Composite Current Collector Welding Region for Stronger Tab Joining
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Solution Overview
Problem
Existing composite current collectors face difficulties in welding tabs and achieving effective conduction between conductor layers, often resulting in low welding strength and poor electrical conductivity due to the use of metal conductor layers on both sides and the complexity of manufacturing porous structures.
Innovation Solution
A composite current collector design featuring a polymer support layer with conductor layers on either side and a welding region devoid of polymer, allowing for improved electrical connection and enhanced welding strength through the use of a conductive adhesive and thickened regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal conductor layers are used on both sides of the current collector, then electrical conductivity is improved, but welding difficulty increases and welding strength decreases
Solution Approach 1:
The current collector is segmented into three distinct regions: a first conductor layer on the first surface, a second conductor layer on the second surface, and an insulating layer covering the edge region. This segmentation allows the conductor layers to provide electrical conductivity where needed while the insulating layer prevents short circuits and enables reliable welding at the edge region.
Solution Approach 2:
An insulating layer is introduced as an intermediary element between the conductor layers and the external environment at the edge region. This insulating layer acts as a mediator that prevents direct contact between conductor layers, eliminating short circuit risks while providing a stable surface for welding operations.
2Reliability
If a porous structure is used in the current collector, then manufacturing complexity increases, but electrical conduction between layers improves
Solution Approach 1:
The current collector uses thin film structures for the conductor layers and insulating layer, which can be deposited using conventional thin film deposition techniques. This approach simplifies manufacturing compared to creating porous structures, while still achieving effective electrical conduction through the conductor layers and reliable insulation through the insulating layer.
3Weight of moving object
If the conductor layers are made thin to reduce weight, then energy density improves, but welding difficulty increases
Solution Approach 1:
The insulating layer serves as a mediator that enables welding of thin conductor layers by providing a stable, non-conductive surface at the edge region. This allows thin conductor layers to be used for weight reduction while the insulating layer ensures reliable welding by preventing short circuits during the welding process.
Solution Approach 2:
The insulating layer is applied specifically at the edge region where welding occurs, while the conductor layers maintain their thin structure in the active areas. This local differentiation allows thin conductor layers for weight reduction while providing sufficient welding surface area with proper insulating properties where needed.
Data Source
AI summary
Provided is a composite current collector. The composite current collector includes a support layer, a first conductor layer, a second conductor layer, and a welding region. The support layer is made of a polymer. The first conductor layer is disposed on a first side of the support layer. The second conductor layer is disposed on a second side of the support layer. In the welding region, no polymer is provided between the first conductor layer and the second conductor layer. A preparation method and a lithium ion battery are further provided.