Low-Moisture Current Collector Coating for High-Temperature Battery Production

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Solution Overview

Problem

Existing current collectors for electrochemical devices face challenges in achieving both high productivity and high-temperature characteristics due to moisture-related issues, leading to adhesion to production equipment and deterioration of device performance.

Innovation Solution

A current collector with a coating layer containing conductive carbon and an aromatic super engineering plastic binder, maintaining a moisture content of 200 mass ppm or less, which suppresses adhesion during high-temperature compression and enhances productivity while improving high-temperature characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a coating layer with conventional binder (PVDF) is used to enhance adhesion, then adhesion between current collector and electrode layer is improved, but moisture content increases leading to adhesion to production equipment and poor high-temperature characteristics

Engineering Contradiction:

ImproveadhesionVSAvoidmoisture content

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters of the binder from conventional PVDF to aromatic super engineering plastics (polyimide, polyether sulfone, or polyamide imide), which fundamentally alters the moisture interaction characteristics while maintaining adhesion properties

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The coating layer is formulated as a composite material combining conductive carbon (5-50 mass%) with aromatic super engineering plastic binder (50-95 mass%), creating a multi-functional coating that simultaneously provides adhesion, conductivity, and low moisture content

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If moisture content is reduced to improve high-temperature characteristics, then adhesion to production equipment is suppressed, but adhesion between current collector and electrode layer may deteriorate

Engineering Contradiction:

Improveadhesion to production equipmentVSAvoidadhesion

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent changes the binder material parameters to aromatic super engineering plastics that inherently provide both low moisture content and high adhesion strength, eliminating the trade-off between these two properties

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The aromatic super engineering plastic binder acts as an intermediary material that mediates between the current collector substrate and electrode layer, providing strong adhesion while maintaining low moisture content that prevents adhesion to production equipment

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If conventional binder materials are used to ensure ease of manufacture, then coating layer formation is simplified, but productivity is reduced due to adhesion to production equipment during high-temperature compression

Engineering Contradiction:

Improvecoating layer formationVSAvoidproductivity

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent changes the thermal properties parameters of the binder to aromatic super engineering plastics with superior heat resistance, which maintain dimensional stability during high-temperature compression and prevent adhesion to production equipment

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The coating layer is designed with specific composition ranges that balance manufacturing ease with performance, using commercially available aromatic polymers that provide sufficient durability during production while maintaining cost-effectiveness

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Temperature

If coating layer composition is optimized for low moisture content, then high-temperature characteristics are improved, but device complexity increases due to specific composition requirements

Engineering Contradiction:

Improvehigh-temperature characteristicsVSAvoidcoating layer composition

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent defines specific parameter ranges for coating layer composition (conductive carbon: 5-50 mass%, aromatic super engineering plastic: 50-95 mass%) that optimize high-temperature characteristics while providing clear manufacturing guidelines

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The coating layer is designed with localized functional distribution where conductive carbon provides conductivity and adhesion enhancement while the aromatic super engineering plastic provides structural integrity and moisture resistance, with each component optimized for its specific function

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250273692A1Current collector, electrode, and battery

Publication Date: 2025.08.28 PANASONIC HOLDINGS CORP

AI summary

A current collector according to the present disclosure includes: a substrate; and a coating layer coating the substrate, wherein the coating layer includes conductive carbon and a first binder, the first binder includes an aromatic super engineering plastic, and a moisture content calculated based on moisture generated from the current collector when heated to 200° C. is 200 mass ppm or less.