Resin-Layer Electrode Current Collector for Low-Resistance Tab Coupling
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Solution Overview
Problem
Existing electrode current collectors with a resin layer between metal layers face difficulties in energizing and securely fixing electrode tabs and leads, due to high resistance and coupling issues.
Innovation Solution
The electrode current collector design includes a polymer resin layer removed from specific uncoated portions, allowing the metal layers to face each other, with various linear or discontinuous shapes, facilitating easy energization and secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin layer is interposed between metal layers to improve safety by cutting off current flow, then safety is improved, but electrical conductivity and ease of energization deteriorate
Solution Approach 1:
The resin layer is segmented by removing it from specific uncoated portions, creating discrete non-conductive regions rather than a continuous barrier. This allows current to flow through metal-to-metal contact points while maintaining insulation in other areas, resolving the contradiction between safety and conductivity.
Solution Approach 2:
The resin layer is selectively removed from uncoated portions where electrical contact is needed, while retaining the resin in coated portions for insulation. This local differentiation allows the structure to simultaneously achieve both electrical conductivity at contact points and safety through insulation elsewhere.
2Reliability
If a resin layer is interposed between metal layers to improve safety, then safety is improved, but ease of coupling electrode tabs to leads deteriorates
Solution Approach 1:
The resin layer is divided into retained and removed portions, creating accessible metal surfaces in uncoated portions for coupling operations while maintaining protective insulation in coated portions. This segmentation enables easy welding or connection of electrode tabs to leads without compromising overall safety.
Solution Approach 2:
The resin layer is extracted (removed) from specific uncoated portions where coupling is required, eliminating the barrier to mechanical and electrical connection while preserving the resin layer's safety function in other areas.
3Weight of moving object
If the metal layer is made thin to reduce weight, then weight is reduced, but electrical resistance increases
Solution Approach 1:
The uncoated portions act as intermediary contact points that provide direct metal-to-metal electrical pathways, compensating for the high resistance of thin metal layers by creating low-resistance shunt paths where the resin layer is removed.
Data Source
Figure 1~2
Figure 3~6
Figure 7(a)~7(h)
AI summary
Disclosed are an electrode current collector including a first metal layer, a polymer resin layer provided on one surface of the first metal layer, and a second metal layer provided on one surface of the polymer resin layer, wherein the polymer resin layer is removed from a part of an uncoated portion corresponding to an electrode tab such that the first metal layer and the second metal layer face each other, a method of manufacturing the same, and a secondary battery electrode assembly including the same.