Fiber-Based Battery Current Collector to Prevent Metal Layer Peeling
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Solution Overview
Problem
Conventional current collectors for lithium-ion batteries, primarily made of pure copper and aluminum foils, are heavy, limiting energy density and difficult to thin further due to reduced strength, and alternative plastic films with deposited metal layers are prone to peeling and deformation.
Innovation Solution
A current collector comprising a fiber base layer with composite fibers, inorganic fillers, and auxiliary agents, along with bonding and metal layers, which provides structural integrity and prevents peeling, while reducing weight and improving energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If pure copper foil or pure aluminum foil is used as current collector, then electrical conductivity is ensured, but the battery weight increases and energy density decreases
Solution Approach 1:
The current collector uses a composite structure consisting of a plastic film base layer combined with metal layers (copper or aluminum). This composite material approach allows the plastic film to provide mechanical strength and flexibility while the metal layers provide electrical conductivity, thereby reducing overall weight compared to conventional pure metal foils while maintaining required electrical performance
Solution Approach 2:
The invention applies different materials to different layers of the current collector: the plastic film base layer provides structural support and flexibility, while thin metal layers deposited on the surfaces provide electrical conductivity. This local differentiation of material functions allows weight reduction in the bulk structure while maintaining conductivity at the functional surfaces
2Weight of moving object
If the thickness of pure copper foil or pure aluminum foil is reduced, then battery weight decreases, but the strength and processing performance deteriorate
Solution Approach 1:
The plastic film base layer serves as a strong, flexible substrate that compensates for the reduced strength of thin metal layers. The composite structure allows the metal layers to be made much thinner than conventional foils while the plastic film provides the mechanical strength and processing performance required for manufacturing and handling
Solution Approach 2:
The plastic film base layer acts as an intermediary between the thin metal layers, providing mechanical support and enabling the metal layers to maintain their integrity during processing and operation without requiring them to be thick enough to provide their own structural support
3Weight of moving object
If metal layers are deposited on plastic film to reduce weight, then battery weight decreases, but the metal layers are prone to peeling off
Solution Approach 1:
The plastic film base layer serves as an intermediary between the metal layers and the underlying structure, providing a surface that enhances adhesion. The plastic film's surface properties and mechanical flexibility create strong bonding interfaces that prevent peeling, while still allowing the metal layers to remain thin for weight reduction
Solution Approach 2:
The plastic film base layer acts as a flexible substrate that conformally supports the metal layers, accommodating thermal expansion and mechanical deformation without creating stress concentrations that would cause peeling. The flexibility of the plastic film allows the composite structure to maintain integrity under various operating conditions
4Weight of moving object
If the thickness of plastic film is reduced for weight reduction, then battery weight decreases, but the film becomes easily deformed
Solution Approach 1:
The composite structure combines thin plastic film with metal layers to achieve weight reduction while the metal layers and bonding layers provide dimensional stability and resistance to deformation. The multi-layer composite maintains the flexibility and light weight of thin plastic film while adding structural rigidity through the metal components
Data Source
AI summary
The present application relates to the technical field of batteries, and in particular, to a current collector, and a preparation method therefor and an application thereof the current collector includes a fiber base layer, in which a first bonding layer and a second bonding layer are respectively arranged on surfaces on two sides of the fiber base layer, a first metal layer and a second metal layer are respectively arranged on the surfaces of the first bonding layer and the second bonding layer away from the fiber base layer, and material composition of the fiber base includes the following components in parts by weight. Based on this, the current collector provided according to the present application can prevent a metal layer from peeling off while realizing the light weight of a battery.