Closed-Pore Conductive Structure for Lightweight Battery Current Paths

The patent applies porous materials by introducing a controlled pore structure into the conductive element. The pores are filled with conductive material or left as voids, creating a lightweight porous matrix that maintains electrical conductivity through the conductive filling or pore wall continuity while significantly reducing material density and weight.

The patent employs composite materials by combining a porous matrix structure with conductive filling materials. This creates a composite system where the porous framework provides mechanical support and reduced weight, while the conductive filling ensures adequate electrical conductivity, achieving a balance between weight reduction and performance maintenance.

The patent specifies predominantly closed pores rather than open pores to maintain mechanical integrity while reducing weight. The closed pore structure prevents electrolyte penetration that would degrade mechanical properties, while the pores still reduce material density. Conductive filling within these closed pores maintains electrical conductivity without requiring open pathways.

The patent changes the pore structure parameters by specifying closed pores with controlled size distribution and filling them with conductive materials. This parameter modification allows the structure to maintain adequate electrical conductivity through the filling material while the closed pore configuration preserves mechanical strength by preventing structural degradation from electrolyte exposure.

The patent employs closed porous structures that are not accessible to the electrolyte. The pores are sealed within the conductive element, preventing electrolyte penetration while still allowing weight reduction and conductive filling. This closed configuration maintains the original external surface area exposed to corrosion, preserving corrosion resistance.

The patent converts the potential harm of pore formation (increased corrosion surface) into a benefit by filling the closed pores with conductive materials. The filling process creates a protective internal structure that maintains conductivity while the closed pore configuration ensures the internal filling is protected from corrosion, turning the pore structure from a corrosion vulnerability into a protected functional feature.