Nanocomposite electrodes and related devices

A lithium secondary cell, comprising:

• a lithium-containing positive electrode in electronic contact with a positive electrode current collector, the positive electrode current collector in electrical connection with an external circuit;
• a negative electrode in electronic contact with a negative electrode current collector, the negative electrode current collector in electrical connection with an external circuit;
• and
• an electrolyte in ionic contact with the positive and negative electrodes, wherein
• the positive electrode comprises
• an electroactive layer comprising an electroactive material having a surface area of at least about 10 m2/g and a first polymer;
• wherein the first polymer is selected from a group consisting of a polyvinylidene fluoride polymer, a copolymer thereof, and a terpolymer thereof;
• a conductive adhesive layer contacting the surface of the positive current collector, wherein the conductive adhesive layer comprises a second polymer selected from the group consisting of a polyolefin, a polyurethane, a polyacrylic acid, a polyacrylic ester, a polyether, a polyacrylate, a polystyrene, a copolymer thereof, a terpolymer thereof, and a mixture thereof;
• and
• an interlayer region interposed between the conductive adhesive layer and the electroactive layer and in electrical communication with the positive current collector and the electroactive layer, the interlayer region comprising a portion of the conductive adhesive intermixed with a portion of the electroactive material.

A process for preparing a lithium-containing electrode, comprising:

• applying a conductive adhesive layer to one or more surfaces of a current collector, forming a current collector coated with an adhesive layer, wherein the conductive adhesive layer comprises a second polymer selected from the group consisting of a polyolefin, a polyurethane, a polyacrylic acid, a polyacrylic ester, a polyether, a polyacrylate, a polystyrene, a copolymer thereof, a terpolymer thereof, and a mixture thereof;
• applying an electroactive layer composition to one or more surfaces of the coated current collector, the electroactive layer composition comprising electroactive material, a first polymer and electrode casting solvent, wherein the electroactive material has a surface area of at least about 10 m2/g and ther first polymer is selected from a group consisting of a polyvinylidene fluoride polymer, a copolymer thereof, and a terpolymer thereof;
• wherein
• a portion of the high surface area electroactive material intermixes with the adhesive to form an interlayer region interposed between the conductive adhesive layer and the electroactive layer and in electrical communication with the coated current collector and the remainder of the high surface area electroactive material, the interlayer region comprising a portion of the conductive adhesive layer intermixed with a portion of the electroactive material.