Thin-Gauge Aluminum Cathode Collectors for Long-Cycle Li-Ion Cells
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Solution Overview
Problem
Conventional lithium-ion battery cathode current collectors made from copper and aluminum face limitations in cycle life and energy density, particularly when using thick gauge materials, which affect the performance and longevity of the battery.
Innovation Solution
Utilizing thin gauge 1xxx series and 8xxx series aluminum alloys with specific thicknesses and compositions, including recycled content, to enhance conductivity and adhesion with active materials, resulting in improved cycle life and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick gauge aluminum or copper is used for cathode current collectors, then mechanical strength and conductivity are improved, but energy density and cycle life deteriorate
Solution Approach 1:
The patent applies parameter changes by transitioning from thick gauge (12-20 μm) to thin gauge (6-12 μm) aluminum alloys, specifically using 1xxx series (e.g., 1080, 1085, 1100, 1230, 1350, 1370, 1435, 1445, 1450, 1490, 1495, 1499) and 8xxx series (e.g., 8077, 8079, 8090, 8093, 8111, 8176, 8177, 8180, 8186, 8190, 8193, 8211, 8277, 8290, 8293, 8311, 8377, 8390, 8393, 8411, 8477, 8490, 8493, 8511, 8577, 8611, 8677, 8690, 8693, 8711, 8777, 8811, 8877, 8911, 8977, 8990, 8993, 8999) aluminum alloys. This parameter change reduces the current collector thickness while maintaining mechanical strength through alloy composition optimization, thereby increasing energy density by reducing the non-active material mass in the battery structure.
2Strength
If thick gauge aluminum or copper is used for cathode current collectors, then mechanical strength is improved, but cycle life deteriorates
Solution Approach 1:
The patent applies parameter changes by using thin gauge (6-12 μm) aluminum alloys with specific compositions (1xxx and 8xxx series) to reduce mechanical stress and deformation during battery cycling. The reduced thickness combined with optimized alloy composition maintains sufficient strength while improving flexibility and reducing strain accumulation, leading to extended cycle life of 3000 cycles or more with above 90% capacity retention.
Solution Approach 2:
The patent employs composite material principles by selecting specific aluminum alloy compositions (1xxx and 8xxx series) that combine aluminum base metal with controlled amounts of alloying elements. These composite aluminum alloys provide an optimal balance of mechanical strength, electrical conductivity, and flexibility, enabling thin gauge construction that maintains structural integrity during cycling while extending battery life.
3Quantity of substance
If thin gauge aluminum alloys are used for cathode current collectors, then energy density and cycle life are improved, but manufacturing precision and adhesion requirements increase
Solution Approach 1:
The patent applies parameter changes by using thin gauge (6-12 μm) aluminum alloys with specific compositions (1xxx and 8xxx series) that optimize surface properties for adhesion. The reduced thickness increases surface area to volume ratio, enhancing contact with active materials, while the alloy composition controls surface energy and roughness to improve bonding quality and manufacturing precision.
Solution Approach 2:
The patent applies local quality principles by optimizing specific surface properties of the thin gauge aluminum alloy current collector. The alloy composition and surface characteristics are tailored to provide enhanced adhesion zones where active materials are deposited, ensuring reliable bonding despite the reduced overall thickness. This localized optimization of surface properties maintains manufacturing precision while achieving improved energy density.
Data Source
AI summary
Described are batteries and battery components including a cathode current collector comprising a 1xxx series aluminum alloy or an 8xxx series aluminum alloy. The cathode current collector can have a thickness of from 5 μm to 12 μm. In some examples, a cathode active material layer may be disposed over at least a portion of the cathode current collector. The cathode current collector may have both surfaces that are in contact with the active material layer being matte surfaces. Battery cells including the cathode current collector may retain a specific capacity above 90% of an initial specific capacity for up to 3000 cycles or more. Additionally, the battery cells including the cathode current collector may retain an energy density above 90% of an initial energy density for up to 3000 cycles or more.