# US 10,873,090 B2 · Reduced-area current collectors for rechargeable batteries

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- Number: US 10,873,090 B2
- Document ID: US10873090B2
- Status: Granted
- Kind: B2
- Application number: 14/129,865
- Filed: 2012-07-05
- Published: 2014-07-31
- Granted: 2020-12-22
- Earliest claimed: 2011-07-06
- Assignees: Research Foundation of the City University of New York
- Applicants: Yasumasa Ito; Sanjoy Banerjee
- Inventors: Yasumasa Ito; Sanjoy Banerjee
- Web page: https://patentgrep.com/patent/US10873090B2

## CPC

- H01M 4/72: Grids
- H01M 4/04: Processes of manufacture in general
- H01M 4/661: {Metal or alloys, e.g. alloy coatings (H01M4/669 take precedence)}
- H01M 4/70: characterised by shape or form
- H01M 10/30: Nickel accumulators (H01M10/34 takes precedence)
- H01M 2004/021: {Physical characteristics, e.g. porosity, surface area}
- H01M 2300/0014: Alkaline electrolytes
- Y02E 60/10: Energy storage using batteries
- Y10T 29/49108: Electric battery cell making
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A novel electrode current collector design that can improve performance and extend cycle life for rechargeable batteries based on metal electrodeposition is disclosed. The novel electrode current collector has a reduced effective surface area that can help to balance efficiencies between battery electrodes and to ensure non-uniform electrodeposition of metal onto the anode current collector during charge. One result is mitigation of internal short circuits that can cause a battery to fail prematurely.

## Claims

### Claim 1

A rechargeable battery, comprising:
a cathode, the cathode having a first overall surface area and a first effective surface area;
an anode current collector, the anode current collector having a second overall surface area and a second effective surface area; and
an electrolyte in ionic communication with both the cathode and the anode current collector;
wherein the second effective surface area is between 10 and 90% of the first effective surface area; and
wherein the anode current collector has one or more regions that are coated to prevent electrodeposition of metals.

### Claim 2 (depends on 1)

The rechargeable battery of claim 1 wherein the anode current collector is configured to accept electrodeposition of an anode metal selected from the group consisting of zinc, lead, lithium, cadmium, and copper.

### Claim 3 (depends on 1)

The rechargeable battery of claim 1 wherein the first overall surface area and the first effective surface area are the same.

### Claim 4 (depends on 1)

The rechargeable battery of claim 1 wherein the first overall surface area and the second overall surface area are about the same.

### Claim 5 (depends on 1)

The rechargeable battery of claim 1 wherein the second effective surface area is between about 25% and 75% of the first effective surface area.

### Claim 6 (depends on 1)

The rechargeable battery of claim 1 wherein the second effective surface area is between about 40% and 60% of the first effective surface area.

### Claim 7 (depends on 1)

The rechargeable battery of claim 1 wherein the cathode comprises nickel.

### Claim 8 (depends on 1)

The rechargeable battery of claim 1 wherein the anode current collector comprises a metal selected from the group consisting of nickel, nickel-coated copper, copper, silver-coated copper, cadmium-coated copper, and brass.

### Claim 9 (depends on 1)

The rechargeable battery of claim 1 wherein the anode current collector has one or more forms selected from the group consisting of perforated sheets, expanded metals, meshes, thin strip metal sheets, and wires.

### Claim 10 (depends on 1)

The rechargeable battery of claim 1 wherein the regions are coated with a material selected from the group consisting of polymers and glasses.

### Claim 11 (depends on 1)

The rechargeable battery of claim 1 wherein the electrolyte comprises one or more selected from the group consisting potassium hydroxide, sodium hydroxide, and lithium hydroxide.

### Claim 12 (depends on 1)

The rechargeable battery of claim 1 wherein the electrolyte is configured to flow along the cathode and the anode current collector as the battery charges.

### Claim 13 (depends on 12)

The rechargeable battery of claim 12, further comprising a pump configured to cause the electrolyte to flow.

### Claim 14 (depends on 1)

The rechargeable battery of claim 1,
wherein the cathode comprises a nickel oxide hydroxide or nickel oxyhydroxide cathode;
wherein the anode current collector comprises a perforated nickel anode current collector; and
wherein the electrolyte comprises a potassium hydroxide electrolyte.

### Claim 15 (depends on 14)

The rechargeable battery of claim 14, wherein the potassium hydroxide electrolyte is configured to flow along the cathode and the anode current collector as the battery charges.