Copper-Graphene Anode Current Collector for Fast-Charging Batteries

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Solution Overview

Problem

Current battery cell current collectors, primarily made of pure copper, face challenges in achieving high energy densities, fast charging rates, and extended operational lifespans, particularly in electric vehicles.

Innovation Solution

The use of copper-graphene (Cu-Gr) multilayer composite (CGMC) coated copper foils as anode current collectors, which involve alternating layers of graphene and plated copper on a pure copper foil substrate, enhancing electrical conductivity and heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If pure copper current collectors are used, then electrical conductivity is maintained at standard levels, but energy density and charging rate performance are limited

Engineering Contradiction:

Improveenergy densityVSAvoidelectrical conductivity stability

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The patent applies composite materials by combining copper foil substrate with graphene layers and plated copper layers to create a Cu-Gr multilayer composite current collector. This composite structure achieves both high energy density (exceeding 120% IACS electrical conductivity) and stable electrical conductivity performance, resolving the contradiction between improving energy density and maintaining conductivity reliability.

Inventive Principle:

Principle #40Composite materials

2Productivity

If pure copper current collectors are used, then manufacturing simplicity is maintained, but fast charging rate and operational lifespan are compromised

Engineering Contradiction:

Improvecharging rateVSAvoidcurrent collector structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent segments the current collector into multiple functional layers: copper foil substrate, graphene layers, and plated copper layers. This segmentation allows each layer to perform specific functions (structural support, electrical conductivity enhancement, surface protection), enabling fast charging rates while managing the increased structural complexity through defined functional zones.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The multilayer composite structure combines materials with complementary properties: copper provides structural integrity and baseline conductivity, graphene enhances electrical conductivity and charge transfer, and plated copper layers provide surface stability. This composite approach achieves superior charging rate performance while maintaining manufacturability through established deposition techniques.

Inventive Principle:

Principle #40Composite materials

3Power

If conventional copper current collectors are used, then heat dissipation is adequate, but electron transport efficiency and battery capacity are insufficient

Engineering Contradiction:

Improveelectron transport efficiencyVSAvoidheat dissipation capability

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The patent employs composite materials with superior thermal and electrical properties. The graphene layers provide exceptional electrical conductivity for enhanced electron transport efficiency, while the copper substrate maintains excellent thermal conductivity for heat dissipation. This composite structure achieves both high power electron transport and effective temperature management simultaneously.

Inventive Principle:

Principle #40Composite materials

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 CGMC coated copper foils exhibit electrical conductivity exceeding 120% of the International Annealed Copper Standard, leading to improved electron transport, enhanced heat dissipation, and increased battery capacity compared to pure copper current collectors.

Implementation Method 1

forming a graphene layer directly on at least one of the top surface and the bottom surface of the copper foil substrate

Methodology Applied

Scientific EffectChemical vapor deposition: Chemical Vapour Deposition

Implementation Method 2

a plated copper layer is directly on the graphene layer

Methodology Applied

Scientific EffectElectroplating: Electroplating

Data Source

PatentUS20250183321A1Copper-graphene multilayer composite coated copper foil for anode current collector

Publication Date: 2025.06.05 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

Aspects of the disclosure include copper-graphene (Cu-Gr) multilayer composite (CGMC) current collectors and methods of manufacturing the same. An exemplary vehicle includes an electric motor and a battery pack electrically coupled to the electric motor. The battery pack includes a battery cell with a cell pouch having therein a plurality of stacked anode current collectors alternating with a plurality of stacked cathode current collectors, and an active material dispersed within the cell pouch to cover the current collectors. Each of the anode current collectors is a CGMC current collector including a copper foil substrate having a top surface and a bottom surface. The copper foil substrate is pure copper. A graphene layer is directly on at least one of the top surface and the bottom surface of the copper foil substrate and a plated copper layer is directly on the graphene layer.