Aluminum Alloy Substrate Adhesion in Nonaqueous Electrolyte Devices
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The use of aluminum alloy substrates in nonaqueous electrolyte energy storage devices leads to increased resistance during repeated charge-discharge cycles due to the poor adhesiveness between the positive electrode composite layer and the substrate, as the particles expand and shrink, causing them to detach from the hard substrate.
Innovation Solution
Incorporating particles A and particles B with different sizes in the positive electrode composite layer on an aluminum alloy substrate containing an element other than aluminum at a content of 1% by mass or more, where the smaller particles act as a cushion and improve adhesiveness, reducing the detachment of larger particles from the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an aluminum alloy substrate is used to maintain sufficient strength with decreased thickness, then the mechanical strength is improved, but the resistance increases due to poor adhesiveness between the positive electrode composite layer and the substrate
Solution Approach 1:
The invention applies local quality by creating a specific aluminum alloy composition with controlled element content (1-10% of specific elements) and using dual particle size distribution (first particles of 3-10 μm and second particles of 1-3 μm) in the positive electrode composite layer. This local optimization of material properties at different locations and scales improves adhesiveness while maintaining substrate strength, resolving the contradiction between mechanical strength and resistance stability.
Solution Approach 2:
The invention uses composite materials by combining aluminum alloy substrate with a positive electrode composite layer containing mixed particle sizes of active material particles. The composite structure of different particle sizes creates a more effective interface between the substrate and active material, improving adhesiveness and reducing resistance increase during cycling while maintaining the strength benefits of the aluminum alloy substrate.
2Quantity of substance
If the substrate thickness is decreased to increase capacity, then the energy density is improved, but the adhesiveness deteriorates causing particle detachment
Solution Approach 1:
The invention applies local quality by optimizing the particle size distribution specifically in the positive electrode composite layer adjacent to the substrate. The combination of first particles (3-10 μm) and second particles (1-3 μm) creates a gradient structure that improves mechanical interlocking and chemical bonding at the substrate interface, maintaining adhesiveness even when substrate thickness is reduced to increase overall battery capacity.
Solution Approach 2:
The invention uses composite materials by creating a positive electrode composite layer with mixed particle sizes of active material particles coated on the aluminum alloy substrate. This composite particle structure improves the surface area-to-volume ratio and creates better mechanical interlocking, enhancing adhesiveness and preventing particle detachment during charge-discharge cycles even with thinner substrates.
3Strength
If an aluminum alloy substrate is used instead of pure aluminum, then the mechanical properties are improved, but the resistance increase during cycling worsens
Solution Approach 1:
The invention applies parameter changes by precisely controlling the composition parameters of the aluminum alloy substrate (1-10% of specific elements) and the particle size parameters of the positive electrode composite layer (first particles: 3-10 μm, second particles: 1-3 μm). These parameter optimizations improve the interface properties between substrate and active material, enhancing adhesiveness and reducing resistance increase during cycling while maintaining the mechanical property improvements of aluminum alloy.
Solution Approach 2:
The invention uses composite materials by combining the aluminum alloy substrate with a positive electrode composite layer containing mixed particle sizes. This composite structure creates a more effective interface that compensates for the potential downsides of aluminum alloy usage, improving adhesiveness and electrochemical stability while maintaining the mechanical strength benefits of the alloy substrate.
Data Source
AI summary
A nonaqueous electrolyte energy storage device according to one aspect of the present invention is a nonaqueous electrolyte energy storage device including a positive electrode which has a conductive substrate and a positive electrode composite layer layered on the substrate, wherein the substrate is made from an aluminum alloy containing an element other than aluminum at a content of 1% by mass or more, and the positive electrode composite layer contains particles A and particles B having different particle sizes from each other as positive active materials.