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EP-4736248-A2 - CURRENT COLLECTOR APPARATUS

EP4736248A2EP 4736248 A2EP4736248 A2EP 4736248A2EP-4736248-A2

Abstract

A current collector apparatus is provided. In one aspect, a current collector (40) includes a first metallic layer (52), a second metallic layer (54), and a porous polymeric layer (56) positioned between the first metallic layer (52) and the second metallic layer (54). In another aspect, a current collector employs a porous polymeric layer (56) including pores (60) and metallic particles (62) disposed therein. The metallic particles (62) electrically connect the first and second metallic layers (52), (54). Each of a first metallic layer (52) and a second metallic layer (54) has a first average thickness (58) that is about 1 nanometer to about 5 micrometers, a porous polymeric layer (56) has a second average thickness (70) that is about 10 nanometers to about 200 micrometers, and/or the current collector (40) has a third average thickness (72) that is about 12 nanometers to about 210 micrometers.

Inventors

  • FANG, Chengcheng
  • LIU, JUNXIANG

Assignees

  • Board Of Trustees Of Michigan State University

Dates

Publication Date
20260506
Application Date
20240627

Claims (20)

  1. 1. A current collector for an electrochemical cell, the current collector comprising: a first metallic layer; a second metallic layer; and a porous polymeric layer disposed between the first metallic layer and the second metallic layer, the porous polymeric layer comprising pores and metallic particles disposed in at least some of the pores; the metallic particles electrically connecting the first metallic layer and the second metallic layer; the first metallic layer and the second metallic layer each having a first average thickness that is greater than or equal to about 1 nanometers to less than or equal to about 5 micrometers; the porous polymeric layer having a second average thickness that is greater than or equal to about 10 nanometers to less than or equal to about 200 micrometers; and the current collector having a third average thickness that is greater than or equal to about 12 nanometers to less than or equal to about 210 micrometers.
  2. 2. The current collector of claim 1 , wherein the first metallic layer, the second metallic layer and the metallic particles comprise aluminum and the porous polymer layer comprises polyethylene (PE), polypropylene (PP), polydimethylsiloxane (PDMS), poly(methyl methacrylate) (PMMA), polycarbonate (PC), polystyrene (PS), polycaprolactone (PCL), polyimide (PI), polyamide (PA), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polytetrafluoroethylene (PTFE), polyurethane (PU), epoxy resins, co-polymers thereof, or combinations thereof.
  3. 3. The current collector of claim 1 , wherein the first metallic layer, the second metallic layer, and the metallic particles comprise copper and the porous polymer layer comprises polyethylene (PE), polypropylene (PP), polydimethylsiloxane (PDMS), poly(methyl methacrylate) (PMMA), polycarbonate (PC), polystyrene (PS), polycaprolactone (PCL), polyimide (PI), polyamide (PA), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polytetrafluoroethylene (PTFE), polyurethane (PU), epoxy resins, co-polymers thereof, or combinations thereof
  4. 4. The current collector of claim 3, wherein the current collector is configured to be electrically connected to a negative electrode of the electrochemical cell.
  5. 5. The current collector of claim 1 , wherein the first metallic layer, the second metallic layer, and the metallic particles comprise nickel and the porous polymer layer comprises polyethylene (PE), polypropylene (PP), polydimethylsiloxane (PDMS), poly(methyl methacrylate) (PMMA), polycarbonate (PC), polystyrene (PS), polycaprolactone (PCL), polyimide (PI), polyamide (PA), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polytetrafluoroethylene (PTFE), polyurethane (PU), epoxy resins, co-polymers thereof, or combinations thereof.
  6. 6. The current collector of claim 1 , wherein the first average thickness of each of the first metallic layer and the second metallic is greater than or equal to about 1 nanometer to less than or equal to about 500 nanometers.
  7. 7. The current collector of claim 1 , wherein the second average thickness of the porous polymeric layer is greater than or equal to about 10 nanometers to less than or equal to about 5 micrometers.
  8. 8. The current collector of claim 1 , wherein the third average thickness of the current collector is greater than or equal to about 12 nanometers to less than or equal to about 6 micrometers.
  9. 9. The current collector of claim 1 , wherein the first average thickness is about 500 nanometers, the second average thickness is about 5 micrometers, and the third average thickness is about 6 micrometers.
  10. 10. The current collector of claim 1 , wherein the first metallic layer and the second metallic layer are selected from the group consisting of: copper, aluminum, nickel, stainless steel, titanium, iron, gold, silver, alloys thereof, or combinations thereof.
  11. 11 . The current collector of claim 1 , wherein the metallic particles comprise the same material as the first metallic layer and the second metallic layer.
  12. 12. The current collector of claim 1 , wherein the porous polymeric layer is selected from the group consisting of: polyethylene (PE), polypropylene (PP), polydimethylsiloxane (PDMS), poly(methyl methacrylate) (PMMA), polycarbonate (PC), polystyrene (PS), polycaprolactone (PCL), polyimide (PI), polyamide (PA), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polytetrafluoroethylene (PTFE), polyurethane (PU), epoxy resins, co-polymers thereof, or combinations thereof.
  13. 13. The current collector of claim 1 , wherein the pores of the porous polymer layer have an average diameter that is greater than or equal to about 1 nanometer to less than or equal to about 20 micrometers.
  14. 14. The current collector of claim 1 , wherein the pores of the porous polymer layer have a volume density that is greater than or equal to about 1 volume percent to less than or equal to about 99 volume percent.
  15. 15. The current collector of claim 1 , wherein the current collector has a specific mass that is greater than or equal to about 0.01 mg/cm 2 to less than or equal to about 5.9 mg/cm 2 .
  16. 16. The current collector of claim 1 , wherein the current collector is configured for use in an electric vehicle battery, a consumer electronics battery, an appliance battery, or a medical device battery.
  17. 17. A current collector for an electrochemical cell, the current collector comprising: a first metallic layer; a second metallic layer; and a porous polymeric layer disposed between the first metallic layer and the second metallic layer, the porous polymeric layer comprising pores and metallic particles disposed in at least some of the pores; the first metallic layer, the second metallic layer, and the metallic particles comprising the same material selected from the group consisting of: copper, aluminum, nickel, stainless steel, titanium, iron, alloys thereof, and combinations thereof; the metallic particles electrically connecting the first metallic layer and the second metallic layer; the current collector having an average thickness that is greater than or equal to about 12 nanometers to less than or equal to about 210 micrometers.
  18. 18. The current collector of claim 17, wherein the porous polymeric layer is selected from the group consisting of: polyethylene (PE), polypropylene (PP), polydimethylsiloxane (PDMS), poly(methyl methacrylate) (PMMA), polycarbonate (PC), polystyrene (PS), polycaprolactone (PCL), polyimide (PI), polyamide (PA), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polytetrafluoroethylene (PTFE), polyurethane (PU), epoxy resins, co-polymers thereof, or combinations thereof.
  19. 19. The current collector of claim 17, wherein the pores of the porous polymer layer have a volume density that is greater than or equal to about 1 volume percent to less than or equal to about 99 volume percent.
  20. 20. The current collector of claim 17, wherein the current collector is configured for use in an electric vehicle battery, a consumer electronics battery, an appliance battery, or a medical device battery.

