Composite Battery Current Collector for Adhesion and Flexibility

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Solution Overview

Problem

Existing current collectors for rechargeable lithium batteries lack sufficient resistance, adhesion, and flexibility, which are essential for high-performance and flexible battery applications.

Innovation Solution

A current collector comprising a polymer support layer, a conductive layer, and a carbon-containing layer with carbon nanotubes or carbon nanofibers extending from the polymer support layer or the conductive layer, enhancing resistance, adhesion, and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional current collector structure is used, then the manufacturing process is simple, but the resistance, adhesion, and flexibility are insufficient

Engineering Contradiction:

Improveresistance and adhesionVSAvoidcurrent collector structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The current collector uses a composite structure consisting of a polymer support layer and a carbon-containing layer with carbon nanotubes or carbon nanofibers. This composite material approach provides enhanced resistance, adhesion, and flexibility compared to conventional single-material current collectors, directly resolving the technical contradiction between reliability and structural simplicity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The carbon-containing layer is selectively formed on the polymer support layer to provide localized enhancement of electrical conductivity and mechanical properties where needed. This allows the current collector to achieve superior resistance and adhesion characteristics in specific regions while maintaining overall structural efficiency.

Inventive Principle:

Principle #3Local quality

2Reliability

If the current collector uses enhanced resistance and adhesion properties, then battery safety improves, but manufacturing complexity increases

Engineering Contradiction:

Improvebattery safetyVSAvoidcurrent collector fabrication

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The polymer support layer is prepared in advance with controlled porosity and surface characteristics before the carbon-containing layer is formed. This preliminary preparation ensures that the subsequent carbon layer formation process achieves optimal adhesion and resistance properties, improving battery safety while maintaining manufacturing feasibility through a systematic multi-step process.

Inventive Principle:

Principle #10Preliminary action

3Strength

If carbon nanotubes or carbon nanofibers are extended from the polymer support layer, then adhesion and flexibility are enhanced, but the manufacturing precision requirements increase

Engineering Contradiction:

ImproveadhesionVSAvoidcarbon layer formation

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The polymer support layer is designed with controlled porosity to facilitate the extension of carbon nanotubes or carbon nanofibers from the layer interior to the surface. This porous structure provides natural pathways for carbon fiber growth, achieving enhanced adhesion and flexibility while reducing the precision requirements for carbon layer formation through self-organizing growth mechanisms.

Inventive Principle:

Principle #31Porous materials

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 proposed current collector improves the safety and manufacturing costs of rechargeable lithium batteries by providing better penetration characteristics, enhanced adhesive strength, and suitable flexibility for flexible applications.

Implementation Method 1

a carbon-containing layer on at least one surface of the polymer support layer, wherein the carbon-containing layer includes at least one of carbon nanotubes or carbon nanofibers extending from the polymer support layer or the conductive layer

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Data Source

PatentUS20250140868A1Current collector for rechargeable lithium battery and rechargeable lithium battery including the same

Publication Date: 2025.05.01 SAMSUNG SDI CO LTD

AI summary

A current collector for rechargeable lithium batteries and a rechargeable lithium battery including the same are disclosed. The current collector includes: a polymer support layer; a conductive layer on at least one surface of the polymer support layer; and a carbon-containing layer on at least one surface of the polymer support layer, and the carbon-containing layer includes at least one of carbon nanotubes or carbon nanofibers extending from the polymer support layer or the conductive layer.