Oxide-Protected Powder Current Collector for Reliable Batteries

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Solution Overview

Problem

Existing batteries with current collectors formed by compacting powders face challenges in reliability due to low corrosion resistance and mechanical strength, especially when exposed to gases and solvents.

Innovation Solution

A battery design featuring a first electrode with a current collector formed from a green compact of metal particles, where each particle has a protection layer composed of an oxide, enhancing corrosion resistance and mechanical reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a current collector is formed by compacting metal powder to increase contact area and reduce internal resistance, then battery performance is improved, but corrosion resistance and mechanical strength deteriorate

Engineering Contradiction:

Improvebattery performanceVSAvoidmechanical strength of current collector

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The current collector is formed as a composite material consisting of metal particles (such as aluminum or copper) compacted together. This composite structure provides both the electrical conductivity needed for battery performance and, when combined with appropriate particle morphology and compaction, can achieve sufficient mechanical strength

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention changes key parameters of the metal powder including particle size (0.1-10 μm), particle shape (spherical, irregular, or elongated), and compaction density (70-95% theoretical density). By optimizing these parameters, the current collector achieves a balance between mechanical strength, electrical conductivity, and corrosion resistance

Inventive Principle:

Principle #35Parameter changes

2Reliability

If a current collector is formed by compacting metal powder to increase contact area, then internal resistance is reduced, but corrosion resistance deteriorates

Engineering Contradiction:

Improvebattery performanceVSAvoidcorrosion resistance

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention optimizes the compaction density parameter to 70-95% of theoretical density. This parameter range creates a structure with sufficient contact area for low internal resistance while maintaining enough structural integrity and surface uniformity to resist corrosion. The specific particle size range (0.1-10 μm) also contributes to forming a more uniform surface that is less susceptible to corrosion initiation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates local quality variations in the current collector structure. The compaction process creates regions of different density and particle arrangement, with some areas having higher contact area for electrical conductivity while other areas maintain structural integrity for corrosion resistance. This local differentiation allows the material to satisfy multiple conflicting requirements simultaneously

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250201864A1battery

Publication Date: 2025.06.19 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

A battery according to this disclosure includes a first electrode, a second electrode, and an electrolyte. The first electrode includes a first current collector and a first active material layer, the first current collector is formed of a green compact including first metal particles, the first metal particles each have a first protection layer on at least a portion of a surface of the first metal particle, and the first protection layer includes an oxide.