Reinforced Current Collectors for Low-Deformation Electrodes
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Solution Overview
Problem
Electrochemical cells face performance degradation due to expansion and contraction of components, leading to defects like wrinkles and gaps in current collectors, which reduce battery life and require expensive high-modulus materials.
Innovation Solution
Incorporating a reinforcing layer with a high modulus of elasticity on the current collector, coupled with a polymer film and adhesive polymer, to reduce stretching and deformation, allowing for thinner current collectors and potentially lower mass and higher energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If current collector material with high tensile strength or high modulus of elasticity is used, then resistance to deformation is improved, but cost increases
Solution Approach 1:
The patent applies composite materials by combining the current collector with a reinforcing layer having high modulus of elasticity. This composite structure provides the necessary mechanical strength and resistance to deformation while allowing the use of more cost-effective base materials, thus resolving the contradiction between strength and manufacturing cost.
2Weight of moving object
If current collector thickness is reduced, then mass and cost are reduced, but mechanical strength and resistance to deformation deteriorate
Solution Approach 1:
The patent uses a composite structure where a thin current collector is reinforced with a layer of material having high modulus of elasticity. This allows the current collector to be made thinner (reducing mass) while the reinforcing layer provides the necessary mechanical strength and resistance to deformation, thus resolving the contradiction between weight and strength.
Solution Approach 2:
The reinforcing layer is applied specifically to the current collector surface where mechanical strength is needed, rather than making the entire current collector thicker. This localized reinforcement reduces overall mass while providing the necessary mechanical properties where required.
3Ease of manufacture
If current collector material is used without reinforcement, then manufacturing simplicity is maintained, but defects like wrinkles and gaps form during operation
Solution Approach 1:
The patent combines the current collector with a reinforcing layer to create a composite structure that prevents defect formation during operation. The reinforcing layer provides the necessary mechanical support to prevent wrinkles and gaps while maintaining a relatively simple manufacturing process, thus resolving the contradiction between manufacturing simplicity and reliability.
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 effectively minimizes defects in electrochemical cells, enhances battery performance, and reduces material costs by using less current collector material while maintaining or improving energy and power density.
Implementation Method 1
The reinforcing layer can have a modulus of elasticity sufficient to reduce the amount of stretching incident on the current collector during operation of the electrode
Implementation Method 2
an adhesive polymer disposed between the reinforcing material and the polymer film
Data Source
AI summary
Embodiments described herein relate to electrochemical cells and electrodes with reinforced current collectors. In some embodiments, an electrode can include a current collector and an electrode material disposed on a first side of the current collector. A reinforcing layer can be disposed on a second side of the current collector. The reinforcing layer can have a modulus of elasticity sufficient to reduce the amount of stretching incident on the current collector during operation of the electrode. In some embodiments, a polymer film can be disposed on the reinforcing material. In some embodiments, the electrode can further include an adhesive polymer disposed between the reinforcing material and the polymer film. In some embodiments, the reinforcing material can have a thickness of less than about 10 μm. In some embodiments, the reinforcing layer can include an adhesive polymer.