Anode Current Collector Protection in EV Batteries

A current collector for anode-free all-solid-state batteries that improves cycle life and reduces voids between the electrolyte and current collector. The current collector has a thin film of metal nanoparticles deposited on one surface. The nanoparticles are made by sputtering a lithiophilic metal with power in the range of 20-50 watts. The nanoparticle layer fills voids between the electrolyte and current collector during cycling, preventing lithium dendrite growth and providing a uniform interface.

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A method to prepare aluminum current collectors for lithium batteries that improves adhesion and reduces coating defects. The method involves treating the aluminum foil with micro-arc oxidation to create an oxide layer with high hardness and wear resistance. This layer replaces the rolling oil on the foil surface, improving bonding with the battery active material. The micro-arc oxidation treatment is done by applying voltage to the foil in an electrolyte solution. The treated foil is then used to make the current collectors.

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Positive electrode current collector for lithium secondary batteries that improves durability by preventing deformation or breakage of the collector when high-density active material layers are formed. The collector has an aluminum layer, an aluminum-copper alloy layer, and a copper layer. The aluminum-copper alloy layer provides electrical conductivity and prevents delamination between the aluminum and copper layers. The aluminum-copper alloy composition can be sequentially changed to act as a buffer. The thicknesses of the aluminum, copper, and alloy layers are optimized.

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A positive electrode current collector for lithium secondary batteries with improved durability, a method to manufacture it, and a battery with the collector. The collector has an aluminum layer, an aluminum-copper alloy layer, and a copper layer. The aluminum-copper alloy layer buffers expansion/contraction between the aluminum and copper layers during cycling to prevent deformation or failure of the collector. The collector composition gradients between the layers can also prevent delamination. The manufacturing method involves hot rolling aluminum and copper foils together to form the alloy layer, then heat treating and cold rolling to form the final collector.

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Flexible lithium-ion battery negative electrode current collector that improves flexibility and reduces internal resistance compared to traditional metal foil collectors. The composite collector has a porous metal foil base, a cross-linked layer on top and bottom, and a conductive coating on the cross-linked layer. The cross-linked layer made of polypropylene with inorganic fillers like carbon black and ceramics improves mechanical strength and bonding to the conductive coating. This allows better adhesion and flexibility compared to metal foils, preventing electrode delamination during bending.

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Lithium metal battery with modified anode current collector to suppress dendrite formation and improve battery performance. The modification is a thin film of metal directly applied to the anode current collector. This metal layer promotes dense and uniform lithium deposition during charging, preventing dendrites. The thin film metal has a low formation energy with lithium (≤0.0123 eV) and low overpotential (≤5 mV) for dense, homogeneous lithium plating without dendrites.

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Anode design for lithium metal batteries that improves cycle life and stability by preventing lithium dendrite growth. The anode structure has a protective layer made of sulfurized polyacrylonitrile (SPAN) between the current collector and the lithium metal or alloy active layer. The SPAN layer reduces reactivity with the electrolyte compared to pure polyacrylonitrile. This inhibits side reactions that degrade the anode. The SPAN layer also prevents direct contact between the lithium metal and electrolyte, reducing lithium dendrite formation.

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Aluminum composite current collector for batteries that improves strength, elongation, and impact resistance compared to conventional composite collectors. The preparation method involves evaporating an aluminum layer onto a polymer film without multiple high-temperature/cooling cycles that cause polymerization and degradation. The polymer film can be a composite of insulating polymer and filler (90% insulating polymer) to provide strength. This avoids polymerization issues and maintains high tensile strength and elongation in the composite. The aluminum composite collector can be used in batteries to improve extrusion, impact, and safety properties compared to conventional composite collectors.

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Aluminum composite current collector for lithium-ion batteries with improved strength and durability compared to conventional composite collectors. The aluminum composite current collector has an aluminum layer sandwiched between two polymer layers. The polymer layers are made using a preparation method that involves rolling up and reusing the copper foil after evaporation and hot pressing to prevent shrinkage compared to the base film. This allows peeling off the copper foil for repeated use. The composite current collector prepared this way has higher tensile strength and elongation compared to conventional composite collectors. This improves extrusion resistance, impact resistance, and battery safety by preventing breakage during manufacturing and use.

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A composite current collector for lithium-ion batteries with improved safety compared to traditional composite collectors. The collector has a polymer layer sandwiched between protective agent layers on each side and a metal foil layer. The protective agent layers contain calcium gluconate that expands rapidly when heated, blocking short circuits and preventing battery damage. The polymer layer provides mechanical support. The metal foil layer collects current. This multi-layer structure provides redundant safety mechanisms to mitigate internal short circuits in lithium-ion batteries.

