Some or all of the particles are encapsulated within a volume enclosed by a shell or matrix which conducts cations of the alkali metal, wherein a volume of the substance upon maximal absorption of the alkali metal does not exceed the volume enclosed by a shell or matrix. Further disclosed herein is a process for preparing a composition-of-matter by coating particles comprising the aforementioned substance with a conductor of cations of the alkali metal, when the substance is saturated with the alkali metal, as well as electrochemical half cells and batteries including the composition-of-matter.

Abstract: A method of manufacturing an electrochemical system comprising an electrode is described herein, comprising dispensing, in a configured pattern corresponding to the shape of the electrode, a model composition which comprises a substance capable of reversibly releasing an electrochemically-active agent (such as lithium) or depleted form of same, wherein dispensing comprises heating a filament comprising the model composition and dispensing a heated composition. Further described is an electrochemical system comprising an electrode which comprises a composite material, as well as batteries and supercapacitors comprising such a system. The composite material comprises a thermoplastic polymer and substance capable of reversibly releasing an electrochemically-active agent (such as lithium) or depleted form of same, wherein at least 20 weight percents of the composite material is thermoplastic polymer.

Abstract: An electrical energy storage device (20) includes a substrate (22), an anode layer (30), a cathode layer (26), and a separator layer (28) between the anode layer and the cathode layer. The substrate has multiple sets of intersecting cavities (21) passing through the substrate in different directions. The anode layer, cathode layer, and separator layer are formed over a surface of the substrate within the cavities.

Abstract: A composition-of-matter comprising a plurality of particles is disclosed herein, the particles comprising a compound (e.g., an element or a mixture of elements) which forms an alloy with an alkali metal and/or an alloy of an alkali metal with said compound. The alloy is characterized by reversibly releasing the alkali metal and absorbing the alkali metal. Some or all of the particles are encapsulated within a volume enclosed by a shell or matrix which conducts cations of the alkali metal, wherein a volume of the alloy upon maximal absorption of the alkali metal does not exceed the volume enclosed by a shell or matrix. Further disclosed herein is a process of preparing a composition-of-matter, which is effected by coating particles comprising an alloy saturated with the alkali metal with a conductor of cations of the alkali metal, as well as electrochemical half cells and batteries including the composition-of-matter.

Abstract: The present invention provides anodes comprising an electrically conductive substrate, comprising at least one non-uniform surface; and a random network of silicon nanowires (Si NWs) chemically grown on said at least one non-uniform surface of the substrate, wherein the Si NWs have at least about 30% amorphous morphology, and methods of manufacturing of the anodes. Further provided are lithium ion batteries comprising said anodes.

Abstract: An electrical energy storage device (20) includes a substrate (22), an anode layer (30), a cathode layer (26), and a separator layer (28) between the anode layer and the cathode layer. The substrate has multiple sets of intersecting cavities (21) passing through the substrate in different directions. The anode layer, cathode layer, and separator layer are formed over a surface of the substrate within the cavities.

Abstract: The present invention provides anodes comprising an electrically conductive substrate, comprising at least one non-uniform surface; and a random network of silicon nanowires (Si NWs) chemically grown on said at least one non-uniform surface of the substrate, wherein the Si NWs have at least about 30% amorphous morphology, and methods of manufacturing of the anodes. Further provided are lithium ion batteries comprising said anodes.

Abstract: A composition-of-matter comprising a plurality of particles is disclosed herein, the particles comprising a compound (e.g., an element or a mixture of elements) which forms an alloy with an alkali metal and/or an alloy of an alkali metal with said compound. The alloy is characterized by reversibly releasing the alkali metal and absorbing the alkali metal. Some or all of the particles are encapsulated within a volume enclosed by a shell or matrix which conducts cations of the alkali metal, wherein a volume of the alloy upon maximal absorption of the alkali metal does not exceed the volume enclosed by a shell or matrix. Further disclosed herein is a process of preparing a composition-of-matter, which is effected by coating particles comprising an alloy saturated with the alkali metal with a conductor of cations of the alkali metal, as well as electrochemical half cells and batteries including the composition-of-matter.

