Buckling Resistant Wire Mesh Current Collector for Zinc-Air Batteries
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Solution Overview
Problem
Conventional current collectors in batteries tend to buckle during insertion, leading to high impedance and cell failure due to their low tensile strength, resulting in poor contact with the battery can and reduced product yields.
Innovation Solution
A wire mesh current collector is developed using a first nickel alloy wire with a high tensile strength for the warp and a second nickel alloy wire with a lower tensile strength for the weft, where the first peak tensile strength is greater than or equal to the second, providing improved buckling resistance and contact with the battery can.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional current collectors are used, then manufacturing cost is reduced, but tensile strength is insufficient leading to buckling during insertion
Solution Approach 1:
The current collector uses a composite wire structure combining nickel alloy (high tensile strength) and stainless steel (corrosion resistance and cost efficiency). This composite material approach achieves the required tensile strength to prevent buckling while maintaining manufacturing cost effectiveness through the strategic selection of alloy composition.
Solution Approach 2:
The invention specifies precise parameter ranges for the alloy composition (nickel content: 40-70 wt%, stainless steel content: 30-60 wt%) and wire dimensions (diameter: 0.02-0.1 inches) to optimize the balance between tensile strength and manufacturing cost. By controlling these parameters, the current collector achieves sufficient mechanical strength without excessive material costs.
2Strength
If high tensile strength wire is used, then buckling resistance is improved, but contact quality with battery can deteriorates due to excessive rigidity
Solution Approach 1:
The current collector employs different wire materials with distinct properties at different structural levels: the nickel alloy component provides high tensile strength for buckling resistance, while the stainless steel component offers appropriate flexibility and surface characteristics for reliable contact with the battery can. This local differentiation of material properties resolves the contradiction between rigidity and contact quality.
Solution Approach 2:
The composite wire structure combines materials with complementary properties: nickel alloy contributes high strength-to-prevent-buckling while stainless steel provides contact-friendly surface characteristics and flexibility. The synergistic combination ensures both buckling resistance and reliable electrical contact without requiring a single material to satisfy conflicting requirements.
3Strength
If nickel alloy wire with high tensile strength is used, then buckling resistance is improved, but corrosion resistance in caustic electrolyte deteriorates
Solution Approach 1:
The current collector uses a composite wire where nickel alloy (40-70 wt%) provides the required high tensile strength for buckling resistance, while the integrated stainless steel component (30-60 wt%) contributes superior corrosion resistance to caustic electrolytes. This composite structure allows both properties to coexist without compromise.
Solution Approach 2:
Different regions of the wire cross-section and surface are effectively assigned different functional qualities: the nickel alloy phase handles mechanical loading and tensile strength requirements, while the stainless steel phase provides the corrosion-resistant barrier against the caustic electrolyte environment. This functional differentiation resolves the strength-corrosion resistance trade-off.
Data Source
AI summary
A wire mesh including a warp which includes a first nickel alloy wire having a first peak tensile strength; and a weft which includes a wire including nickel having a second peak tensile strength, wherein the first peak tensile strength is greater than or equal to the second peak tensile strength, is provided. A current collector and a zinc-air battery that includes the wire mesh are also provided.