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Current collectors with three-dimensional porous structures for lithium-ion batteries that improve battery performance by reducing internal resistance and improving rate capability. The collectors have micron-sized through holes that penetrate vertically through the foil and are surrounded by irregularly-shaped metal burrs. This three-dimensional porous structure provides multiple benefits: 1) it allows better electrolyte distribution and penetration, reducing concentration gradients and resistance, 2) it facilitates more uniform electrode compression and contact, improving cycle life, and 3) it provides mechanical stability to the porous structure.

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Anode structures for lithium-ion batteries that enable transport and handling of lithium metal in high-volume manufacturing. The anode structures have protective films on the lithium metal to prevent dendrite growth and short circuits. The protective films are lithium ion conductive materials like ceramics, glasses, polymers, or liquid crystals. The protective films are stacked on the lithium metal between the current collector and the electrolyte. This allows lithium metal anodes to be used in batteries without the safety issues of bare lithium, enabling higher energy density compared to graphite anodes. The protective films prevent lithium plating and allow lithium ion intercalation into the films during charge/discharge cycles.

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Multi-layer structure current collector for lithium-ion batteries with improved electrical performance and mechanical strength compared to conventional current collectors. The multi-layer structure current collector has alternating layers of carbon coating and metal plating stacked on both sides of a polymer film layer. This configuration protects the polymer film from damage, reduces interface resistance, and improves adhesion. The carbon coating layers on the polymer film prevent delamination and enhance electrical contact. The carbon coating also provides a conductive path between the metal layers. By alternating carbon and metal layers, the number of evaporation steps can be reduced compared to traditional current collectors, which improves mechanical properties and reduces porosity.

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A lithium-rich composite current collector for lithium-ion batteries that provides additional functions compared to conventional single-purpose metal foil collectors. The composite collector has layers of polymer, aluminum, and lithium-rich materials. The lithium-rich layers improve battery capacity and cycle life by providing more active lithium compared to just the cathode. The aluminum layers provide electrical conductivity like traditional collectors. The polymer layer helps bind the composite together.

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Preparation method and application of a gradient copper phosphide/copper oxide/copper foam lithium metal anode current collector to address the stability and safety issues of lithium metal batteries. The current collector has a copper foam base with copper oxide and copper phosphide nanowires grown on it. The copper oxide top layer provides lithium nucleation uniformity, while the copper phosphide bottom layer induces dense lithium filling. This gradient structure balances lithium plating uniformity and conductivity compared to a pure copper collector. It reduces dendrite growth, short circuits, and improves cycle life for lithium metal batteries.

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Current collector for lithium batteries that provides high conductivity, stability, and weight savings compared to traditional aluminum and copper foils. The collector structure has a thin aluminum base layer, barrier layers formed by sputtering metals/nitrides on one side, and a protective layer on the other side. This design provides ion barrier and electrochemical passivation to prevent corrosion, while the aluminum base has lower weight and better conductivity than copper. A transition layer between the barrier and protective layers strengthens the connection. The composite collector structure offers high electrical conductivity, stability, and light weight for lithium batteries compared to conventional aluminum or copper foils.

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Copper foil with improved puncture strength for use as a current collector in high capacity lithium secondary batteries. The copper foil has a particle size difference between the deposition side and drum side of less than 0.55 microns. This reduces voids created during electrodeposition and improves strength. The deposition surface roughness is 2.0 microns or less to allow uniform coating of the negative electrode material. This copper foil has puncture strength suitable for high capacity lithium batteries without being brittle during manufacturing or cycling.

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Lithium metal anode for lithium secondary batteries using a 3D porous copper current collector to suppress dendrite growth and improve battery performance. The copper collector has a 3D porous structure formed on its surface. This porous structure provides internal spaces where lithium dendrites can deposit during charging/discharging instead of vertically growing. This prevents dendrite short circuits and stabilizes the electrode. The porous copper can be made by modifying its surface through electrochemical plating. The porous collector can also be used in cathode-less battery designs to further increase energy density.

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Composite metal foil for lithium battery current collectors that balances surface resistance, energy density, and strength. The composite foil has a thin polymer layer sandwiched between metal layers. The outer metal layer has a thickness of 15-100nm, the inner metal layer has a thickness of 50-110nm, and an intermediate metal layer has a thickness of 750-1100nm. The polymer layer improves strength, while the graded metal layers provide low surface resistance and high energy density. The composite foil can also absorb battery expansion stress.

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Reducing dendrite formation in lithium-ion batteries to improve battery performance and reliability by using an indium nitride (InN) layer on the anode. The InN layer, containing indium nitride, a conductive material, and a polymer binder, suppresses lithium dendrite growth during charging and discharging. The InN layer provides a lithium-ion conductive surface that limits direct contact between lithium and the electrolyte, reducing dendrite formation. The InN layer is formed by coating a slurry of indium nitride, conductive material, and polymer binder onto the anode current collector and curing it to bond the layer to the substrate.

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