Metal-Coated Wire Mesh Current Collectors for Low-Resistance Joints
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Solution Overview
Problem
Wire mesh current collectors for battery cells exhibit low strength, stiffness, and high internal resistance due to inadequate physical and electrical contact at mesh joints, which affects the performance of anode and cathode electrodes.
Innovation Solution
Coating the wire mesh current collectors with a metal coating, such as indium, tin, or zinc, and subsequent annealing to increase the strength and stiffness by rigidly connecting the wires at the mesh joints, reducing internal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If wire mesh current collectors are used with thin wires (4 μm to 100 μm diameter), then the flexibility and surface area are improved, but the strength and stiffness at mesh joints deteriorate due to inadequate physical contact
Solution Approach 1:
The patent applies composite materials by combining the wire mesh structure with a metal coating layer. The coating material (such as copper, aluminum, or alloy) is deposited onto the wire mesh, creating a composite structure where the coating reinforces the mesh joints and improves mechanical strength while maintaining the flexibility and surface area benefits of the thin wire mesh structure.
2Area of stationary object
If wire mesh current collectors are used with thin wires (4 μm to 100 μm diameter), then the flexibility and surface area are improved, but the stiffness at mesh joints deteriorates due to inadequate physical contact
Solution Approach 1:
The patent applies composite materials by combining the wire mesh structure with a metal coating layer. The coating material (such as copper, aluminum, or alloy) is deposited onto the wire mesh, creating a composite structure where the coating reinforces the mesh joints and improves mechanical strength while maintaining the flexibility and surface area benefits of the thin wire mesh structure.
3Device complexity
If wire mesh current collectors are used, then the manufacturing complexity is reduced compared to solid foils, but the internal resistance increases due to inadequate electrical contact at mesh joints
Solution Approach 1:
The patent applies parameter changes by modifying the electrical and mechanical properties of the wire mesh through metal coating. The coating process changes parameters such as surface conductivity, joint contact pressure, and electrical contact area, thereby reducing internal resistance and improving reliability while maintaining the manufacturing simplicity of wire mesh structures.
4Strength
If metal coating is applied to wire mesh current collectors, then the strength and electrical contact are improved, but the manufacturing process complexity increases due to additional coating and annealing steps
Solution Approach 1:
The patent applies parameter changes by optimizing the coating process parameters (coating thickness, material composition, annealing temperature and time) to achieve the desired strength and electrical contact improvement with minimal process complexity. The annealing process parameters are specifically controlled to enhance joint strength without requiring excessively complex manufacturing procedures.
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 coated and annealed wire mesh current collectors demonstrate improved manufacturability, increased contact between wires, reduced resistance, and enhanced lithium adhesion, leading to improved performance and rate capabilities of lithium metal anode electrodes.
Implementation Method 1
coating the wire mesh current collector with a metal coating by immersing the wire mesh current collector in a bath including a metal salt
Implementation Method 2
The method includes annealing the wire mesh current collector after coating the wire mesh current collector to increase physical and electrical contact at the plurality of mesh joints. The annealing is performed at a temperature greater than a melting temperature of a metal of the metal coating
Data Source
AI summary
A method for manufacturing a current collector for an electrode of a battery cell includes providing a wire mesh current collector including a plurality of first wires and a plurality of second wires that overlap to form a plurality of mesh joints. A diameter of the plurality of first wires and the plurality of second wires is in a range from 4 μm to 100 μm. The method includes coating the wire mesh current collector with a metal coating by immersing the wire mesh current collector in a bath including a metal salt.