ZnO-Coated Current Collectors for Lithium Dendrite Mitigation

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Solution Overview

Problem

Lithium dendrites grow on anode electrodes during use, reducing efficiency and causing galvanic corrosion of current collectors in battery cells, which is not effectively addressed by existing methods.

Innovation Solution

An electrochemical deposition process is used to grow a zinc oxide (ZnO) layer on current collectors, which reduces lithium nucleation overpotential and minimizes dendrite growth by increasing lithium particle size and lowering galvanic corrosion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If lithium metal is used as anode material, then energy density is improved, but lithium dendrites grow in three dimensions reducing efficiency

Engineering Contradiction:

Improveenergy densityVSAvoidefficiency

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

A zinc oxide (ZnO) layer is deposited on the current collector to serve as an intermediary between the lithium metal and the current collector. This intermediate layer modifies the substrate properties, reducing lithium nucleation overpotential and guiding lithium deposition to form larger, more uniform particles rather than three-dimensional dendrites, thereby maintaining high energy density while improving efficiency and reliability

Inventive Principle:

Principle #24Intermediary (Mediator)

2Use of energy by moving object

If lithium metal is used as anode material, then energy density is improved, but galvanic corrosion of current collector occurs

Engineering Contradiction:

Improveenergy densityVSAvoidgalvanic corrosion

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The zinc oxide layer acts as a protective intermediary barrier between the lithium metal and the current collector. This layer prevents direct contact between the reactive lithium and the current collector material, thereby eliminating galvanic corrosion while allowing ionic transport to maintain high energy density performance

Inventive Principle:

Principle #24Intermediary (Mediator)

3Quantity of substance

If high Li nucleation overpotential is present, then lithium deposits form with high surface area, but this promotes dendrite growth

Engineering Contradiction:

Improvelithium deposit surface areaVSAvoiddendrite growth

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The zinc oxide layer modifies the surface energy and electrical properties of the current collector, changing the nucleation parameters for lithium deposition. This results in lower nucleation overpotential and promotes the formation of larger, more uniform lithium particles with reduced surface area, thereby preventing dendrite growth while maintaining adequate lithium capacity

Inventive Principle:

Principle #35Parameter changes

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 ZnO layer effectively reduces lithium dendrite formation and corrosion, enhancing battery cell efficiency and durability through a scalable, low-cost process.

Implementation Method 1

electrochemically grown zinc oxide layer on current collectors

Methodology Applied

Scientific EffectElectrochemical deposition: Electrodeposition

Implementation Method 2

electrochemically coating the current collector with a zinc oxide layer

Methodology Applied

Scientific EffectElectrochemical coating: Electrodeposition

Implementation Method 3

supplying molecular oxygen into the liquid

Methodology Applied

Scientific EffectGas dissolution: Solvation

Data Source

PatentUS12592376B2Electrochemically grown zinc oxide layer on current collectors for mitigating growth of lithium dendrites

Publication Date: 2026.03.31 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A method for manufacturing a battery cell includes connecting a current collector to a working electrode; connecting a zinc metal portion to a counter electrode; immersing the current collector and a portion of the working electrode in a liquid; immersing the zinc metal portion and a portion of the counter electrode in the liquid; supplying molecular oxygen into the liquid; and electrochemically coating the current collector with a zinc oxide layer.