Electrode substrate with a polymer layer with a thickness gradient

A 3D electrode substrate with a polymer layer of increasing resistance at terminal ends addresses dendrite formation in secondary batteries by uniformly distributing ion deposition, enhancing battery performance and reducing dendrite growth.

WO2026132443A1PCT designated stage Publication Date: 2026-06-25LIONVOLT BV
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Patent Information

Authority / Receiving Office
WO · WO
Patent Type
Applications
Current Assignee / Owner
LIONVOLT BV
Filing Date
2025-12-19
Publication Date
2026-06-25

AI Technical Summary

Technical Problem

In secondary batteries, particularly those with a metal anode, uncontrolled growth of dendrite structures and unstable solid electrolyte interface (SEI) occur due to preferential electrodeposition on high electron density areas, leading to excessive volume changes and dendrite formation, which existing strategies like high salt concentration electrolytes and high temperature charging are difficult to implement practically.

Method used

A method of manufacturing an electrode substrate with a 3D current collector having upstanding protrusions, where a polymer layer with increasing electronic resistance is deposited, controlling alkali metal ion deposition by redistributing electric lines of force, thereby reducing dendrite formation without affecting battery performance.

Benefits of technology

The polymer layer with progressive resistance at terminal ends of protrusions uniformly distributes ion deposition, reducing dendrite formation and potentially improving battery performance by controlling electrodeposition, while maintaining conductivity and structural integrity.

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Abstract

The invention is in the field of secondary batteries. In particular, the present invention is directed to a method of manufacturing an electrode substrate and to an electrode substrate. There is provided a method of manufacturing an electrode substrate, comprising the steps of: i) providing an electrically conductive 3D current collector substrate comprising a plurality of electrically conductive upstanding protrusions, ii) depositing on the 3D current collector substrate a polymer layer having a thickness that progressively increases towards terminal ends of the upstanding protrusions, the step of depositing comprising: iia) exposing a first face of the 3D current collector to one or more organic monomers, one or more initiators, and optionally one or more crosslinkers, iib) applying a temperature gradient to the 3D current collector substrate with an increasing temperature towards terminal ends of the upstanding protrusions, iic) activating the initiator, thereby polymerizing the one or more monomers into a polymer layer.
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