Nickel-Coated Battery Electrode Substrate for Strength and Flexibility
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Solution Overview
Problem
Existing battery electrode substrates for alkaline secondary batteries face issues with strength, flexibility, high electrical resistance, and reduced cycle life due to inadequate metal coverage and adhesiveness, leading to increased costs and impaired charge/discharge characteristics.
Innovation Solution
A battery electrode substrate with a metallic porous body featuring a nickel film coating of at least 85% coverage on plastic fibers, a core/sheath composite fiber structure, and a specific pore size range, combined with a gradient nickel film density and electroplating methods to enhance strength, flexibility, and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the amount of Ni metal is increased to secure strength, then the collector strength is improved, but the flexibility is lost and metal fiber protrusion causes short circuiting
Solution Approach 1:
The patent uses a composite structure combining metal fibers (for strength and conductivity) with polymer unwoven fabric (for flexibility and structural support). This composite approach allows the collector to achieve both high strength and flexibility simultaneously, preventing metal fiber protrusion while maintaining bendability for electrode formation.
2Strength
If the amount of Ni metal is increased to secure strength, then the collector strength is improved, but the cost is driven up
Solution Approach 1:
By combining metal fibers with polymer unwoven fabric, the patent reduces the overall amount of expensive Ni metal required while maintaining structural strength. The polymer fabric provides mechanical support, allowing less metal to be used without compromising collector integrity.
Solution Approach 2:
The patent applies metal plating selectively to specific regions where conductivity and strength are most needed, rather than uniformly coating the entire collector. This localized approach reduces total metal consumption while maintaining performance in critical areas.
3Quantity of substance
If the amount of Ni plating is reduced to lower cost, then the cost is reduced, but the electrical resistance increases and output characteristics are impaired
Solution Approach 1:
The composite structure of metal fibers embedded in polymer fabric provides inherent electrical conductivity through the metal network, reducing dependence on thick Ni plating layers. This allows cost reduction through minimized plating while maintaining low electrical resistance.
Solution Approach 2:
The patent applies Ni plating selectively to regions requiring enhanced conductivity and current collection, rather than uniform coverage. This localized plating strategy reduces total Ni consumption and cost while maintaining adequate electrical performance in critical zones.
4Quantity of substance
If the metal film coverage on fiber surface is reduced to lower cost, then the cost is reduced, but the current flow is impaired and electrical resistance increases
Solution Approach 1:
The patent implements selective Ni plating on metal fiber surfaces, applying coating only in regions where current collection is critical. This partial coverage approach reduces Ni consumption and cost while maintaining sufficient conductivity for effective current flow in active zones.
Solution Approach 2:
The metal fiber-polymer composite structure provides continuous electrical pathways through the metal network, reducing dependence on complete fiber surface coating. This allows reduced plating coverage while maintaining adequate current flow capability.
5Shape
If the unwoven fabric is bent by winding, then the battery structure is formed, but the metal layer exfoliates and electrical resistance increases
Solution Approach 1:
The composite of metal fibers and polymer unwoven fabric creates a flexible, integrated structure where the polymer matrix holds metal fibers together during winding. This prevents metal layer exfoliation during battery assembly while enabling the necessary bent configuration for electrode formation.
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 solution results in a substrate with improved strength, flexibility, and reduced electrical resistance, enabling high-rate charge/discharge capabilities and extended cycle life while minimizing nickel usage and costs.
Implementation Method 1
a metallic porous body, the metallic porous body having a structure in which a surface of a plastic fiber in a woven or unwoven fabric is coated with a nickel film
Implementation Method 2
a conductive layer is formed on a polymer core material such as unwoven fabric by a vapor-phase method such as sputtering
Implementation Method 3
a conductive layer is formed on a polymer core material such as unwoven fabric by a vapor-phase method such as sputtering
Data Source
AI summary
A battery electrode substrate includes a metallic porous body. The metallic porous body has a structure in which a surface of a plastic fiber in a woven or unwoven fabric is coated with a nickel film. The nickel film coats the surface with an average coverage ratio of not less than 85%.