Thermoplastic Composite Anode Without Copper Collector
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Solution Overview
Problem
Existing secondary batteries, particularly Li-ion batteries, face issues such as instability, lithium dendrite formation, low energy density, inefficiency in cycle number, high production costs, and environmental hazards due to limited recyclability, primarily because conventional graphite-based anodes are difficult to process and costly.
Innovation Solution
Development of thermoplastic composite materials with electrical conductivity and energy storage properties by combining thermoplastics with metals, metal salts, organo-metallic compounds, and carbon derivatives, which are processed using twin screw extruders to create a conductive anode material without a copper collector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional graphite-based anodes are used, then energy storage capacity is achieved, but processing difficulty and production cost increase
Solution Approach 1:
The patent uses composite materials consisting of thermoplastic matrix combined with conductive fillers (carbon black, graphite particles, metal powders) to create anode materials that are both processable and functional. This composite approach allows the material to maintain energy storage capacity while becoming easier to manufacture through standard thermoplastic processing techniques.
Solution Approach 2:
The patent changes the fundamental parameter of anode material from conventional graphite to thermoplastic-based composite. This parameter change enables the use of injection molding and extrusion processes, dramatically improving ease of manufacture while maintaining energy storage functionality through the conductive filler content (1-50 wt%).
2Quantity of substance
If conventional graphite-based anodes are used, then energy storage capacity is achieved, but production cost increases
Solution Approach 1:
The composite structure allows substitution of expensive graphite with cheaper thermoplastic matrices combined with cost-effective conductive fillers. The thermoplastic base material is generally less expensive than high-purity graphite, and the composite formulation optimizes the balance between cost and performance.
Solution Approach 2:
Changing from graphite to thermoplastic-based anode material fundamentally alters the cost structure. Thermoplastics offer lower material costs and eliminate expensive processing steps, reducing overall production cost while maintaining energy storage capacity through optimized filler content.
3Reliability
If copper plate is used as collector, then electrical conductivity is improved, but device complexity and production cost increase
Solution Approach 1:
The patent extracts and eliminates the copper collector component from the anode structure. By incorporating conductive fillers directly into the thermoplastic anode matrix, the separate copper collector layer becomes unnecessary, simplifying the overall device structure and reducing production complexity.
Solution Approach 2:
The patent merges the functions of the anode active material and the electrical conductor into a single integrated component. The conductive fillers embedded in the thermoplastic matrix perform both structural and electrical conduction functions, eliminating the need for separate copper collector layers.
4Ease of manufacture
If thermoplastic composite materials are used, then ease of manufacture is improved, but electrical conductivity must be enhanced
Solution Approach 1:
The patent uses composite materials where conductive fillers (carbon black, graphite, metal powders) are dispersed within the thermoplastic matrix. This composite structure provides both the processability of thermoplastics and the electrical conductivity needed for anode function, with filler content optimized at 1-50 wt%.
Solution Approach 2:
The patent changes the electrical conductivity parameter of the thermoplastic material by adding conductive fillers. The filler concentration, particle size, shape, and distribution are controlled to achieve the required conductivity level while maintaining the ease of manufacture inherent to thermoplastic processing.
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
Enhances charge-discharge capacity, prevents lithium dendrite formation, improves recyclability, and reduces production costs by providing a faster, more efficient anode production process.
Implementation Method 1
combining thermoplastics with metals, metal salts, organo-metallic compounds, and carbon derivatives, which are processed using twin screw extruders to create a conductive anode material
Implementation Method 2
enhances charge-discharge capacity, prevents lithium dendrite formation, improves recyclability
Data Source
AI summary
A reinforcement and/or filler element is added to the thermoplastic resin intended for use in the anode elements of secondary batteries to make the electrically insulating thermoplastic material a conductive material and to impart energy storage properties. In this way, it has been made possible to use a thermoplastic composite material developed with electrical conductivity and energy storage properties as an alternative to the traditionally used carbon derivated to single-layer anode without the use of copper plate.