Anode Current Collector Protection in EV Batteries

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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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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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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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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An anode current collector for all-solid-state batteries that prevents lithium dendrites during charging and discharging. The anode current collector has two coatings on the surface that contact the solid electrolyte layer. The first coating is a lithiophilic metal layer that attracts lithium ions. The second coating has less electronic conductivity than the first coating. This prevents electrons from moving into the solid electrolyte layer, preventing dendrite formation.

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An anode current collector for all-solid-state batteries that enables uniform lithium plating without dendrite formation. The anode has a unique double coating structure. The outer coating has reduced electrical conductivity compared to the inner coating. The inner coating contains a lithiophilic metal that attracts lithium ions. The outer coating prevents electrons from moving into the solid electrolyte layer, preventing short circuits and efficiency loss. The double coating allows lithium plating on the anode while preventing electron migration into the electrolyte.

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Multilayer lithium metal current collector for high energy density lithium batteries that addresses safety and utilization issues of lithium metal anodes. The collector has layers of materials stacked in order: conductive support, lithium-philic nucleation, electron/ion transport, and nano-lithium rectifying. The layers are applied in thin (5-200um) successive coatings using techniques like spraying or scraping. The layers enhance lithium deposition uniformity, suppress dendrite growth, and improve rate capability. The lithium-philic nucleation layer promotes initial lithium plating, the transport layer aids ion transfer, and the rectifying layer regulates lithium diffusion.

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Multi-layer current collector design for anodeless lithium metal cells that enables stable cycling of lithium metal anodes without dendrite formation and capacity fade. The multi-layer current collector has a seed layer of a lithium-alloying or lithium-soluble material like silver between the current collector and a protective layer. This prevents direct lithium plating on the current collector and allows gradual lithium alloying with the seed layer. The protective layer shields the electrolyte from the current collector and seed layer.

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A current collector structure for lithium batteries with improved lithium plating uniformity and reduced dendrite formation. The structure has a porous metal layer sandwiched between a substrate layer and a lithium-friendly layer. The porous metal layer has holes to accommodate lithium expansion. The lithium-friendly layer between the metal and substrate reduces lithium nucleation overpotential. This stack of layers allows lithium plating uniformity and volume expansion accommodation without dendrite formation.

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Composite current collector for batteries with improved performance and reliability compared to traditional metal foil collectors. The composite collector has a polymer substrate sandwiched between metal foils. The metal foils partially overlap the polymer substrate edge and extend out. This provides multiple benefits: 1) A larger metal contact area compared to just the welding seam, improving conductivity and overcurrent capability. 2) Secure tab attachment without needing metal-on-metal welding, preventing tab falloff. 3) Reduced weight compared to thick metal tabs. The composite collector can be made by partially overlapping the metal foils with the polymer substrate edge.

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Anode current collector for lithium metal batteries that suppresses dendrite formation, improves electrochemical performance, and prevents lithium metal plating. The anode current collector has a coating layer containing a ferroelectric material, a metal alloying with lithium, a conductive material, and a binder. The coating promotes uniform lithium growth and reduces dendrite formation compared to bare copper anodes. The ferroelectric and lithium alloy seeds control lithium ion concentration and nucleation sites around the anode.

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A multi-layer current collector for batteries that reduces weight, improves energy density, and prevents degradation compared to conventional aluminum foil collectors. The collector has a base material, an adhesion-enhancing layer, and a conductive layer with alternating aluminum and carbon layers. The adhesion layer improves bonding between the base and conductive layers. The carbon layers prevent aluminum corrosion by hydrofluoric acid from the electrolyte. The aluminum alloy containing Mg can also improve corrosion resistance. The lightweight base material like PET reduces weight further.

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Current collector design for lithium-ion batteries that improves battery performance and safety. The current collector has a flexible polymer substrate sandwiched between reinforcing layers containing inorganic fillers. The reinforcing layers provide mechanical strength and prevent short circuits. The metal coating is applied on the reinforcing layer surface. The reinforcing layers bond strongly to the polymer substrate after plasma treatment, preventing delamination during battery manufacturing. This allows thinning the metal foil to increase battery energy density.

