Composite Electrode Current Collector for Uniform Battery Reactions
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Solution Overview
Problem
Conventional electrode current collectors, such as metal foils, require significant metal usage, and alternatives like resin current collectors increase battery resistance due to nonuniform electrode reactions.
Innovation Solution
An electrode current collector comprising a metal foil, an electrically-conductive resin layer, and a carbon particle layer, where the electrically-conductive resin layer includes a contiguous phase and a dispersed phase, and the carbon particle layer covers the resin layer to distribute electrons uniformly, reducing in-plane resistance variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If metal foil is replaced by resin current collector, then metal usage is reduced, but battery resistance increases
Solution Approach 1:
The patent uses a composite structure consisting of a resin current collector layer combined with a metal foil layer. The resin layer (contiguous phase) provides insulation and structural support, while the metal foil layer (dispersed phase) provides electrical conductivity. This composite approach reduces overall metal usage while maintaining sufficient electrical conductivity and preventing nonuniform electrode reactions, thereby resolving the contradiction between reducing metal usage and maintaining low battery resistance.
2Ease of manufacture
If electrically-conductive resin layer is used without carbon particle layer, then manufacturing is simpler, but in-plane resistance variations increase
Solution Approach 1:
The patent applies a carbon particle layer specifically on the surface of the electrically-conductive resin layer where electrode reactions occur. This localized application of conductive carbon particles addresses the in-plane resistance variations at the critical interface with the electrode, while the bulk resin layer maintains its manufacturing simplicity. The carbon particles create a conductive network at the surface level, ensuring uniform electron distribution without complicating the overall manufacturing process.
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
This configuration reduces metal usage while minimizing battery resistance by ensuring uniform electrode reactions, making it suitable for bipolar and all-solid-state batteries.
Implementation Method 1
The electrically-conductive resin layer includes a contiguous phase and a dispersed phase. The contiguous phase includes a resin material. The dispersed phase includes electrically-conductive particles.
Implementation Method 2
the carbon particle layer covers the electrically-conductive resin layer. It is expected that electrons can be distributed uniformly in the carbon particle layer. This is expected to reduce in-plane resistance variations to a significant extent.
Data Source
AI summary
An electrode current collector comprises a metal foil, an electrically-conductive resin layer, and a carbon particle layer in this order. The electrically-conductive resin layer includes a contiguous phase and a dispersed phase. The contiguous phase includes a resin material. The dispersed phase includes electrically-conductive particles. The carbon particle layer includes electrically-conductive carbon particles.