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: 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: 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 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) includes a microchannel plate (MCP) (22) having channels (24) formed therein, the channels having surface areas. Thin films (26) are formed over the surface areas and define an anode (34,38), a cathode (34,38), and a solid electrolyte (36) disposed between the anode and the cathode.

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.