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Current collector design for lithium-ion batteries that improves safety and reduces internal resistance. The current collector has two metal layers with thinned sections connected by adhesive and welding. One metal layer has a partially thinned section adhered to the other layer. This allows the thinned areas to corrode away during battery assembly, reducing thickness and weight. The adhesive and welding join the layers together. The thinned sections connect to the unthinned sections. This allows thinner, lighter current collectors with lower internal resistance. The thinned sections can be corroded using electrolyte during assembly to achieve the thinning.

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Lithium-ion battery design with improved safety and cycle life by oxidizing the current collector surface and coating a primer. The current collector foil is oxidized to form a hydrated oxide film covering 20-60% of the surface area. This oxidized region prevents direct contact between the foil and electrode during short circuits, reducing power and heating. A primer layer is then coated over the oxidized and non-oxidized areas. This primer adheres well to the oxidized foil and protects it further.

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Lithium battery current collector with improved cycle life and safety compared to conventional aluminum foil collectors. The collector has multiple material layers on both sides of the metal foil. These layers contain polymers and conductive materials. The polymers provide adhesion and prevent delamination during cycling. The conductive layers maintain electrical contact with the battery active material. This reduces resistance and improves cycle life. The polymers also help prevent thermal runaway propagation by absorbing heat and acting as a thermal barrier.

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A lithium-ion battery current collector design to improve cycle life and safety of lithium-ion batteries. The current collector has multiple layers, including a metal foil, a resistance layer, and additional layers with resistance. These layers provide improved cycle life and safety compared to bare foils. The resistance layers prevent dendrite growth and short circuits, while the additional resistance layers mitigate thermal runaway. The layers are applied using methods like spin coating, thermal compression, and vacuum plating.

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A lithium battery current collector design that improves cycle life and safety of lithium batteries. The current collector has multiple material layers on both sides of a metal foil. The layers include a polymer layer with conductive filler, and a conductive layer. This configuration provides better adhesion to the battery active material, reduces contact resistance, and enables active thermal management to prevent thermal runaway. The layers are applied using coating techniques like spin coating, printing, and spraying.

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Coating technique for battery electrode current collectors that suppresses dendrite growth in lithium-ion batteries. The technique involves forming a layer of a metal-coordinating polymer like polydopamine on the surface of the current collector, followed by contacting it with metal ions to form a layer of the metal like copper on the polymer layer. This coating helps uniform lithium plating and prevents dendrite growth.

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Current collector design for lithium metal batteries that suppresses dendrite growth during cycling. The current collector is a copper sheet with concave structures like pits or grooves. The concave shapes prevent excess lithium plating on the collector during battery charging. By limiting the lithium thickness to match the depth of the recesses, dendrite propagation is prevented. This allows thinner lithium layers compared to flat collectors, reducing dendrite formation. The concave collectors can be prepared by etching a convex alumina sheet onto the copper.

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Lithium metal anode for lithium-ion batteries that improves safety by preventing dendrite growth and internal short circuits. The anode has a current collector with recesses or pores covered by a protective layer. Lithium metal is deposited inside the recesses/pores during battery manufacturing. This provides a contained location for the highly reactive lithium metal to prevent reaction with the electrolyte and avoid dendrite growth. It also enables higher charge/discharge rates compared to free lithium metal. The recesses/pores have specific size ranges for optimal performance and energy density.

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A multifunctional lithium battery current collector with improved cycle life and safety compared to conventional collectors. The collector has a thin layer of multifunctional material covering the top and bottom surfaces of the metal foil current collector. The multifunctional material has a thickness of 0.1-10 microns and contains materials like Ti2AlN, Ti2GaN, Ti3AlC2, etc. The thin coating reduces contact resistance with the active material, improves cycle life, and also provides active thermal management to prevent battery runaway. The coating is applied using techniques like spin coating, printing, spraying, etc.

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A current collector for lithium metal batteries that reduces dendrite formation and improves cycling stability. The collector has a three-dimensional network structure with a carbon nanofiber film sandwiched between a non-conductive oxide layer and a conductive metal layer. The oxide layer attracts lithium deposition to spread it uniformly, while the conductive metal layer improves electrical contact. This prevents dendrite growth and short circuits compared to flat collectors.

