Abstract: Described herein are current collectors comprising metal grids as well as electrodes and lithium-metal cells comprising such current collectors and methods of fabricating such current collectors, electrodes, and lithium-metal cells. A thin current collector comprises a polymer base and a metal layer positioned on, directly interfaces, and supported by one side of the polymer base. A thin current collector also comprises a metal grid, which directly interfaces and is supported by the edge of the polymer base. The metal grid is electrically coupled to the metal layer, e.g., by overlapping or at least forming an interface with the metal layer. In an electrode that further comprises an active material layer supported on the metal layer, the metal grid extends away from the active material layer. In an electrochemical cell, the metal grid can be connected to the metal grids of other electrodes and/or cell tabs.

Abstract: Described herein are current collectors comprising metal grids as well as electrodes and lithium-metal cells comprising such current collectors and methods of fabricating such current collectors, electrodes, and lithium-metal cells. A thin current collector comprises a polymer base and a metal layer positioned on, directly interfaces, and supported by one side of the polymer base. A thin current collector also comprises a metal grid, which directly interfaces and is supported by the edge of the polymer base. The metal grid is electrically coupled to the metal layer, e.g., by overlapping or at least forming an interface with the metal layer. In an electrode that further comprises an active material layer supported on the metal layer, the metal grid extends away from the active material layer. In an electrochemical cell, the metal grid can be connected to the metal grids of other electrodes and/or cell tabs.

Abstract: Described herein are electrochemical cells fabricated with current collectors comprising polymer bases and metal layers and methods of interconnecting these current collectors or, more specifically, interconnecting their metal layers. For example, a current collector, positioned between two other current collectors, can have an opening allowing these two other current collectors to form a direct interface. This interface not only directly interconnects the metal layers on these two current collectors but also indirectly interconnects the two metal layers of the middle current collector, which are positioned on the opposite sides of the polymer base of this current collector. In some examples, the metal layers of current collectors are reinforced by external metal foils that help to maintain continuity and/or repair any discontinuities in the metal layers when these metal layers are welded together. For example, welding may push portions of the polymer bases away from the weld zone.