Electrode including current collector with nano-scale coating and method of making the same

A method of making a current collector comprising:

• providing a metallic substrate;
• and
• applying to the substrate without a solvent present, a dry composition including graphite particles;
• buffing an effective amount of said particles on said substrate at a pressure normal to the surface of greater than 0 and less than about 30 g/cm2 using an applicator pad, said applicator pad moving in a plane parallel to said surface in a plurality of directions relative to a point on the surface such that a substantially uniform coating of said particles is provided, and
• providing an active electrode material,
• wherein said particles have a Mohs' hardness between 0.4 and 3 and a largest dimension of less than about 100 microns,
• wherein the substantially uniform coating has a maximum average thickness of less than about 100 nanometers with a variation in thickness of no more than 10%, ;and
• wherein the metallic substrate is selected from aluminum, copper, magnesium, nickel, tin, and alloys thereof,
• wherein the substantially uniform coating is disposed between the active electrode material and the metallic substrate;
• and
• wherein the substantially uniform coating is substantially free of a binder.