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Lithium battery current collector that improves energy density, cycle life, and safety by covering the upper and lower surfaces of a porous metal foil with a material layer having a positive temperature coefficient of resistance. The material layer contains conductive material and crystalline polymer to provide resistance that increases with temperature. The porous metal foil allows embedding of the material layer inside the pores, improving interface bonding compared to covering solid metal foils. The resulting current collector for lithium batteries has improved energy density, cycle life, and safety versus conventional metal foils.

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Aluminum foil current collector for lithium batteries with improved safety and performance. The collector has a carbon film deposited on both sides of the aluminum foil, followed by anode material coating. This provides a barrier against electrolyte corrosion of the aluminum. The carbon film prevents direct contact between the aluminum and electrolyte. The carbon film also reduces dendrite growth during charging/discharging.

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Current collector for lithium-ion batteries that prevents capacity loss during cycling. The current collector has a conductive layer sandwiched between a lithium ion barrier metal layer and the battery electrode. The lithium ion barrier metal layer is formed by plating and has no grain boundaries or at least one end of the grain boundaries present at the interface with the conductive layer. This prevents lithium ions from penetrating through the metal layer and occluding in the conductive layer, which reduces capacity fade during cycling.

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Aluminum-carbon composite current collector for lithium-ion batteries with improved cycle stability and life. The collector is made by coating carbon onto an aluminum foil substrate. The carbon coating reduces contact resistance between the collector and the battery active material, preventing lithium dendrites and aluminum degradation. The aluminum-carbon composite collector can be prepared by immersing the aluminum foil in an acid solution, drying, and then applying a carbon layer using methods like vacuum deposition or electrophoresis. The composite collector improves battery performance compared to bare aluminum foil.

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Improving the performance and lifespan of ion batteries by modifying the collector current electrode. The collector has a tapered surface with a layer containing W (tungsten) and C (carbon) to prevent dissolution into the electrolyte and improve adhesion to the active material. The W layer with bound oxygen on W and C reduces electrolyte dissolution, and the C layer improves wetting for uniform coating. This prevents battery degradation from collector corrosion and active material peeling.

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Battery collector cladding material and electrode design to prevent warping and reduce contact resistance between the collector and active materials. The cladding material has a two-layer structure with a thin Al layer on one side and a thicker Cu layer on the other. The ratio of Al thickness to total thickness is <=35%. This prevents warping during rolling and cooling. For even lower warping, the ratio is <=25%. The Cu layer provides better contact with the active materials. An optional core layer between the Al and Cu provides rigidity. This prevents warping during rolling and cooling. The core layer material can be Ni or Fe alloys with high modulus.

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High strength aluminum alloy foil for electrode current collectors in lithium-ion batteries that maintains strength after heat treatments during battery manufacturing. The alloy contains controlled amounts of Fe, Si, Cu, and Mn. The alloy is made by homogenization at 570-620°C followed by rolling. This forms solid solutions that prevent strength loss during heat treatments like drying at 100-200°C. The alloy has >210 MPa tensile strength after drying heat treatments.

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A secondary battery cell, stacked battery, and battery assembly design to prevent local degradation in stacked battery packs. The cell has a collector electrode adjacent to the cathode or anode with a terminal portion that protrudes from the end. The terminal has a larger current path width further from the contact area compared to the closest path. This avoids current concentration at the contact area and spreads it out to prevent localized heating and degradation. In stacked cells, the collector connects adjacent cells with a separate terminal. In the assembly, stacked cells alternate cathode/anode facing. This distributes current paths between cells and prevents concentration.

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Non-aqueous secondary battery with improved long-term reliability and durability by using a specific type of current collector material. The battery has a positive electrode, negative electrode, and electrolyte sandwiched between them. The current collector on the positive side is made of a specific alloy-based metal foil, like stainless steel, with a formula index of at least 45. This improves the heat resistance and prevents issues like pinhole formation and electrolyte leakage during cycling that can cause short circuits.

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