Metallized Polymer Current Collectors for Sealed Stacked Cells

Solution Overview

Problem

Conventional metal current collectors in stacked batteries face challenges in maintaining high conductivity in the z-direction while limiting xy-direction conductivity, and require seals to prevent short circuits and electrolyte leakage.

Innovation Solution

The use of polymeric current collectors with metallization layers and conductive materials within apertures, allowing for z-direction conductivity while using polymer edge regions for sealing, thus eliminating the need for separate seals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional metal current collectors are used in stacked batteries, then high conductivity in the z-direction is achieved, but xy-direction conductivity cannot be limited and separate seals are required to prevent short circuits

Engineering Contradiction:

Improveprevention of short circuitsVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The current collector and seal are merged into a single integrated component. The polymeric current collector body provides both electrical conductivity through embedded conductive materials and sealing functionality through its polymeric material, eliminating the need for separate seal components and reducing structural complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The current collector uses composite materials consisting of polymeric material combined with conductive materials (such as metal particles or conductive polymers). This composite structure provides both the electrical conductivity needed for current collection and the sealing properties of the polymeric material, resolving the contradiction between conductivity and sealing requirements

Inventive Principle:

Principle #40Composite materials

2Reliability

If conventional metal current collectors are used, then electrical conductivity is maintained, but separate seals are required to prevent electrolyte leakage

Engineering Contradiction:

Improveprevention of electrolyte leakageVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The current collector and seal are merged into a single integrated component. The polymeric current collector body provides both electrical conductivity through embedded conductive materials and sealing functionality through its polymeric material, eliminating the need for separate seal components and reducing structural complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The polymeric current collector performs multiple functions simultaneously: it collects current through embedded conductive materials, provides structural support, and acts as a seal to prevent electrolyte leakage. This multi-functionality reduces the number of components needed in the battery structure

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If polymeric current collectors with metallization layers are used, then z-direction conductivity is enhanced while xy-direction conductivity is minimized, but manufacturing complexity increases

Engineering Contradiction:

Improvedirectional conductivity controlVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Conductive materials are selectively embedded or deposited only in specific regions where z-direction conductivity is needed, rather than uniformly throughout the entire polymeric current collector. This localized approach to conductivity enhancement reduces material costs and simplifies manufacturing compared to full metallization

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The current collector uses composite materials consisting of polymeric material combined with conductive materials (such as metal particles or conductive polymers). This composite structure provides both the electrical conductivity needed for current collection and the sealing properties of the polymeric material, resolving the contradiction between conductivity and sealing requirements

Inventive Principle:

Principle #40Composite materials

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

This design enhances z-direction conductivity while minimizing xy-direction conductivity and prevents short circuits, providing a more efficient and sealed battery structure.

Implementation Method 1

polymer current collectors with metallization layers and conductive materials within apertures, allowing for z-direction conductivity while using polymer edge regions for sealing

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

the separator and the first current collector may be laminated proximate the edge region of the first current collector along the first surface of the first current collector

Methodology Applied

Scientific EffectLamination: Lamination

Data Source

PatentUS12412903B1Metallized current collector for stacked battery

Publication Date: 2025.09.09 STACKED ENERGY INC

AI summary

Batteries according to embodiments of the present technology may include a stacked battery cell having a first and second battery cell. The first battery cell may include a first cathode current collector comprising a first polymer and a first metal at least partially coating the first polymer, and a first anode current collector comprising may comprise a second polymer and a second metal at least partially coating the second polymer. The second battery cell may include a second cathode current collector comprising the first polymer and the first metal at least partially coating the first polymer, and a second anode current collector comprising the second polymer and the second metal at least partially coating the second polymer. The first anode current collector is coupled with the second cathode current collector along a first surface of the first anode current collector and a first surface of the second cathode current collector.