US 9,178,217 B2 · Multiply-conductive matrix for battery current collectors

Abstract

A multiply-conductive matrix (MCM) for a current collector/electrode and a method of making the MCM are disclosed. The MCM includes a frame, preferably including a lug, the frame preferably made from a reticulated polymer foam substrate, and a body preferably made from the same substrate. The specific surface area of the frame is greater than the specific surface area of the body, resulting in greater rigidity and strength of the frame when the body and frame are joined to form an assembled matrix. Electrically conductive material is applied to the matrix to form the current collector. Optionally, a bonding material is also applied. Electro-active paste is applied to current if collector. The resulting MCM-based electrodes are ultra light and may be used as anode or cathodes in a lead-based battery, lithium ion battery, and nickel metal hydride battery for improved performance.

Claims22

Dependent claims

A current collector comprising:

(a) a multiply-conductive matrix (MCM), said MCM comprising a porous substrate, the porous substrate comprising:
(i) a porous first section;
and
(ii) a porous second section;
wherein at least a part of said porous second section circumscribes said porous first section and said part of said porous second section forms a frame around said porous first section, and
wherein said part of said porous section is porous;
and
(b) an electroconductive coating applied to said porous substrate;
wherein at least said porous first section and said part of said porous second section are electrically conductive, and the electrical conductivity of said part of said porous second section is greater than the electrical conductivity of said porous first section;
and
wherein the specific surface area of said part of said porous second section is greater than the specific surface area of said porous first section.

8 more elements

A method for producing the multiply-conductive matrix (MCM) for a current collector, wherein said MCM comprises a porous substrate, wherein said porous substrate comprises:

(i) a first region having pores;
and (ii) a second region having pores;
wherein at least part of said second region forms a frame around said first region, and the electrical conductivity of said second region is greater than the electrical conductivity of said first region, said method comprising the steps of:
Step (a) providing the substrate wherein the second region has a higher specific surface area than the first region;
and,
Step (b) applying an electrically conductive substance to the substrate,
whereby the electrical conductivity of said second region is greater than the electrical conductivity of said first region.

4 more elements

Dependencies are inferred from the claim text.

Multiply-conductive matrix for battery current collectors

Life of this patent

Multiply-conductive matrix for battery current collectors

Life of this patent

Abstract

Claims22