Composite Current Collector with Polymer Openings
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Solution Overview
Problem
Current battery current collectors, typically made of solid metal foils like aluminum and copper, are too heavy for weight-sensitive applications due to their high metal content and thickness requirements for strength and conductivity, limiting the specific energy and power of batteries.
Innovation Solution
A composite current collector is developed using a polymer film with a first and second layer on its surfaces and a third layer inside openings, providing electrical conductivity while reducing weight by allowing for roll-to-roll processing and lower metal content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid metal foils are used as current collectors, then sufficient strength and conductivity are achieved, but weight increases
Solution Approach 1:
The patent applies composite materials by combining a polymer substrate with metal layers to create a current collector that leverages the lightweight properties of polymers while incorporating metal only where necessary for conductivity and strength, thereby reducing overall weight while maintaining performance
Solution Approach 2:
The patent applies local quality by placing metal layers only in specific locations where conductivity and strength are needed, rather than using solid metal throughout the entire current collector structure, thus reducing weight while maintaining necessary functional properties
2Strength
If metal foil thickness is increased, then strength and conductivity improve, but weight and metal content increase
Solution Approach 1:
The patent uses composite materials to replace thick solid metal foils with a thin polymer substrate reinforced with metal layers, significantly reducing metal content while maintaining the mechanical strength and electrical conductivity required for current collection
Solution Approach 2:
The patent applies metal layers locally on the polymer substrate only where electrical conductivity and mechanical reinforcement are needed, rather than using uniform thick metal foil throughout, thereby reducing overall metal content while maintaining functional performance
3Weight of moving object
If polymer film is used instead of metal foil, then weight is reduced, but strength and conductivity decrease
Solution Approach 1:
The patent creates a composite current collector by combining a polymer substrate with metal layers, where the polymer provides lightweight structure and the metal layers provide the necessary strength and electrical conductivity, thus achieving weight reduction without sacrificing mechanical or electrical performance
4Weight of moving object
If polymer film with openings is used, then weight is reduced and conductivity is maintained, but manufacturing complexity increases
Solution Approach 1:
The patent uses a porous polymer substrate with openings that allows electrolyte penetration and maintains electrical conductivity through the metal layers, reducing weight while preserving functional performance despite the increased structural complexity
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 composite current collector enables lighter batteries with improved specific energy and power by maintaining sufficient strength and conductivity, suitable for weight-sensitive applications like airplanes and extraterrestrial vehicles.
Implementation Method 1
the metal foil serves as a current collector, i.e., conducting electrons between the electrode material and a terminal of the battery
Implementation Method 2
serves as a mechanically supportive substrate during both the manufacture of the electrode and the battery assembly process
Data Source
AI summary
A current collector including: a polymer film including a first major surface, an opposite second major surface, and a plurality of openings extending through a thickness of the polymer film; a first layer on the first major surface of the polymer film; a second layer on the second major surface of the polymer film; and a third layer on an inner surface of an opening of the plurality of openings, wherein the third layer contacts the first layer and the second layer, and wherein the first layer, the second layer, and the third layer each independently has an electrical conductivity of greater than 10 Siemens per meter.