Clad Current Collector Interface Layer for Bipolar Solid-State Batteries

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Solution Overview

Problem

Bipolar solid-state batteries face issues with thick clad foil layers that have inferior mechanical bonding and a time-consuming, energy-inefficient fabrication process.

Innovation Solution

A clad current collector with a thermal interface layer comprising copper and aluminum foil layers bonded by a polyolefin adhesive and materials like pyrolytic graphite sheets and carbon nanotubes, enhancing thermal and electrical conductivity, and using a hot-rolling process for efficient production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If thick clad foil current collectors are used, then mechanical strength is improved, but thermal and electrical conductivity deteriorate

Engineering Contradiction:

Improvemechanical strengthVSAvoidthermal and electrical conductivity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The current collector uses a composite structure with copper foil providing electrical conductivity, aluminum foil providing mechanical strength, and a thermal interface layer with high thermal conductivity materials (pyrolytic graphite, carbon nanotubes) to enhance heat dissipation. This composite approach allows each layer to contribute its superior property, resolving the contradiction between mechanical strength and thermal/electrical conductivity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different regions of the current collector are assigned different materials optimized for their specific functions: copper for electrical conduction, aluminum for structural support, and thermally conductive materials at the thermal interface. This local optimization ensures that each part performs its designated function efficiently without compromising overall performance.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If conventional fabrication processes are used, then manufacturing simplicity is maintained, but energy consumption increases and production time lengthens

Engineering Contradiction:

Improvefabrication process simplicityVSAvoidenergy consumption

Core Design Contradiction:

Ease of manufactureVSUse of energy by stationary object

Solution Approach 1:

The thermal interface layer is pre-formed with thermally conductive materials before final assembly, allowing for optimized material distribution and reduced energy consumption during the bonding process. The polyolefin adhesive is applied in advance to ensure proper positioning and reduce rework, thereby decreasing overall production time and energy use.

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If conventional current collectors are used, then structural integrity is maintained, but mechanical bonding deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoidmechanical bonding

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

A thermal interface layer containing polyolefin adhesive is introduced as an intermediary between the copper and aluminum foil layers. This intermediate layer provides strong mechanical bonding between the dissimilar metals while maintaining the structural integrity of the overall current collector assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution provides improved mechanical integrity, efficient heat dissipation, and reduced thickness, enabling cost-effective large-scale production of bipolar solid-state batteries.

Implementation Method 1

a thermal interface layer including adhesive and at least one material that increases thermal and electrical conductivity of the thermal interface layer

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

A clad current collector includes a first foil layer, a second foil layer and a thermal interface layer including adhesive and at least one material that increases thermal and electrical conductivity

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS12603296B2Clad current collectors including thermal interface layer for bipolar solid-state batteries

Publication Date: 2026.04.14 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A battery cell includes a plurality of cathodes and a plurality of anodes. A plurality of solid electrolyte layers are arranged between first adjacent ones of the plurality of cathodes and the plurality of anodes. A plurality of clad current collectors are arranged between second adjacent ones of the plurality of cathodes and the plurality of anodes. The plurality of clad current collector includes a first foil layer, a second foil layer and a thermal interface layer including adhesive and at least one material that increases thermal and electrical conductivity of the thermal interface layer.