Composite Battery Current Collector for Winding Damage Resistance
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Solution Overview
Problem
Current collectors made of foam metal materials are prone to damage during winding into a roll due to poor mechanical properties, leading to reduced electrical energy storage performance.
Innovation Solution
A current collector design comprising a strength enhancement layer and a current collecting layer with a combination of foam metal and solid metal portions, where the solid metal portions provide support to prevent damage and enhance mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a foam metal material is used for the current collector, then the electrical energy storage performance is improved, but the mechanical strength deteriorates causing damage during winding
Solution Approach 1:
The current collector uses a composite structure combining foam metal material (for electrical performance) with solid metal portions (for mechanical strength). The solid metal portions are formed by selectively removing parts of the foam metal structure to create regions with different densities, achieving both high electrical energy storage performance and sufficient mechanical strength to prevent damage during winding.
2Quantity of substance
If the foam metal portion has high porosity to improve energy density, then the volumetric energy density increases, but the mechanical resistance to pressing deteriorates
Solution Approach 1:
The current collector features local quality variation through solid metal portions with different densities distributed within the foam metal matrix. These solid metal portions act as reinforcement elements that provide localized mechanical support to resist pressing forces, while the surrounding high-porosity foam metal regions maintain high volumetric energy density. This spatial differentiation of material properties resolves the contradiction between energy density and mechanical resistance.
Data Source
AI summary
A current collector may comprise a strength enhancement layer and a current collecting layer, wherein the current collecting layer may be stacked and bonded with the strength enhancement layer, and the current collecting layer may comprise a foam metal portion and a solid metal portion.