Battery Electrode Interlayer for Low-Resistance Current Collection

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Solution Overview

Problem

Existing electrode structures in battery cells face challenges in achieving optimal electrical contact between the electrode and the current collector, leading to high contact resistance and reduced performance due to surface roughness and material compatibility issues with costly deposition techniques.

Innovation Solution

The introduction of a deformable electrically conducting interlayer between the current collector and the free-standing electrode, which can be made of materials like graphite or carbon, enhances electrical contact by accommodating surface roughness and providing improved conductivity, and can be adhesive to secure the layers together.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a free-standing electrode is used without a current collector, then material compatibility issues and cost reduction are achieved, but electrical contact and conductivity are worsened

Engineering Contradiction:

Improvemanufacturing costVSAvoidelectrical contact

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent introduces a conductive interlayer as an intermediary component between the free-standing electrode and the current collector. This interlayer serves as a mediator that ensures reliable electrical contact while allowing the electrode to remain free-standing without direct attachment to the current collector, thus resolving the contradiction between manufacturing simplicity and electrical contact reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the electrode surface is rough, then better accommodation of surface irregularities is achieved, but contact area and conductivity are reduced

Engineering Contradiction:

Improvesurface roughness accommodationVSAvoidcontact resistance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent employs a thin film interlayer that exhibits flexibility and deformability to accommodate surface roughness. This thin film can conform to irregular electrode surfaces, maintaining intimate contact across the interface and preventing increased contact resistance despite surface roughness, thus resolving the contradiction between adaptability and contact reliability.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the physical parameters of the interlayer, specifically its deformability and compliance, to enable it to adapt to surface roughness variations. By selecting materials and structures with appropriate mechanical properties, the interlayer can deform to match the electrode surface topology, maintaining good electrical contact despite surface irregularities.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If a deformable interlayer is used, then contact area is increased and contact resistance is reduced, but structural complexity increases

Engineering Contradiction:

Improvecontact resistanceVSAvoidlayer structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies local quality by introducing deformability and compliance specifically at the electrode-current collector interface through the interlayer, while keeping the rest of the battery structure simple and rigid. This localized application of special properties ensures good electrical contact only where needed, without unnecessarily complicating the overall device structure.

Inventive Principle:

Principle #3Local quality

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

This configuration significantly reduces contact resistance, improves battery cell performance by increasing the contact area, and allows for the use of cost-effective materials and manufacturing processes, such as slurry casting and extrusion, while maintaining structural integrity and adhesion.

Implementation Method 1

the interlayer may be compressible in a direction substantially orthogonal to the electrode surface

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

the interlayer can deform to accommodate any roughness of the electrode surface

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 3

the interlayer comprising a conducting material... electrical contact between the electrode and the current collector layer is improved

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 4

the interlayer may be an adhesive layer that adheres the electrode to the current collector

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS20240055578A1Electrode structure and method of making an electrode structure

Publication Date: 2024.02.15 DYSON TECH LTD

AI summary

An electrode structure for use in a battery cell includes: a current collector layer having a current collector surface; a free-standing electrode layer having an electrode surface that faces the current collector surface; and an interlayer arranged between the current collector surface and the electrode surface. The interlayer includes an electrically conducting material.