Composite Current Collector Passivation Against Electrolyte Corrosion
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Solution Overview
Problem
Existing current collectors in electrochemical devices suffer from reduced energy density and poor corrosion resistance due to thick metal layers, which can lead to metal layer detachment and device failure.
Innovation Solution
A composite current collector design featuring a passivation layer on the conductive layer surface facing the connecting layer, preventing electrolyte contact and corrosion, with specific materials and thickness ranges for the base body, connecting layers, conductive layers, and passivation layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a larger thickness of metal layer is deposited on the polymer film to improve electrical conductivity, then the electrical conductivity of the current collector is improved, but the energy density of the electrochemical device is reduced
Solution Approach 1:
The current collector uses a composite structure consisting of a polymer film substrate combined with a metal layer. This composite design allows the thin metal layer (100-5000 nm) to provide sufficient electrical conductivity while the thin polymer substrate maintains low weight and high energy density, resolving the contradiction between conductivity and energy density
Solution Approach 2:
The invention optimizes the thickness parameter of the metal layer to be in the range of 100-5000 nm, which is sufficient to provide good electrical conductivity while being thin enough to maintain high energy density. This precise parameter control resolves the contradiction by finding the optimal thickness value that satisfies both requirements
2Reliability
If a larger thickness of metal layer is deposited on the polymer film to improve electrical conductivity, then the electrical conductivity of the current collector is improved, but the current collector becomes poor in resisting corrosion of electrolyte
Solution Approach 1:
The composite structure of polymer film plus thin metal layer creates a system where the polymer provides corrosion resistance to the electrolyte while the metal layer provides electrical conductivity. The polymer substrate acts as a protective barrier, preventing direct contact between the metal and corrosive electrolyte, thus resolving the contradiction between conductivity and corrosion resistance
Solution Approach 2:
The polymer film serves as an intermediary layer between the metal conductive layer and the electrolyte. This intermediary protects the metal from direct exposure to corrosive electrolyte while still allowing the metal to perform its electrical function, thereby resolving the contradiction between conductivity and corrosion resistance
3Reliability
If a larger thickness of metal layer is deposited on the polymer film to improve electrical conductivity, then the electrical conductivity of the current collector is improved, but the metal layer is likely to fall off during long-term operation
Solution Approach 1:
The composite structure of polymer film combined with thin metal layer creates strong interfacial adhesion. The close integration of the thin metal layer with the polymer substrate prevents delamination during long-term operation, while still providing sufficient electrical conductivity. This composite design resolves the contradiction between conductivity and adhesion stability
Solution Approach 2:
By controlling the metal layer thickness to be thin (100-5000 nm), the stress and weight on the interface are reduced, preventing delamination. This parameter optimization ensures good adhesion stability while maintaining adequate electrical conductivity, resolving the contradiction between conductivity and adhesion
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
Enhances the stability and durability of the current collector by preventing corrosion, thereby improving the overall performance and longevity of electrochemical devices.
Implementation Method 1
a passivation layer is formed on one surface of a conductive layer facing toward a connecting layer, the passivation layer may prevent an electrolyte from contacting the conductive layer and causing the conductive layer to be corroded and damaged
Implementation Method 2
a metal polymer film is generally first obtained by metal physical vapor deposition on the surface of a low-density polymer film
Data Source
AI summary
A composite current collector includes a base body, a first connecting layer and a first conductive layer, the first connecting layer bonds the first conductive layer to a first surface of the base body; a first passivation layer is formed on one surface of the first conductive layer facing toward the first connecting layer. the first passivation layer may prevent an electrolyte from contacting the first conductive layer and causing the first conductive layer to be corroded and damaged when the electrolyte enters from one surface of the first connecting layer facing away from the first conductive layer, thereby improving the stability of the current collector; an electrode plate and an electrochemical device are provide.