Abstract: A composition-of-matter comprising a plurality of particles is disclosed herein, the particles comprising a substance reversibly releasing an alkali metal while decreasing in volume and absorbing the alkali metal while increasing in volume. Some or all of the particles are encapsulated within a volume enclosed by a shell or matrix which conducts cations of the alkali metal, wherein a volume of the substance upon maximal absorption of the alkali metal does not exceed the volume enclosed by a shell or matrix. Further disclosed herein is a process for preparing a composition-of-matter by coating particles comprising the aforementioned substance with a conductor of cations of the alkali metal, when the substance is saturated with the alkali metal, as well as electrochemical half cells and batteries including the composition-of-matter.

Abstract: Methods for forming three-layer thin-film battery (TFB) structures by sequential electrophoretic deposition (EPD) on a single conductive substrate. The TFBs may be two-dimensional or three-dimensional. The sequential EPD includes EPD of a first battery electrode followed by EPD of a porous separator on the first electrode and by EPD of a second battery electrode on the porous separator. In some embodiments of a Li or Li-ion TFB, the separator includes a Li ion conducting solid. In some embodiments of a Li or Li-ion TFB, the separator includes an inorganic porous solid rendered ionically conductive by impregnation with a liquid or polymer. In some embodiments, the TFBs are coated and sealed with an EPDd PEEK layer.

Abstract: An energy storage cell (20) including: an anode (40) formed of a molten alkali metal; an air cathode (60); and an electrolyte medium (50) located between the anode and cathode.

Abstract: Methods for forming three-layer thin-film battery (TFB) structures by sequential electrophoretic deposition (EPD) on a single conductive substrate. The TFBs may be two-dimensional or three-dimensional. The sequential EPD includes EPD of a first battery electrode followed by EPD of a porous separator on the first electrode and by EPD of a second battery electrode on the porous separator. In some embodiments of a Li or Li-ion TFB, the separator includes a Li ion conducting solid. In some embodiments of a Li or Li-ion TFB, the separator includes an inorganic porous solid rendered ionically conductive by impregnation with a liquid or polymer. In some embodiments, the TFBs are coated and sealed with an EPDd PEEK layer.

Abstract: Methods for forming three-layer thin-film battery (TFB) structures by sequential electrophoretic deposition (EPD) on a single conductive substrate. The TFBs may be two-dimensional or three-dimensional. The sequential EPD includes EPD of a first battery electrode followed by EPD of a porous separator on the first electrode and by EPD of a second battery electrode on the porous separator. In some embodiments of a Li or Li-ion TFB, the separator includes a Li ion conducting solid. In some embodiments of a Li or Li-ion TFB, the separator includes an inorganic porous solid rendered ionically conductive by impregnation with a liquid or polymer. In some embodiments, the TFBs are coated and sealed with an EPDd PEEK layer.

Abstract: An energy storage cell (20) including: an anode (40) formed of a molten alkali metal; an air cathode (60); and an electrolyte medium (50) located between the anode and cathode.

Abstract: An electrical energy storage device (20,70) includes a substrate (22), which is formed so as to define a multiplicity of micro-containers separated by electrically-insulating and ion-conducting walls (32). A first plurality of anodes (A) is disposed in a first subset (24) of the micro-containers, and a second plurality of cathodes (C) is disposed in a second subset (26) of the micro-containers. The anodes and cathodes are arranged in an interlaced pattern.

Abstract: A method, including placing a substrate of a battery in a bath consisting of a metal M chosen from a metal group consisting of Fe, Ni, Co, Cu, W, V, and Mn, an oxidant selected from an oxidant group consisting of oxygen and sulfur, and a polymer. The method also includes applying an electrical current so as to form on the substrate a metal M compound cathode having a nanoscale grain structure.

Abstract: An electrical energy storage device includes a substrate having an outer surface and having a plurality of cavities communicating with the outer surface. The cavities have interior cavity surfaces. A first electrode layer is deposited at least over the interior cavity surfaces. An electrolyte separator layer is formed over the first electrode layer so as to fill the cavities and to extend over the outer surface of the planar substrate. A second electrode layer is formed over the electrolyte separator layer on the outer surface of the planar substrate.

Abstract: An electrical energy storage device (20,70) includes a substrate (22), which is formed so as to define a multiplicity of micro-containers separated by electrically-insulating and ion-conducting walls (32). A first plurality of anodes (A) is disposed in a first subset (24) of the micro-containers, and a second plurality of cathodes (C) is disposed in a second subset (26) of the micro-containers. The anodes and cathodes are arranged in an interlaced pattern.