Current collectors for rechargeable batteries
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Solution Overview
Problem
Current current collectors in lithium-ion batteries face challenges such as high electrode/electrolyte interface area leading to electrolyte consumption, disordered microstructures with low packing density, stability issues, and scalability problems in manufacturing.
Innovation Solution
The development of augmented metallic foils with a seamless repeating pattern of non-piercing textural elements, offering a functional porosity of at least 10%, which can be produced in a roll-to-roll configuration, enhancing surface area and mechanical stability while maintaining cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If 3D porous current collectors are used to increase surface area and improve charge/discharge capacity, then energy density and power density are enhanced, but electrolyte consumption increases due to large electrode/electrolyte interface area
Solution Approach 1:
The patent employs a porous coating layer applied on top of a flat current collector substrate. This porous layer provides the necessary high surface area for improved charge/discharge capacity and energy density while the underlying flat substrate maintains a controlled, reduced electrode/electrolyte interface area, thereby minimizing electrolyte consumption.
Solution Approach 2:
The patent transitions from a purely 3D porous current collector to a hybrid structure combining a 2D flat current collector substrate with a 3D porous coating layer. This dimensional hybridization allows the system to benefit from high surface area in the coating while maintaining the space-saving and electrolyte-efficient characteristics of the flat substrate.
2Power
If 3D porous current collectors with disordered microstructures are used to increase surface area, then charge/discharge capacity is improved, but packing density decreases leading to larger battery volume
Solution Approach 1:
The patent applies a porous coating layer (adding vertical dimensionality) on top of a flat current collector substrate. This approach increases the effective surface area for charge/discharge reactions without requiring a bulky 3D porous substrate, thereby maintaining compact battery volume while achieving high power density.
Solution Approach 2:
The porous coating layer provides high surface area for improved charge/discharge capacity while being applied as a thin layer on the flat substrate, avoiding the volume expansion associated with disordered 3D porous structures.
3Power
If complex 3D current collector structures are synthesized to achieve high performance, then charge/discharge capacity and energy density are improved, but manufacturing scalability and cost-effectiveness are reduced
Solution Approach 1:
The patent divides the current collector system into two functional segments: a simple flat substrate that provides mechanical support and electrical conductivity, and a porous coating layer that provides high surface area. This segmentation allows each component to be optimized and manufactured separately using existing industrial processes, improving scalability.
Solution Approach 2:
Instead of synthesizing complex 3D porous structures from scratch, the patent applies a porous coating layer on top of a conventional 2D flat current collector. This approach leverages existing flat current collector manufacturing infrastructure while adding the functional benefits of porosity through a separate coating process, greatly enhancing manufacturability and scalability.
4Ease of manufacture
If flat planar current collectors are used to maintain manufacturing simplicity and cost-effectiveness, then ease of manufacture is improved, but charge/discharge capacity and energy density are limited due to low surface area
Solution Approach 1:
The patent applies a porous coating layer on top of the flat current collector substrate. This porous layer dramatically increases the surface area available for charge/discharge reactions, enabling high power density and energy density while the underlying flat substrate maintains manufacturing simplicity and cost-effectiveness.
Solution Approach 2:
The patent adds vertical dimensionality through a porous coating layer on the flat substrate, transforming the effective surface area from 2D to 3D without changing the fundamental 2D nature of the substrate itself. This allows high capacity while maintaining ease of manufacture.
Data Source
AI summary
The present invention provides electrodes comprising a current collector in the form of an augmented metallic foil having a fine and uniform corrugation that augments the functional porosity of the foil. The presently disclosed electrodes having augmented metallic foil, exhibiting high functional porosity, as current collectors are useful in many application, including, but not limited to lithium-ion barratries and electric devices using the same for energy.