Composite Electrode Substrate With Thin Metal Layers for Higher Energy Density
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Solution Overview
Problem
Secondary batteries face challenges with reduced energy density and efficiency due to increased weight, particularly in portable devices and automotive applications, necessitating a reduction in battery weight without compromising performance.
Innovation Solution
A composite substrate is used in electrode assemblies, comprising a polymer substrate with different metal layers on opposite surfaces, optimizing their thickness and width to reduce the collector volume and enhance energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of metal layers is increased to improve conductivity and performance, then the electrical performance is improved, but the volume of the collector increases leading to reduced energy density
Solution Approach 1:
The patent applies parameter changes by precisely controlling the thickness of metal layers to be smaller than the thickness of the polymer substrate. This parameter optimization ensures sufficient electrical conductivity while minimizing the collector volume, thereby resolving the contradiction between electrical performance and energy density
Solution Approach 2:
The patent uses composite materials by combining different metal layers with a polymer substrate to form a composite collector structure. This composite design allows the system to achieve both adequate electrical conductivity through the metal layers and reduced overall volume through the lightweight polymer substrate, thus resolving the technical contradiction
2Strength
If the thickness of the polymer substrate is increased to improve mechanical strength, then the structural integrity is improved, but the overall volume increases reducing energy density
Solution Approach 1:
The patent applies parameter changes by optimizing the polymer substrate thickness to a specific range that provides sufficient mechanical strength while keeping the volume minimal. The metal layers are designed with thickness smaller than the polymer substrate, creating a balanced structure that achieves both strength and compactness
Solution Approach 2:
The composite structure of polymer substrate with metal layers provides synergistic effects where the polymer contributes mechanical strength and the thin metal layers provide electrical conductivity with minimal volume addition, resolving the contradiction between strength and volume
3Quantity of substance
If different metal layers with optimized thickness are used, then the energy density is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by specifying that the metal layers have thickness smaller than the polymer substrate thickness, with specific thickness ranges provided. This parameter standardization simplifies the manufacturing process while achieving high energy density, as the consistent thickness relationship can be easily controlled during production
Solution Approach 2:
The patent applies local quality by using different metal materials on opposite surfaces of the polymer substrate, each optimized for their specific function. This localized optimization allows different regions to have different properties while maintaining overall manufacturing simplicity through a symmetric structure
Data Source
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AI summary
A composite substrate comprises a polymer substrate, a first metal layer disposed on a first surface of the polymer substrate, and a second metal layer disposed on a second surface of the polymer substrate opposite the first surface, wherein the first metal layer and the second metal layer comprise different materials, and either the first metal layer or the second metal layer has a smaller thickness than the polymer substrate in a first direction.