A lamination device of the present invention includes a pattern roller part embodying a pattern on an electrode assembly, wherein the pattern roller part includes a rotation roller disposed on a surface of the electrode assembly to emit heat and a pattern cover wound around an outer circumferential surface of the rotation roller and partially pressing the surface of the electrode assembly together with the heat transferred from the rotation roller to embody a pattern, and the pattern cover includes a pattern film wound around the outer circumferential surface of the rotation roller and a deformation member disposed on an inner surface of the pattern film to wind the pattern film around the outer circumferential surface of the rotation roller while being deformed by the heat transferred from the rotation roller.

Various embodiments disclosed relate to novel methods of fabricating 3-D Li ion batteries using direct nanoimprint lithography. The present invention includes methods of fabricating high surface area electrodes, including imprint patterning of high aspect ratio parallel grating style electrodes. The method includes coating a substrate with an ink containing nanoparticles and subsequently annealing the ink into a desired pattern.

A battery plate having a substrate with opposing surfaces and one or more nonplanar structures and one or more active materials disposed on at least one of the opposing surfaces; wherein the battery plate includes one or more of: i) one or more projections disposed within but do not extend beyond the active material; ii) one or more projections which project beyond the active material and substantially free of the active material or dust formed from the active material; and/or iii) a frame about the periphery of the substrate which projects beyond the active material and is substantially free of the active material or dust formed from the active material; and wherein the battery plate is adapted to form part of one or more electrochemical cells in a battery assembly.

Provided is an electrode for a secondary cell capable of obtaining excellent output values and input values when used in the secondary cell. The electrode for a secondary cell is formed of an electrode mixture layer molded body formed of an active material and at least one of a carbon nanotube and a three-dimensional carbon nanotube fiber bundle skeleton formed of a plurality of carbon nanotubes that intersect one another to form an aggregation, which are in intimate contact with the surface of the active material; and a current collector layered on the electrode mixture layer molded body. The electrode mixture layer molded body includes a first roughened surface, and the current collector includes a second roughened surface. The first roughened surface of the electrode mixture layer molded body and the second roughened surface of the current collector are pressed and attached to each other.

A separator for a bobbin-style electrochemical cell is inserted into an interior opening within a ring-shaped cathode in an electrochemical cell can. An expansion force is then applied to an interior surface of the separator to press the separator against the interior walls of the cathode. A tool may then remove various creases and/or wrinkles in the separator and/or may then heat seal at least a portion of the tubular walls of the separator to minimize the void space between the separator and active material (e.g., cathode and/or anode) within the electrochemical cell.

A method of manufacturing an electrochemical cell includes transferring an anode semi-solid suspension to an anode compartment defined at least in part by an anode current collector and an separator spaced apart from the anode collector. The method also includes transferring a cathode semi-solid suspension to a cathode compartment defined at least in part by a cathode current collector and the separator spaced apart from the cathode collector. The transferring of the anode semi-solid suspension to the anode compartment and the cathode semi-solid to the cathode compartment is such that a difference between a minimum distance and a maximum distance between the anode current collector and the separator is maintained within a predetermined tolerance. The method includes sealing the anode compartment and the cathode compartment.

An electrode assembly having a positive electrode current collector, a positive electrode active material layer, a separator, a negative electrode active material layer and a negative electrode current collector stacked successively in a thickness direction of the electrode assembly is provided. A plurality of through-holes is formed to pass through the positive electrode active material layer, separator and the negative electrode active material layer. The positive electrode current collector includes a first sheet shaped current collector and a plurality of first column shaped current collectors extending from the first sheet shaped current collector along the thickness direction of the electrode assembly. The negative electrode current collector includes a second sheet shaped current collector and a plurality of second column shaped current collectors extending from the second sheet shaped current collector along the thickness direction of the electrode assembly.

An energy storage electrode is formed by heat-pressing preformed electrode membranes into the pore structures of a metal mesh current collector without use of any solvents. The electrodes are utilized primarily for Li-ion batteries, as well as supercapacitors. This solvent-free method for electrode preparation is more cost-efficient and environmentally-friendly, in comparison with the method involving preparation and casting slurries or pastes onto metal foil current collectors, where a solvent is required.

Aspects relate to patterned nanostructures having a feature size not including film thickness below 5 microns. The patterned nanostructures are made up of nanoparticles having an average particle size less than 100 nm. A nanoparticle composition, which, in some cases, includes a binder material, is applied to a substrate. A patterned mold used in concert with electromagnetic radiation manipulate the nanoparticle composition in forming the patterned nanostructure. In some embodiments, the patterned mold nanoimprints a suitable pattern onto the nanoparticle composition and the composition is cured through UV or thermal energy. Three-dimensional patterned nanostructures may be formed. A number of patterned nanostructure layers may be prepared and joined together. In some cases, a patterned nanostructure may be formed as a layer that is releasable from the substrate upon which it is initially formed. Such releasable layers may be arranged to form a three-dimensional patterned nanostructure in accordance with suitable applications.

A method of manufacturing an electrochemical cell includes transferring an anode semi-solid suspension to an anode compartment defined at least in part by an anode current collector and an separator spaced apart from the anode collector. The method also includes transferring a cathode semi-solid suspension to a cathode compartment defined at least in part by a cathode current collector and the separator spaced apart from the cathode collector. The transferring of the anode semi-solid suspension to the anode compartment and the cathode semi-solid to the cathode compartment is such that a difference between a minimum distance and a maximum distance between the anode current collector and the separator is maintained within a predetermined tolerance. The method includes sealing the anode compartment and the cathode compartment.