Perforated Composite Current Collector for Lightweight Li-Ion Electrodes
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Solution Overview
Problem
Existing lithium ion battery current collectors lack sufficient conductivity, mechanical stability, and weight energy density, leading to issues with polarization, corrosion, and reduced service life.
Innovation Solution
A current collector design featuring an insulation layer with conductive and protective layers, perforated to allow electrolyte passage, enhancing mechanical strength and conductivity while reducing weight, and incorporating a three-dimensional conductive network for improved electron flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a plastic current collector coated with a metal layer is used to reduce weight, then weight energy density is improved, but conductivity and mechanical strength deteriorate
Solution Approach 1:
The patent uses a composite structure consisting of a plastic film substrate combined with metal layers (first protective layer, second protective layer, and conductive layer). This composite design allows the plastic film to provide light weight while the metal layers contribute conductivity and mechanical strength, resolving the contradiction between weight reduction and maintaining electrical/mechanical properties
Solution Approach 2:
The patent applies different metal layers with specific functions at different locations: the first protective layer (Al, Ti, or Zn) provides oxidation resistance, the second protective layer (Ni, Cr, or their alloys) provides corrosion resistance and mechanical strength, and the conductive layer (Cu or Al) provides electrical conductivity. This localized functional distribution optimizes each layer's contribution to resolve the overall performance contradiction
2Weight of moving object
If the conductive layer thickness is reduced to decrease weight, then weight energy density is improved, but conductivity deteriorates
Solution Approach 1:
The patent combines the conductive layer with highly conductive metal materials (Cu or Al) and optimizes its thickness to 0.01-1.0 μm. The conductive layer works synergistically with the protective layers to maintain overall conductivity while minimizing weight, achieving both light weight and good conductivity
Solution Approach 2:
The patent optimizes the thickness parameter of the conductive layer to a specific range (0.01-1.0 μm) that balances weight reduction and conductivity maintenance. This parameter optimization ensures sufficient electrical conductivity while minimizing the weight contribution of the conductive layer
3Duration of action of stationary object
If protective layers are added to prevent corrosion and oxidation, then service life is improved, but weight increases
Solution Approach 1:
The patent applies specific thin metal layers (first protective layer: Al/Ti/Zn; second protective layer: Ni/Cr or their alloys) with thicknesses optimized to provide sufficient corrosion and oxidation protection while minimizing weight. Each protective layer is selectively applied to address specific degradation mechanisms without excessive weight penalty
Solution Approach 2:
The patent uses a multi-layer composite structure where thin protective metal layers are combined with a lightweight plastic film substrate. This composite design provides effective corrosion and oxidation protection through the protective layers while the plastic substrate maintains light weight, resolving the contradiction between protection and weight
4Ease of manufacture
If the current collector structure is simplified to reduce manufacturing complexity, then ease of manufacture is improved, but conductivity and mechanical stability deteriorate
Solution Approach 1:
The patent employs a multi-layer composite structure (plastic film + first protective layer + second protective layer + conductive layer) that, while structurally complex, can be manufactured using established industrial techniques such as vacuum deposition and sputtering. The standardized manufacturing processes for these composite structures make them industrially feasible despite the multiple layers
Solution Approach 2:
The patent divides the current collector into functionally segmented layers, where each layer (protective layer, conductive layer) has a specific function. This segmentation allows for specialized optimization of each layer's properties and simplifies the manufacturing process by enabling independent deposition and control of each functional layer
Data Source
Figure 1~3
Figure 4~7
AI summary
The present disclosure relates to the technical field of battery, and in particular, relates to a current collector, an electrode plate and an electrochemical device. The current collector includes an insulation layer; a conductive layer at least located on at least one surface of the insulation layer; and a first protective layer provided on a surface of the conductive layer facing away from the insulation layer. The first protective layer is made of a metal. The current collector is provided with a plurality of holes penetrating through the insulation layer, the conductive layer and the first protective layer. The current collector according to the present disclosure is a light-weight current collector, which has good mechanical strength and conductivity, so that the current collector has a good mechanical stability, a good long-term reliability, and a good service life.