ELECTRODE FOR A LITHIUM-BASED SECONDARY ELECTROCHEMICAL DEVICE AND METHOD OF FORMING SAME

1 . An electrode for a lithium-based secondary electrochemical device, the electrode comprising:

a current collector including;

a substrate having a surface defining a plurality of pores therein; and

a lithium powder disposed within each of the plurality of pores; and

a cured film disposed on the current collector and formed from an electrically-conductive material.

2 . The electrode of claim 1 , wherein the current collector further includes a sealing layer disposed on the surface and formed from a carbon paste, wherein the sealing layer covers the lithium powder and the surface and the cured film covers the sealing layer.

3 . The electrode of claim 2 , wherein the sealing layer surrounds and contacts the lithium powder.

4 . The electrode of claim 1 , wherein the substrate is formed from an element selected from Groups 4-11, Period 4 of the periodic table of the elements.

5 . The electrode of claim 4 , wherein the substrate is a copper foam.

6 . The electrode of claim 4 , wherein the substrate is a copper mesh.

7 . The electrode of claim 4 , wherein the substrate is a titanium foam.

8 . The electrode of claim 4 , wherein the substrate is a nickel foam.

9 . The electrode of claim 1 , wherein the substrate is an aluminum foam.

10 . The electrode of claim 1 , wherein the substrate is a stainless steel foam.

11 . The electrode of claim 1 , further including a plurality of surfaces each spaced opposite and apart from one another and defining the plurality of pores therein.

12 . The electrode of claim 11 , wherein the current collector further includes a plurality of sealing layers each disposed on a respective one of the plurality of surfaces and formed from the carbon paste, wherein each of the plurality of sealing layers covers the lithium powder and a respective one of the plurality of surfaces.

13 . The electrode of claim 12 , further including a plurality of cured films each disposed on a respective one of the plurality of sealing layers and formed from the electrically-conductive material.

14 . The electrode of claim 1 , wherein the electrode is a positive electrode of the lithium-based secondary electrochemical device.

15 . The electrode of claim 1 , wherein the electrode is a negative electrode of the lithium-based secondary electrochemical device.

16 . A method of forming an electrode for a lithium-based secondary electrochemical device, the method comprising:

defining a plurality of pores in a surface of a substrate;

inserting a lithium powder into each of the plurality of pores to form a current collector; and

after inserting, forming a cured film comprising an electrically-conductive material on the current collector to thereby form the electrode.

17 . The method of claim 16 , wherein defining includes electrochemically depositing an element onto the substrate, wherein the element is selected from the group consisting of aluminum and Groups 4-11, Period 4 of the periodic table of the elements.

18 . The method of claim 16 , wherein inserting includes spraying the lithium powder into each of the plurality of pores.

19 . The method of claim 16 , further including, after inserting and before forming, depositing a sealing layer formed from a carbon paste onto the lithium powder and the surface.

20 . A lithium-based secondary electrochemical device comprising:

a positive electrode;

a negative electrode spaced opposite the positive electrode; and

a separator positioned between the positive electrode and the negative electrode;

wherein at least one of the positive electrode and the negative electrode includes;

a current collector including;

a substrate having a surface defining a plurality of pores therein; and

a lithium powder disposed within each of the plurality of pores; and

a cured film disposed on the current collector and formed from an electrically-conductive material.