Electroplated Multilayer Metal Plate for Thin Current Collector Strength
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Solution Overview
Problem
The reduction of metal thin plate thickness in negative electrode current collectors for secondary batteries and fuel cells leads to degraded mechanical properties, such as tensile strength and elongation, making them prone to cracking and deformation, which compromises the durability of these energy storage devices.
Innovation Solution
A method of manufacturing a multilayer metal plate by electroplating, where a first metal layer with larger grains and lower specific resistance is formed, followed by a second metal layer with nanometer-size grains and higher tensile strength, using specific plating solutions and current densities to achieve a thickness of several to tens of micrometers and a tensile strength of 74.3 to 111.4 kgf/mm².
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of the metal thin plate is reduced to several to tens of micrometers to increase energy density, then the capacity of the secondary battery increases, but the mechanical properties such as tensile strength and elongation are degraded
Solution Approach 1:
The patent applies composite materials by creating a multilayer metal thin plate structure consisting of a first metal layer (Cu, Ag, or Au) and a second metal layer (Ni, Pt, Ru, or Rh) with different properties. The first layer provides electrical conductivity while the second layer provides high strength, achieving both high energy density and mechanical strength in the final product
Solution Approach 2:
The patent applies local quality by giving different regions of the metal thin plate different properties through the multilayer structure. The first metal layer has high electrical conductivity suitable for current collection, while the second metal layer has high tensile strength to prevent cracking, with each layer optimized for its specific function
2Quantity of substance
If the thickness of the metal thin plate is reduced to several to tens of micrometers, then the capacity of the secondary battery increases, but the metal thin plate becomes prone to cracking and deformation
Solution Approach 1:
The multilayer composite structure combines a soft, ductile first metal layer with a strong, rigid second metal layer. This composite structure prevents cracking and deformation during battery operation while maintaining the thin profile needed for high capacity
Solution Approach 2:
The second metal layer acts as a protective layer that beforehand cushions the first metal layer against thermal and mechanical stresses during battery fabrication and operation, preventing cracking and deformation before they can occur
3Quantity of substance
If a single metal layer is used to reduce thickness, then the energy density increases, but the mechanical strength and durability decrease
Solution Approach 1:
The patent uses composite materials with two distinct metal layers, each selected for specific properties. The first layer (Cu, Ag, Au) provides electrical conductivity and the second layer (Ni, Pt, Ru, Rh) provides mechanical strength, achieving both high energy density and mechanical strength that cannot be obtained with a single metal layer
Solution Approach 2:
Different regions of the metal thin plate have different local qualities through the multilayer structure. The first layer is optimized for electrical properties while the second layer is optimized for mechanical properties, allowing the thin plate to achieve high energy density without sacrificing mechanical strength
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 multilayer metal plate exhibits improved tensile strength and durability, enhancing the performance and longevity of secondary batteries and fuel cells by protecting the first metal layer from thermal and mechanical stresses.
Implementation Method 1
a first forming operation of forming one of a first metal layer and a second metal layer on a substrate by electroplating
Data Source
AI summary
A method of manufacturing a multilayer metal plate by electroplating includes a first forming operation of forming one of a first metal layer and a second metal layer on a substrate by electroplating, wherein the second metal layer is less recrystallized than the first metal layer, the second metal layer is comprised of nanometer-size grains, and the second metal layer has a higher level of tensile strength than the first metal layer; and a second forming operation of forming, by electroplating, a third metal layer not formed in the first forming operation on a surface of one of the first metal layer and the second metal layer formed in the first forming operation.