Chromium-Coated Lead Tab for Adhesion and Corrosion Resistance
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Solution Overview
Problem
Conventional surface treatment methods for lead tabs in secondary batteries using hexavalent chromium are regulated due to human health and environmental hazards, necessitating the development of an alternative solution for improved adhesion and corrosion resistance.
Innovation Solution
A lead tab design featuring a metal substrate with a nickel-plated layer and a metal layer containing 70 to 99.9 wt% chromium, formed through a sputtering process, achieving a gloss of 60 to 100 (Gs 60°) and a water contact angle of 60 to 80°, enhancing adhesion and preventing corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hexavalent chromium is used for surface treatment, then adhesion and corrosion resistance are improved, but human health and environmental safety deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the surface treatment layer, replacing hexavalent chromium with a multi-layer structure consisting of nickel-plated layer and chromium-containing metal layer (70-99.9 wt% Cr) with controlled thickness (10-500 nm), achieving comparable adhesion and corrosion resistance without hexavalent chromium's harmful effects
Solution Approach 2:
The patent employs a composite multi-layer surface structure comprising a metal substrate, nickel-plated layer, and chromium-containing metal layer. This composite structure combines the advantages of different materials: nickel provides base adhesion and corrosion resistance, while the chromium-containing layer provides enhanced adhesion and oxidation resistance, achieving performance comparable to or exceeding hexavalent chromium treatment without its environmental hazards
2Reliability
If conventional surface treatment is used, then adhesion is improved, but peeling defects occur under stimulation in actual use environments
Solution Approach 1:
The patent applies preliminary surface preparation including nickel plating followed by chromium-containing metal layer deposition through sputtering, creating a stable, oxidation-resistant surface structure before the lead tab is subjected to actual use conditions, thereby preventing peeling defects from occurring during service
Solution Approach 2:
The multi-layer composite structure (metal substrate + nickel-plated layer + chromium-containing metal layer) provides enhanced stability under stimulation. The chromium-containing layer acts as a protective barrier that prevents oxidation and adhesion degradation, maintaining bonding strength even when exposed to moisture, heat, or mechanical stress in actual use environments
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 new lead tab design improves adhesion and corrosion resistance, preventing defects such as peeling and corrosion in actual use environments, while reducing the use of harmful hexavalent chromium.
Implementation Method 1
formed through a sputtering process
Data Source
AI summary
Another embodiment of the present disclosure provides a lead tab including: a metal substrate; a nickel-plated layer laminated on both sides of the metal substrate; and a metal layer on the nickel-plated layer, wherein the metal layer contains 70 to 99.9 wt % of chromium and wherein the lead tab has a gloss of 60 to 100 (Gs 60°), and has a water contact angle of 60 to 80°.