Electrode having protective and locking layers on current collector

Abstract

An electrode includes a current collector, a metal shell in direct contact with and encapsulating the current collector, green dendritic columnar growths extending out of the metal shell and having protrusions thereon, and active material in contact with the metal shell and having embedded therein the green dendritic columnar growths. The protrusions penetrate the active material to form a mechanical retainer that prevents delamination of the active material from the metal shell and define localized regions of increased current density during operation of the electrode that promote deposition of the active material first on the protrusions and then on areas of the green dendritic columnar growths adjacent to the protrusions such that the active material electrochemically adheres to the green dendritic columnar growths and the protrusions enlarge during repeated charge and discharge cycling of the electrode.

What is claimed is: 
     
         1 . An electrode comprising:
 a current collector;   zinc green dendritic columnar growths supported by and extending away from the current collector and having protrusions thereon; and   active material having embedded therein the zinc green dendritic columnar growths, wherein the protrusions (i) penetrate the active material to form a mechanical retainer that prevents delamination of the active material from the current collector and (ii) define localized regions of increased current density during operation of the electrode that promote deposition of the active material first on the protrusions and then on areas of the zinc green dendritic columnar growths adjacent to the protrusions such that the active material electrochemically adheres to the zinc green dendritic columnar growths and the protrusions enlarge during repeated charge and discharge cycling of the electrode.   
     
     
         2 . The electrode of  claim 1 , wherein the active material is zinc based. 
     
     
         3 . The electrode of  claim 1 , wherein the current collector includes aluminum, brass, bronze, chromium, copper, graphite, nickel, silver, stainless steel, tin, zinc, or combinations thereof. 
     
     
         4 . The electrode of  claim 1 , wherein the zinc green dendritic columnar growths further include bismuth, cadmium, gallium, indium, lead, mercury, silver, thallium, tin, or combinations thereof. 
     
     
         5 . A battery comprising:
 the electrode of  claim 1 .