# US 12,603,296 B2 · Clad current collectors including thermal interface layer for bipolar solid-state batteries

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- Number: US 12,603,296 B2
- Document ID: US12603296B2
- Status: Granted
- Kind: B2
- Application number: 17/888,613
- Filed: 2022-08-16
- Published: 2024-02-01
- Granted: 2026-04-14
- Earliest claimed: 2022-07-29
- Assignees: GM Global Technology Operations LLC
- Applicants: GM Global Technology Operations LLC
- Inventors: Zhe Li; Dave G. Rich; Meiyuan Wu; Jingyuan Liu; Haijing Liu
- Web page: https://patentgrep.com/patent/US12603296B2

## CPC

- H01M 4/667: {in the form of layers, e.g. coatings}
- H01M 4/661: {Metal or alloys, e.g. alloy coatings (H01M4/669 take precedence)}
- H01M 4/663: {containing carbon or carbonaceous materials as conductive part, e.g. graphite, carbon fibres}
- H01M 4/668: {Composites of electroconductive material and synthetic resins}
- H01M 10/0585: of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
- H01M 2004/021: {Physical characteristics, e.g. porosity, surface area}
- Y02E 60/10: Energy storage using batteries
- 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

## Abstract

A battery cell includes a plurality of cathodes and a plurality of anodes. A plurality of solid electrolyte layers are arranged between first adjacent ones of the plurality of cathodes and the plurality of anodes. A plurality of clad current collectors are arranged between second adjacent ones of the plurality of cathodes and the plurality of anodes. The plurality of clad current collector includes a first foil layer, a second foil layer and a thermal interface layer including adhesive and at least one material that increases thermal and electrical conductivity of the thermal interface layer.

## Claims

### Claim 1

A battery cell, comprising:
a plurality of cathodes;
a plurality of anodes;
a plurality of solid electrolyte layers arranged between first adjacent ones of the plurality of cathodes and the plurality of anodes;
a plurality of clad current collectors arranged between second adjacent ones of the plurality of cathodes and the plurality of anodes,
wherein the plurality of clad current collector includes:
a first foil layer including copper;
a second foil layer including aluminum; and
a thermal interface layer including a polyolefin hotmelt adhesive at 25% volume, pyrolytic graphite sheets at 70% volume, and carbon nanotubes at 5% volume of the thermal interface layer.

### Claim 2 (depends on 1)

The battery cell of claim 1, wherein:
the first foil layer has a thickness in a range from 1 μm to 30 μm;
the second foil layer has a thickness in a range from 1 μm to 30 μm;
the thermal interface layer has a thickness in a range from 1 μm to 30 μm; and
the plurality of clad current collectors have a thickness in a range from 3 μm to 90 μm.

### Claim 3 (depends on 1)

The battery cell of claim 1, wherein:
the first foil layer has a thickness of 6 μm;
the second foil layer has a thickness of 6 μm;
the thermal interface layer has a thickness of 4 μm; and
the plurality of clad current collectors have a thickness of 16 μm.

### Claim 4

A method for manufacturing a clad current collector for a battery cell, comprising:
supplying a first foil layer between a first roller and a second roller, the first foil layer including copper;
supplying a second foil layer between the first roller and the second roller, the second foil layer including aluminum;
supplying a thermal interface layer including a polyolefin hotmelt adhesive at 25% volume, pyrolytic graphite sheets at 70% volume, and carbon nanotubes at 5% volume of the thermal interface layer; and
applying heat and pressure to the first foil layer, the second foil layer and the thermal interface layer.

### Claim 5 (depends on 4)

The method of claim 4, wherein:
the first foil layer has a thickness in a range from 1 μm to 30 μm;
the second foil layer has a thickness in a range from 1 μm to 30 μm;
the thermal interface layer has a thickness in a range from 1 to 30 μm; and
the clad current collector has a thickness in a range from 3 μm to 90 μm.

### Claim 6 (depends on 4)

The method of claim 4, wherein:
the first foil layer has a thickness of 6 μm;
the second foil layer has a thickness of 6 μm;
the thermal interface layer has a thickness of 4 μm; and
the clad current collector has a thickness of 16 μm.

### Claim 7

A clad foil current collector for a bipolar battery cells, comprising:
a first foil layer made of copper (Cu);
a second foil layer made of aluminum (Al); and
a thermal interface layer arranged between the first foil layer and the second foil layer including:
a hotmelt adhesive comprising polyolefin at 25% volume of the thermal interface layer;
a first material comprising pyrolytic graphite sheets at 70% volume of the thermal interface layer; and
a second material comprising carbon nanotubes at 5% volume of the thermal interface layer.

### Claim 8 (depends on 7)

The clad foil current collector of claim 7, wherein:
the first foil layer has a thickness in a range from 1 μm to 30 μm;
the second foil layer has a thickness in a range from 1 μm to 30 μm;
the thermal interface layer has a thickness in a range from 1 to 30 μm; and
the clad foil current collector has a thickness in a range from 3 μm to 90 μm.

### Claim 9 (depends on 7)

The clad foil current collector of claim 7, wherein:
the first foil layer has a thickness of 6 μm;
the second foil layer has a thickness of 6 μm;
the thermal interface layer has a thickness of 4 μm; and
the clad foil current collector has a thickness of 16 μm.