Battery Electrode Conductive Structure for Current Collection
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Solution Overview
Problem
Batteries, particularly lithium-ion batteries, face issues with electrical resistance and inhomogeneous current flow, leading to local overheating, premature aging, and thermal damage due to defects in electrode disposition and coating irregularities.
Innovation Solution
Incorporating electrically conductive structure elements on the carrier foil, such as grid- or rib-shaped conductor elements or graduated profiles, to reduce electrical resistance and enhance conductivity, which can be achieved through electrodeposition, printing technologies, or joining methods, allowing for improved current distribution and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the carrier foil has a sufficient cross section for current intensity, then electrical conduction is improved, but the weight and thickness of the foil increase
Solution Approach 1:
The invention divides the current collection function into two parts: the carrier foil provides basic support and collection, while additional discrete conductive structure elements (grids, ribs, or thickness variations) provide enhanced conductivity only where needed. This segmentation allows the foil to maintain adequate electrical performance without requiring uniform thickness or cross-section throughout, thereby reducing overall weight.
Solution Approach 2:
The invention applies conductive structure elements selectively at specific locations on the carrier foil, particularly in regions where current density is highest or where coating defects exist. This local enhancement of conductivity means the foil can be thinner and lighter in other areas, optimizing the weight-conductivity trade-off by providing quality enhancement only where locally required.
2Reliability
If the current flows out from all electrode regions toward the collector, then electrical collection is achieved, but current density rises continuously in the direction of the collector causing local heating
Solution Approach 1:
The conductive structure elements (grids, ribs, or thickness variations) segment the current flow path into multiple parallel channels distributed across the electrode surface. This segmentation prevents current from concentrating in a single path toward the collector, distributing the current density more evenly and reducing resistive heating at any single location.
Solution Approach 2:
The invention transitions from planar current collection to three-dimensional current distribution by adding vertical thickness variations or out-of-plane conductive structures. This dimensional change creates additional current pathways that distribute current flow more uniformly across the electrode-collector interface, reducing current density gradients and associated thermal effects.
3Ease of manufacture
If defects in electrode disposition or coating irregularities exist, then manufacturing is simplified, but inhomogeneous current flow occurs leading to zonal overheating
Solution Approach 1:
The conductive structure elements are incorporated into the carrier foil design before electrode assembly and coating, creating a pre-engineered current distribution network. This beforehand cushioning compensates for potential coating defects or disposition irregularities by providing alternative current pathways that bypass high-resistance areas, maintaining uniform current flow despite manufacturing variations.
Solution Approach 2:
The invention modifies the electrical conductivity parameter of the carrier foil by adding conductive structure elements with different conductivity than the base foil material. This parameter change creates regions of enhanced conductivity that compensate for areas with poor contact or coating defects, ensuring uniform current distribution despite manufacturing imperfections.
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 conductive structure elements effectively reduce the risk of local overheating, distribute temperature evenly, and minimize weight by optimizing foil thickness, thereby enhancing battery performance and longevity.
Implementation Method 1
the electrical resistance between the terminal region and a point on the carrier foil is reduced
Implementation Method 2
Electrical conduction is often associated with losses, which become evident as local heating of the battery
Data Source
AI summary
An electrode in a battery, e.g., a lithium-ion battery, has an electrically conductive carrier foil including (i) a terminal region for connection to an electrical circuit and (ii) at least one electrically conductive structure element configured to reduce the electrical resistance between the terminal region and a point on the carrier foil in order to improve electrical collection via the terminal region.