Current Collector with Conductive Fiber Layer for Battery
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Solution Overview
Problem
Current battery technologies face challenges in reducing internal resistance between the current collector and the electrically active material layer, which affects charging/discharging efficiencies, speed, cycle characteristics, and life expectancy.
Innovation Solution
A current collector with a conductive substrate and a conductive fiber layer comprising metal filaments and linear binders, forming a non-woven fabric structure that reduces internal resistance by allowing easy impregnation of electrically active material and absorbing stress changes during battery operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional current collector structure is used, then the battery structure is simple and easy to manufacture, but the internal resistance between the current collector and electrically active material layer is high
Solution Approach 1:
The current collector uses a composite structure combining a conductive substrate (metal foil or mesh) with a conductive fiber layer containing metal filaments and carbon fibers. This composite material approach reduces internal resistance by providing multiple conductive pathways and improving electrical contact with the electrically active material layer, while maintaining manufacturing feasibility through established composite material processing techniques.
Solution Approach 2:
The conductive fiber layer is formed with a porous non-woven fabric structure that allows easy impregnation of electrically active material. The porous structure increases the surface area for electrical contact and facilitates better penetration of active material into the current collector, thereby reducing internal resistance while maintaining a relatively simple overall structure.
2Productivity
If a conductive fiber layer with metal filaments and linear binders is used, then charging/discharging efficiency is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The conductive fiber layer uses metal filaments with specific length ranges (1mm to 150mm, preferably 10mm to 50mm) and controlled diameter (1μm to 50μm, preferably 5μm to 20μm). These parameter optimizations ensure adequate conductivity and mechanical strength while facilitating easier handling and manufacturing. The linear binder content is controlled at 10wt% to 50wt% of the conductive fiber layer to balance binding effectiveness with manufacturing simplicity.
Solution Approach 2:
The current collector structure provides different functions in different regions: the conductive substrate provides structural support and baseline conductivity, while the conductive fiber layer provides enhanced conductivity and active material contact. This local differentiation of quality and function improves charging/discharging efficiency while allowing each layer to be manufactured using optimized processes for its specific requirements.
3Ease of operation
If a non-woven fabric structure is used for the conductive fiber layer, then electrically active material impregnation is facilitated, but the structural integrity may be compromised
Solution Approach 1:
The conductive fiber layer combines metal filaments (providing conductivity and strength) with linear binder fibers (providing structural cohesion). This composite fiber structure maintains the porous non-woven characteristics that facilitate active material impregnation, while the interwoven network of metal and binder fibers provides sufficient structural integrity to prevent deformation during battery assembly and operation.
Solution Approach 2:
The non-woven fabric structure inherently provides porosity that facilitates easy impregnation of electrically active material. The controlled porosity is maintained by using appropriate fiber diameter (1μm to 50μm) and length (1mm to 150mm), which create adequate void spaces for material penetration while the dense network of fibers maintains structural strength.
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
The present invention relates to a battery technology, and more particularly, to a current collector that may be widely used in secondary batteries and an electrode employing the same. The current collector according to an embodiment of the present invention includes a conductive substrate; and a conductive fiber layer, which is dispersed on the conductive substrate and comprises pores. The conductive fiber layer comprises a plurality of metal filaments and liner binders mixed with the plurality of metal filaments, and the conductive fiber layer is combined with the conductive substrate via the mixed linear binders.