Aluminum Oxide Composite Layer for Electrode Adhesion
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Solution Overview
Problem
The existing electrochemical devices face challenges in achieving low resistance between the current collector and the active material layer due to high resistivity of phosphorus compounds and variability in oxyhydroxide formation on the current collector surface, leading to inconsistent performance.
Innovation Solution
An electrochemical device electrode is developed with an aluminum oxide layer formed on the current collector, which improves adhesion between the conductive layer and the current collector, reducing resistance. This layer contains both aluminum oxide and aluminum hydroxide, and is formed using an alkaline solution with carboxyl salt, ensuring stability and strong affinity with the conductive material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a phosphorus compound anchor coat layer is provided between the current collector and the active material layer, then the adhesion between the current collector and the active material layer is improved, but the resistance between them increases due to the relatively high resistivity of phosphorus
Solution Approach 1:
The invention uses a composite layer containing both aluminum oxide and aluminum hydroxide instead of a single phosphorus compound material. This composite structure combines the adhesion benefits of aluminum hydroxide with the low resistivity of aluminum oxide, resolving the contradiction between improving adhesion and maintaining low resistance.
2Reliability
If water is attached to the current collector after corona discharge treatment to form a protective layer containing oxyhydroxide, then the anchor coat layer is partially embedded and resistance drops, but the production of oxyhydroxide varies leading to inconsistent resistance
Solution Approach 1:
The invention changes the chemical parameters by using an alkaline solution with carboxyl salt instead of simple water attachment after corona discharge. This parameter change ensures consistent and controlled formation of the aluminum oxide layer with stable composition, eliminating the variability in oxyhydroxide production while maintaining low resistance.
3Strength
If an aluminum oxide layer containing both aluminum oxide and aluminum hydroxide is formed on the current collector, then the adhesion between the aluminum oxide layer and the conductive layer is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The invention employs self-service by using an alkaline solution with carboxyl salt that automatically forms the desired aluminum oxide and aluminum hydroxide composite layer when contacted with the current collector. This self-forming mechanism simplifies the manufacturing process despite the complexity of creating a composite material structure, as no additional steps are needed to separately form each component layer.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The approach results in a significant reduction in resistance between the active material layer and the current collector, enhancing the electrochemical device's performance by improving adhesion and conductivity through the anchor effect of the aluminum oxide layer.
Implementation Method 1
an aluminum oxide layer which contains aluminum hydroxide and aluminum oxide is formed on a principle surface of the current collector
Implementation Method 2
the resistance between the active material layer and the current collector, drops
Data Source
AI summary
An electrochemical device electrode pertaining to one mode of the present invention has a current collector, an aluminum oxide layer, a conductive layer, and an active material layer. The current collector is an aluminum foil. The aluminum oxide layer is formed on a principle surface of the current collector and contains aluminum hydroxide and aluminum oxide. The conductive layer is formed on the aluminum oxide layer and contains conductive material, while the active material layer is formed on the conductive layer.