利用三维通孔泡沫铝三维导电，导热与容积大的优势，将其用作锂离子电池的正极集流体以构筑高功率与高能量兼顾的器件，对于拓展锂离子电池的应用领域非常关键。然而，欲达成接近或超越商业级电池的性能，必须采用小孔径，高孔隙率，高强度，高化学稳定性的三维通孔泡沫铝。这对三维通孔泡沫铝的控制制备提出了巨大的挑战。同时，需要从原理上回答，改变集流体后的新型极片结构是否具有与传统铝箔极片同样形式的电子与离子极化和电化学反应行为。研究泡沫铝的关键制备技术与泡沫铝极片的电化学基本问题，对于达成高性能的器件原型非常关键，具有重要的科学意义与工程价值。系统研究了物理沉积中的关键过程对泡沫铝强度与塑性的影响。借鉴金属学强化理论，通过多步骤调控实现Al晶粒尺寸梯度分布微观结构，使得泡沫铝强度和塑性协同提高，在锂离子电解液中验证了电化学稳定性，适合作为电极集流体使用。泡沫铝制备技术工艺可靠，易放大，与企业合作实现了宽幅达0.5米的泡沫铝量产和商品化销售，为电极集流体的研究与工程化应用提供了材料基础。建立了稳态的泡沫铝多孔电极数学模型，分析了影响极化分布的关键因素。系统性分析了泡沫铝和铝箔作为集流体在电化学极化行为上的差异性，从数学角度证明了三维电子传导相比二维电子传导在均匀化过电势分布方面的优势。利用COMSOL建立了全三维泡沫铝与铝箔电池电化学有限元模型，研究了不同活性物质属性在泡沫铝和铝箔两种集流体中的电化学反应行为，得出泡沫铝极片具有更加均匀电化学反应的结论，并通过原位电化学拉曼、原位软包透射式XRD及相关电化学研究手段对理论结果进行实验验证。实现了大尺寸泡沫铝极片的活性物质均匀负载与加工工艺，制备了不同类型的软包级电池单体器件。详细研究了三维泡沫铝锂离子电池能量密度和功率密度多项影响因素。以磷酸铁锂为活性物质，厚极片（260μm）能量型电池体积能量密度为367Wh/L，薄极片（100μm）功率型电池10s脉冲充、放电功率密度为10kW/L。实现了集流体优势的发挥与电池性能的统一。在1C充、放电循环测试条件下，泡沫铝型厚极片电池的循环性能远优于铝箔型厚极片的电池。上述关于三维通孔泡沫铝的制备工艺及强化机制研究，三维通孔泡沫铝锂离子电池系统的数学模型、有限元模拟以及单体软包器件集成规律系统性研究，为开发全新的泡沫铝制备生产工艺，深入理解三维泡沫铝电极的微观结构和器件性能关系，促进新型锂离子电池器件应用提供了基础。

3D aluminum foam with special 3D electric conductivity, thermal conductivity and large pore volume, found potential application as positive current collector of lithium-ion batteries (LIBs), as well as building devices with high power and high energy. To achieve performance close to or exceed that of commercial grade batteries, it called for an Al foam product with small thickness, high porosity but high mechanical strength and high chemical stability to endure the practical processing. Meanwhile, it still remained unclear for the electron and ion polarization and electrochemical reaction behavior inside the new but thick electrode with 3D current collector, compared to the traditional Al foil electrode. And it remained a great challenge to fabricate such a device with excellent performance not realized yet. Apparent, it is a challenging work but of great scientific and engineering significance, which the present thesis tried to figure out.First, the present work proposed a new technical route to fabricate Al foam including the physical deposition of Al on template surface (polymer sponge), the removal of template by controlled oxidation and the gradient annealing to tailor their strength and strain. The structure of gradient grain size distribution was successfully realized in Al foams by regulating the interface grain boundary energy and the plasticity and strength of the 3D Al foams were significantly improved. The as-prepared Al foam was adjustable from 0.1-2 mm in terms of thickness, had the pore diameter of less than 0.5 mm, porosity of more than 95%, tensile strength of 3.0 MPa, elongation of 6%, and electrical conductivity of 10388.26 S/cm. The product had 10 times higher strength and 2 times higher conductivity than that prepared by electrodeposition method. In addition, the technology is easy scaled-up for the mass production of Al foam with a width of 0.5 m but nearly the same hole ratio, mechanical strength ang purity.Second, the steady-state porous mathematical model of Al foam electrode was established, and the parameters that affected the polarization distribution of liquid and solid phases in Al foam electrode were determined. Besides, the key factors affecting the polarization distribution were analyzed. The difference of electrochemical polarization behavior between Al foam and Al foil as current collector was systematically analyzed. And the advantage of 3D electron conduction over 2D electron conduction in homogenizing over-potential distribution was proved from the mathematical perspective. The fully 3D finite element model of Al foam and Al foil battery was established with COMSOL software. The time domain process of constant rate discharge was simulated. The electrochemical reaction behavior of different active substance properties in Al foam and Al foil was explored. It was concluded that the Al foam electrode sheet allowed the more uniform electrochemical reaction. Moreover, the theoretical results were validated and analyzed by in situ electrochemical Raman, in situ transmission XRD and related electrochemical research methods. It was the first time to reach the experimental conclusion in the Al foam pouch that the lithium-ion intercalation/extraction reaction polarization of the cathode material during charge and discharge could be significantly alleviated, and the phase transformation reaction was enhanced due to its 3D conduction and uniform electrochemical reaction characteristics.Third, the Al foam-based electrode technology was developed as optimizing the component and visocity of slurry and the subsequent filling and compressing technology for active material. Different types of pouch of LIBs were fabricated. Many factors affecting the energy density and power density of 3D Al foam lithium-ion battery were investigated in detail. Using LiFePO4 as the active material, the volume energy density of the thick electrode (260 μm) energy-type battery was 367 Wh/L, and the power density of the thin electrode (10 0μm) power-type LIBs was 10 kW/L. The pouch would exhibit much higher power density (532Wh/L) as using NCM523-Al foam electrode with 186μm thick. Furthermore, the power density of the NCM523-Al foam electrode (100 μm)-based LIBs approached to 12 kW/L in 10s instant discharge, comparable to that of the most excellent power type start-stop LIBs (with 15 μm thin electrode layer and 30 μm thick Al foil) to this date. Based on the comparison of 1C charging and discharging cycle, the battery with thick Al foam electrode exhibited much better cycle performance than that with thick Al foil electrode.The above researches stressed on the mechanism and preparation technology of 3D Al foam, the building of mathematical model and the finite element simulation of 3D foam porous electrode, and monomer pouch device integration law of 3D Al foam-based LIBs system. It provides the basis for developing new Al foam production process, enhancing the understanding of the 3D Al foam electrode microstructure and performance relationship, and promoting the application of new LIBs device.