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US 2026/0180131 A1Published application
Bilayer battery structure
AssigneeFord Global Technologies, LLC
InventorBenjamin Jason EMLEY
Life of this patent
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Abstract
An electrode assembly for lithium-ion batteries is presented. The electrode assembly includes a metal foil current collector, an active material layer with aligned pores, and an intermediary layer positioned between the current collector and the active material layer. The intermediary layer includes a polymer matrix with active material particles dispersed throughout, forming a network of randomly oriented pores.
Claims20
An electrode assembly comprising:
- a metal foil current collector;
- an active material layer defining aligned pores;
- and
- an intermediary layer adhered to the metal foil current collector and the active material layer, and including a polymer matrix with active material particles dispersed within the polymer matrix to form a network of randomly dispersed pores.
1 more element
A lithium-ion battery electrode comprising:
- a current collector foil;
- a primer layer disposed on the current collector foil, the primer layer having a binder network that holds active material particles and defines randomly dispersed voids where no active material particles are present;
- and
- an active material layer with directionally aligned channels, with non-channeled portions anchored to the voids of the primer layer.
1 more element
A method for forming an electrode comprising:
- coating a primer layer of active material and a binder onto a metal foil current collector;
- and
- freeze-casting an active material slurry onto the primer layer to form a freeze-cast active material layer with an ordered porous structure adhered to the primer layer.
Dependencies are inferred from the claim text.