Resin-Supported Electrode Stack for Lightweight Battery Collectors
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Solution Overview
Problem
Existing battery technologies face challenges in achieving high energy density and capacity per unit mass due to the limitations of conventional current collectors and electrode structures.
Innovation Solution
The use of a current collector with a support layer made of thermoplastic resin material and featuring through-holes, which allows for improved fluidity and reduced volume expansion during welding, enhancing the integration of metal layers and improving the battery's energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional current collectors are used, then structural integrity is maintained, but energy density per unit mass is limited
Solution Approach 1:
The current collector is designed with through-holes penetrating it, creating a porous structure that reduces the mass of the current collector while maintaining its structural integrity and electrical conductivity functions, thereby improving energy density per unit mass
Solution Approach 2:
The patent uses a composite structure combining the current collector with a thermoplastic resin material that fills the through-holes and integrates metal layers, creating a composite material system that optimizes both mechanical strength and electrical conductivity while reducing overall mass
2Strength
If welding is performed on stacked welding targets, then integration of metal layers is achieved, but volume expansion occurs
Solution Approach 1:
The through-holes in the current collector provide void space that accommodates volume expansion during welding without causing deformation or damage to the stacked welding targets, allowing successful integration of metal layers
Solution Approach 2:
The thermoplastic resin material acts as an intermediary substance that fills the through-holes and provides a compliant matrix that absorbs welding-induced volume expansion, protecting the metal layer integration process
3Ease of manufacture
If thermoplastic resin material is used in support layer, then fluidity improves during welding, but manufacturing complexity increases
Solution Approach 1:
The thermoplastic resin material undergoes parameter changes during welding (temperature-induced softening) that improve its fluidity and weldability, allowing it to flow and fill the through-holes effectively during the welding process
Solution Approach 2:
The current collector is segmented into regions with through-holes, allowing the thermoplastic resin to be selectively placed and welded in specific areas, managing complexity through localized functional zones
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 approach results in a power storage cell with improved energy density per unit mass and capacity per unit mass of active material, making it suitable for applications such as flight vehicles.
Implementation Method 1
a support layer including a thermoplastic resin material... improved fluidity and reduced volume expansion during welding
Implementation Method 2
welding a part of a plurality of welding targets stacked together
Data Source
AI summary
A stack including a plurality of stacked sheet materials is provided. Each of the plurality of sheet materials has a support layer including a resin material and a first metal layer and a second metal layer formed on both faces of the support layer. In a part of the plurality of sheet materials, the plurality of first metal layers and the plurality of second metal layers included in the plurality of sheet materials are integrated.