Foam Metal Current Collector With Solid Weld Edges
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Solution Overview
Problem
Current collectors made of foam metal are difficult to connect to a housing by laser welding, leading to production challenges due to issues like scalding and potential explosion points, and compressing the edges for welding reduces porosity and pore uniformity.
Innovation Solution
A current collector design with a solid metal part connected to the edge of a porous foam metal part, where the solid metal part serves as the welding area, preventing laser leakage and ensuring stable connection without compressing the foam metal, thus maintaining porosity and pore uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If foam metal is used as current collector, then porosity and pore uniformity are improved, but laser welding capability deteriorates
Solution Approach 1:
The current collector is divided into two distinct parts: a foam metal part maintaining porosity for electrochemical performance, and a solid metal part providing laser welding capability. This segmentation allows each part to fulfill its specific function without compromise.
Solution Approach 2:
The patent combines foam metal and solid metal into a composite current collector structure. The solid metal part is connected to the foam metal part, merging the advantages of both materials: porosity from foam metal and weldability from solid metal.
2Strength
If edges of foam metal are compressed for welding, then connection stability is improved, but porosity and pore uniformity deteriorate
Solution Approach 1:
The current collector is divided into two distinct parts: a foam metal part maintaining porosity for electrochemical performance, and a solid metal part providing laser welding capability. This segmentation allows each part to fulfill its specific function without compromise.
Solution Approach 2:
Different regions of the current collector have different properties: the foam metal part has high porosity for electrochemical activity, while the solid metal part has zero porosity for reliable laser welding. Each region is optimized for its specific function.
3Reliability
If solid metal part thickness exceeds foam metal part thickness, then welding area is improved, but separator arching risk increases
Solution Approach 1:
The thickness of the solid metal part is precisely controlled to be less than or equal to the thickness of the foam metal part. This parameter optimization ensures adequate welding area while preventing the solid metal part from protruding and causing separator arching.
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
The design effectively prevents laser leakage and explosion risks, ensuring stable connection to the housing while preserving the foam metal's porosity and pore distribution, enhancing the safety and performance of the electrode assembly.
Implementation Method 1
the solid metal part is used as the welding area of the current collector. When laser welding is performed, the solid metal part can effectively prevent laser leakage
Data Source
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AI summary
The present application discloses a current collector, and manufacturing method and equipment thereof, and a current collector preform, wherein the current collector includes a porous foam metal part and solid metal part(s); the porous foam metal part is uncompressed, and the porous foam metal part includes a first edge and a second edge oppositely distributed in a first direction, the first direction is perpendicular to the thickness direction of the current collector; the first edge and/or the second edge are connected with the solid metal part(s). For the current collector of embodiments of the present application, the solid metal part(s) is connected to edge(s) of the porous foam metal part, which can alleviate the problem that current collector in the form of foam metal is difficult to be connected to the housing by laser welding.