Description

CURRENT COLLECTOR APPARATUS CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Application No. 63/523,389, filed on June 27, 2023. The entire disclosure of the above-mentioned application is incorporated herein by reference. BACKGROUND AND SUMMARY [0002] The present disclosure relates generally to a current collector apparatus for an electrochemical cell and methods of making the current collector apparatus. [0003] Improving cell-level gravimetric and volumetric energy density is desired to achieve high-performance batteries in the rapidly evolving field of energy storage technology. The fast-paced advancement of portable electronic devices, electrical vehicles, electrical planes and aviation devices, and smart grid technology has led to a growing need for high-performance energy storage devices. It is advantageous to increase the energy density of batteries as it directly affects their energy storage capacity in unit weight and volume. Energy storage capacity may impact user experiences such as the mileage per charge for electric vehicles (e.g., a battery having a lower energy storage capacity decreases the mileage per charge for electric vehicles as compared to a battery having a higher energy storage capacity). Significant efforts in enhancing energy density have been made in improving the performance of electrochemically active components such as electrode active materials, and electrolytes, as well as optimizing battery structure and new battery chemistry. [0004] It is advantageous to also consider decreasing the mass of non- electrochemically active components like cell cases, separators, and current collectors to improve cell-level energy storage capacity. One of the key non-electrochemically active components in batteries is the current collector. Current collectors are configured to support active material, such as anode active material and cathode active material and serve as an electrical connection between an electrode and an external circuit. [0005] Conventional current collectors are made of a metal foil, such as a copper or aluminum foil. Conventional current collectors may have a thickness that is greater than or equal to about 6 micrometers (pm). These conventional current collectors possess high mass and cost yet do not contribute to the capacity or energy density of the battery. For example, a conventional copper foil current collector of an anode may have an average specific mass that is greater than or equal to about 5 mg/cm2 (e.g., a copper foil current collector having a thickness of about 10 pm has a specific mass of about 8.96 mg/cm2), which is about 8% of the total weight of the battery (e.g., the total weight of the battery without cell cases or housings). In another example, a conventional aluminum foil current collector of a cathode may have an average specific mass that is greater than or equal to about 2.5 mg/cm2 (e.g., when the thickness of the aluminum foil current collector is about 10 pm), which is about 7% of the total weight of the battery. In combination, conventional anode and cathode current collectors contribute to about 15% of the weight of a battery pack and limit the battery energy density. Reducing the weight of current collectors to achieve minimum thickness while maintaining desired mechanical, chemical, and thermal characteristics is beneficial in enhancing the energy density of a battery. [0006] Conventional methods for fabricating current collectors include mechanical rolling (e.g., via reversibly hot rolling copper ingots) and/or electrochemical deposition techniques. These methods generate copper current collectors that are thick (e.g. having a thickness that is greater than 6 pm) and heavy (e.g., having an average specific mass that is greater than 5 mg/cm2). Furthermore, carbon-based, MXenes- based and composite current collectors have been fabricated, for example via polymer- assisted metal deposition (PAMD) methods and/or pulsed DC magnetron sputtering. The relatively high cost of fabrication via such methods impedes large-scale production. The challenge remains to find a simple method reducing the thickness of the current collector for mass production of ultra-thin and lightweight current collectors. [0007] In accordance with the present invention, a current collector apparatus is provided. In one aspect, a current collector apparatus includes a first metallic layer, at least a second metallic layer, and a porous polymeric layer positioned between the first metallic layer and the second metallic layer. In another aspect, a current collector employs a porous polymeric layer which includes pores and metallic particles disposed in at least some of the pores. In another aspect, metallic particles disposed in at least some of the pores electrically connect a first metallic layer and a second metallic layer of a current collector apparatus. In yet another aspect, each of a first metallic layer and a seco