Current Collector Apparatus

{
  "publication_number": "US2026106172A1",
  "country": "US",
  "kind": "A1",
  "title": "Current Collector Apparatus",
  "abstract": "A current collector apparatus is provided. In one aspect, a current collector includes a first metallic layer, 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 including pores and metallic particles disposed therein. The metallic particles electrically connect the first and second metallic layers. Each of a first metallic layer and a second metallic layer has a first average thickness that is about 1 nanometer to about 5 micrometers, a porous polymeric layer has a second average thickness that is about 10 nanometers to about 200 micrometers, and/or the current collector has a third average thickness that is about 12 nanometers to about 210 micrometers.",
  "claims": [
    "1. A current collector for an electrochemical cell, the current collector comprising: a first metallic layer; a second metallic layer; 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; and 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 about 1.5 micrometers. 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. 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. 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. 5. The current collector of claim 1, wherein the current collector is configured to be electrically connected to a negative electrode of the electrochemical cell. 6. The current collector of claim 1, wherein the current collector is configured to be electrically connected to a positive electrode of the electrochemical cell. 7. The current collector of claim 1, wherein the first average thickness of the porous polymeric layer is greater than or equal to about 1 nanometer to less than or equal to about 1 micrometer. 8. The current collector of claim 1, wherein a 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. 9. The current collector of claim 1, wherein a 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. 10. The current collector of claim 1, wherein the first average thickness is about 500 nanometers, a second average thickness of the porous polymeric layer is about 5 micrometers, and a third average thickness of the current collector is about 6 micrometers. 11. 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. 12. The current collector of claim 1, wherein the metallic particles comprise the same material as the first metallic layer and the second metallic layer. 13. 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. 14. The current collector of claim 1, wherein: the first metallic layer, the second metallic layer, and the metallic particles comprise copper, and the porous polymeric layer comprises polyethylene (PE), polypropylene (PP), co-polymers thereof, or combinations thereof. 15. 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. 16. 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. 17. 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. 18. 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. 19. A current collector for an electrochemical cell, the current collector comprising: a first metallic layer; a second metallic layer; 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; and 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. 20. The current collector of claim 19, 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. 21. The current collector of claim 19, 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. 22. The current collector of claim 19, 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. 23. A current collector for an electrochemical cell, the current collector comprising: a first metallic layer; a second metallic layer; a porous polymeric layer located between the first metallic layer and the second metallic layer, the porous polymeric layer comprising metallic particles in at least some pores; the first metallic layer, the second metallic layer, and the metallic particles comprising the same material including at least one 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; and the first metallic layer and the second metallic layer each having an average thickness that is greater than or equal to 1 nanometer to less than or equal to 5 micrometers. 24. The current collector of claim 23, wherein the porous polymeric layer includes at least one 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. 25. The current collector of claim 23, wherein an average thickness of the porous polymeric layer is greater than or equal to 10 nanometers to less than or equal to 5 micrometers. 26. The current collector of claim 23, wherein an average thickness of the current collector is greater than or equal to 12 nanometers to less than or equal to 6 micrometers. 27. The current collector of claim 23, wherein the average thickness of the first metallic layer and the second metallic layer is about 500 nanometers, an average thickness of the porous polymeric layer is about 5 micrometers, and an average thickness of the current collector is about 6 micrometers. 28. The current collector of claim 23, wherein the pores of the porous polymer layer have a volume density that is greater than or equal to 1 volume percent to less than or equal to 99 volume percent. 29. The current collector of claim 23, wherein the current collector has a specific mass that is greater than or equal to 0.01 mg/cm 2 to less than or equal to 5.9 mg/cm 2. 30. The current collector of claim 23, 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_excerpt": "The present disclosure relates generally to a current collector apparatus for an electrochemical cell and methods of making the current collector apparatus.\n\nImproving 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.\n\nIt 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.",
  "cpc": [
    "H01M 4/667",
    "H01M 10/0525",
    "H01M 4/661"
  ],
  "assignees": [
    "Michigan State University MSU"
  ],
  "inventors": [
    "Chengcheng Fang",
    "Junxiang Liu"
  ],
  "filing_date": "2025-12-16",
  "publication_date": "2026-04-16",
  "priority_date": "2023-06-27",
  "application_number": "US-202519421539-A",
  "cited_by_count": 0
}