An alkaline electrochemical cell has a central cathode having a corresponding cathode current collector electrically connected with a positive terminal of the electrochemical cell. The cathode current collector has a tubular shape, such as a cylindrical shape or rectangular shape, extending parallel with the length of the central cathode. The cathode current collector is embedded within the central cathode, such as at a medial point of a radius of the central cathode, thereby minimizing the distance between the cathode current collector and any portion of the central cathode, thereby increasing the mechanical strength of the cathode and facilitating charge transfer to the cathode current collector.

An alkaline electrochemical cell has a central cathode having a corresponding cathode current collector electrically connected with a positive terminal of the electrochemical cell. The cathode current collector has a tubular shape, such as a cylindrical shape or rectangular shape, extending parallel with the length of the central cathode. The cathode current collector is embedded within the central cathode, such as at a medial point of a radius of the central cathode, thereby minimizing the distance between the cathode current collector and any portion of the central cathode, thereby increasing the mechanical strength of the cathode and facilitating charge transfer to the cathode current collector.

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.

Aspects relate to patterned nanostructures having a feature size not including film thickness of below 5 microns. The patterned nanostructures are made up of nanoparticles having an average particle size of less than 100 nm. A nanoparticle composition, which, in some cases, includes a binder, is applied to a substrate. A patterned mold used in concert with electromagnetic radiation function to manipulate the nanoparticle composition in forming the patterned nanostructure. In some embodiments, the patterned mold nanoimprints a 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 for suitable applications.

Described herein is a process for the production of moldings made of porous material impregnated with polysulfide, the process including the following steps: (a) insertion of the porous material into a mold; (b) introduction of liquid polysulfide into the mold at a flow velocity within the porous material in the range from 0.5 to 200 cm/s; (c) cooling of the polysulfide to a temperature below the melting point of the polysulfide; and (d) removal of the porous material impregnated with the polysulfide.

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.

An electrode assembly, in which a plurality of unit electrodes and a plurality of separators are alternately laminated, is provided. Each of the unit electrodes is provided by connecting a plurality of electrodes, each electrode being entirely made of a solid electrode mixture, to each other, and the solid electrode mixture including a mixture of an electrode active material with at least one or more of a conductive material and a binder.

Provided is method of preparing an alkali metal-sulfur cell, comprising: (a) combining a quantity of a cathode active material (selected from sulfur, a metal-sulfur compound, a sulfur-carbon composite, a sulfur-graphene composite, a sulfur-graphite composite, an organic sulfur compound, a sulfur-polymer composite or a combination thereof), a quantity of an electrolyte, and a conductive additive to form a deformable cathode material, wherein the conductive additive, containing conductive filaments, forms a 3D network of electron-conducting pathways and the electrolyte contains an alkali salt and an ion-conducting polymer dissolved or dispersed in a solvent; (b) forming the cathode material into a quasi-solid cathode, wherein the forming includes deforming the cathode material into an electrode shape without interrupting the 3D network of electron-conducting pathways such that the cathode maintains an electrical conductivity no less than 10.sup.−6 S/cm; (c) forming an anode; and (d) forming a cell by combining the cathode and the anode.

Disclosed is a manufacturing method for an electrode of an electricity storage device. The manufacturing method includes: a working procedure of acquiring a long metal fiber by cutting an end surface of a metal foil coil; a working procedure of cutting the long metal fiber so that the average length is less than 5 mm in a state of pressing a bundle of the acquired long metal fibers or in a state of configuring the bundle of the long metal fibers in a cylinder; a working procedure of mixing a metal short fiber obtained from this with a positive electrode material or a negative electrode material constituting a positive electrode or a negative electrode of a lithium battery, to prepare slurry; a working procedure of coating a foil with the slurry; and a working procedure of forming a positive or negative electrode containing the short fibers through a working procedure of drying it to form a predetermined shape.

A punching system for an electrode base material is disclosed, in which the electrode base material coated with an active material on a surface of a collector is molded or cut in a predetermined shape. The punching system comprises: an unwinder on which the electrode base material in the form of a roll is mounted and around which the electrode base material is unwound; a punching device spaced a predetermined distance from the unwinder, the punching device being configured to mold or cut the electrode base material supplied from the unwinder in a predetermined shape; and a curl correcting device disposed between the unwinder and the punching device to inject or suction air onto a surface of the electrode base material while the electrode base material moves to the punching device so as to planarize the electrode base material. A punching method for an electrode base material is also disclosed.