Abstract: Process for the fabrication of an electrode structure comprising an electrochemically active material suitable for use in an energy storage device. The method includes electrodepositing the electrochemically active material onto an electrode in electrodeposition bath containing a non-aqueous electrolyte. The electrode structure can be used for various applications such as electrochemical energy storage devices including high power and high-energy lithium-ion batteries.

Abstract: Process for the fabrication of an electrode structure comprising an electrochemically active material suitable for use in an energy storage device. The method includes electrodepositing the electrochemically active material onto an electrode in electrodeposition bath containing a non-aqueous electrolyte. The electrode structure can be used for various applications such as electrochemical energy storage devices including high power and high-energy lithium-ion batteries.

Abstract: An illustrated example method of making a porous carbon composite includes mixing a carbon-based material, a binder and pore former particles to establish a mixture. The mixture is placed into a mold where it is subjected to pressure at an ambient temperature to form a compacted body. Subsequently, the compacted body is heated to a temperature that causes at least partial removal of the pore former particles to establish pores in place of at least some of the pore former particles.

Abstract: An illustrated example method of making a porous carbon composite includes mixing a carbon-based material, a binder and pore former particles to establish a mixture. The mixture is placed into a mold where it is subjected to pressure at an ambient temperature to form a compacted body. Subsequently, the compacted body is heated to a temperature that causes at least partial removal of the pore former particles to establish pores in place of at least some of the pore former particles.

Abstract: An illustrative example embodiment of a fuel cell includes a cathode electrode, an anode electrode, and a porous matrix layer between the electrodes. The porous matrix layer includes pores and solids. The solids comprises at least 90% boron phosphate. A phosphoric acid electrolyte is within the pores of the matrix layer.

Abstract: Process for the fabrication and manufacture of highly porous open-cell structures using templates that are formed by mechanical pressing, injection molding, sintering, or any combination thereof. The processing scheme includes coating, filling or depositing a material on, or inside the porous template. The highly porous structure results after the selective removal of the template and can be used for various applications such as electrochemical energy storage devices including high power and high-energy lithium-ion batteries.

Abstract: Process for the fabrication of an electrode structure comprising an electrochemically active material suitable for use in an energy storage device. The method includes electrodepositing the electrochemically active material onto an electrode in electrodeposition bath containing a non-aqueous electrolyte. The electrode structure can be used for various applications such as electrochemical energy storage devices including high power and high-energy lithium-ion batteries.

Abstract: An illustrative example fuel cell electrolyte management device includes a first component having a first density and a second component having a second density that is less than the first density. The first component has a first side including a pocket and a second side facing opposite the first side. The second side of the first component includes a first plurality of fluid flow channels. The second component has a porosity configured for storing electrolyte in the second component. The second component fits within the pocket. The second component has a first side received directly against the first side of the first component. The second component has a second side including a second plurality of fluid flow channels.

Abstract: An illustrative example embodiment of a fuel cell includes a cathode electrode, an anode electrode, and a porous matrix layer between the electrodes. The porous matrix layer includes pores and solids. The solids comprises at least 90% boron phosphate. A phosphoric acid electrolyte is within the pores of the matrix layer.

Abstract: Process for the fabrication of an electrode structure comprising an electrochemically active material suitable for use in an energy storage device. The method includes electrodepositing the electrochemically active material onto an electrode in electrodeposition bath containing a non-aqueous electrolyte. The electrode structure can be used for various applications such as electrochemical energy storage devices including high power and high-energy lithium-ion batteries.

Abstract: An illustrative example fuel cell electrolyte management device includes a first component having a first density and a second component having a second density that is less than the first density. The first component has a first side including a pocket and a second side facing opposite the first side. The second side of the first component includes a first plurality of fluid flow channels. The second component has a porosity configured for storing electrolyte in the second component. The second component fits within the pocket. The second component has a first side received directly against the first side of the first component. The second component has a second side including a second plurality of fluid flow channels.

Abstract: Process for the fabrication of an electrode structure comprising an electrochemically active material suitable for use in an energy storage device. The method includes electrodepositing the electrochemically active material onto an electrode in electrodeposition bath containing a non-aqueous electrolyte. The electrode structure can be used for various applications such as electrochemical energy storage devices including high power and high-energy lithium-ion batteries.

Abstract: A method of fabricating a 3D porous electrode architecture comprises forming a microbattery template that includes (a) a lattice structure comprising a first lattice portion separated from a second lattice portion on a substrate, and (b) a solid structure on the substrate including a separating portion between the first and second lattice portions. Interstices of the first lattice portion are infiltrated with a first conductive material and interstices of the second lattice portion are infiltrated with a second conductive material. Each of the first and second conductive materials fill the interstices to reach a predetermined thickness on the substrate. The solid structure and the lattice structure are removed from the structure, thereby forming first and second conductive scaffolds comprising a porosity defined by the lattice structure and having a lateral size and shape defined by walls of the solid structure.

Abstract: Process for the fabrication of an electrode structure comprising an electrochemically active material suitable for use in an energy storage device. The method includes electrodepositing the electrochemically active material onto an electrode in electrodeposition bath containing a non-aqueous electrolyte. The electrode structure can be used for various applications such as electrochemical energy storage devices including high power and high-energy lithium-ion batteries.

Abstract: Process for the fabrication and manufacture of highly porous open-cell structures using templates that are formed by mechanical pressing, injection molding, sintering, or any combination thereof. The processing scheme includes coating, filling or depositing a material on, or inside the porous template. The highly porous structure results after the selective removal of the template and can be used for various applications such as electrochemical energy storage devices including high power and high-energy lithium-ion batteries.

Abstract: A method of fabricating a 3D porous electrode architecture comprises forming a microbattery template that includes (a) a lattice structure comprising a first lattice portion separated from a second lattice portion on a substrate, and (b) a solid structure on the substrate including a separating portion between the first and second lattice portions. Interstices of the first lattice portion are infiltrated with a first conductive material and interstices of the second lattice portion are infiltrated with a second conductive material. Each of the first and second conductive materials fill the interstices to reach a predetermined thickness on the substrate. The solid structure and the lattice structure are removed from the structure, thereby forming first and second conductive scaffolds comprising a porosity defined by the lattice structure and having a lateral size and shape defined by walls of the solid structure.