All-solid battery slurry with clustered complex for adhesion

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Solution Overview

Problem

The existing manufacturing methods for all-solid secondary batteries face challenges in achieving uniform current distribution and adhesion between the current collector and electrodes, leading to reduced performance due to high reactivity of sulfide-based solid electrolytes with moisture and polar materials, and the need for a binder that balances adhesion and resistance.

Innovation Solution

An electrode active material slurry with a clustered complex comprising an electrode active material, solid electrolyte, and conductive material, combined with a first binder applied through energy treatment, and a second binder in a solvent, which reduces the surface area and binder content, enhancing adhesion and conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a binder solution is used to form adhesion between current collector and electrodes, then adhesion is improved, but resistance in the electrodes increases

Engineering Contradiction:

ImproveadhesionVSAvoidresistance

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters of the binder from conventional polar materials to non-polar hydrocarbon-based polymers. This parameter change allows the binder to provide adhesion without the harmful resistance effect, as non-polar materials do not react with sulfide-based solid electrolytes and do not increase electrode resistance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies different binder types at different locations: a first binder (polytetrafluoroethylene) is applied to the surface of electrode active material particles, while a second binder (hydrocarbon-based polymer) is used in the slurry for casting. This local differentiation optimizes both adhesion and resistance properties in different regions of the electrode structure

Inventive Principle:

Principle #3Local quality

2Reliability

If sulfide-based solid electrolyte is used, then safety is improved, but reactivity to moisture and polar materials increases

Engineering Contradiction:

ImprovesafetyVSAvoidreactivity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces non-polar hydrocarbon-based polymers as intermediary materials between the sulfide-based solid electrolyte and the electrode structure. These intermediary binders act as a protective interface that prevents direct contact and harmful reactions between polar materials and the sulfide electrolyte, while still providing necessary adhesion

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates an inert chemical environment by using non-polar hydrocarbon-based polymers that do not react with sulfide-based solid electrolytes. This inert binder environment protects the reactive sulfide electrolyte from moisture and polar materials, maintaining safety while enabling electrode formation

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Ease of manufacture

If compression molding method is used, then manufacturing process is simplified, but uniform current distribution is not achieved

Engineering Contradiction:

Improvemanufacturing processVSAvoiduniform current distribution

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent employs a slurry casting method where a liquid slurry is applied to the current collector and then dried to form a uniform electrode layer. This fluid-based approach ensures uniform distribution of active materials and binders, achieving consistent current distribution across the electrode surface, unlike compression molding which creates non-uniform density

Inventive Principle:

Principle #29Pneumatics and hydraulics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution improves the adhesion and conductivity of the electrode active material with the current collector, leading to enhanced capacity and lifespan of the all-solid secondary battery by minimizing resistance and maintaining electrode properties.

Implementation Method 1

a first binder applied on a surface of the electrode active material through energy treatment

Methodology Applied

Scientific EffectEnergy treatment:

Implementation Method 2

an electrode active material slurry having improved dispersibility and adhesion property to strongly adhere the electrode active material with a current collector

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 3

an electrode active material slurry having improved dispersibility and adhesion property

Methodology Applied

Scientific EffectDispersibility: Dispersion (of waves)

Data Source

PatentUS10756352B2Electrode active material slurry, preparation method thereof, and all-solid secondary battery comprising the same

Publication Date: 2020.08.25 HYUNDAI MOTOR CO LTD

AI summary

Provided is an electrode active material slurry including a clustered complex and a slurry, wherein the clustered complex includes an electrode active material, a solid electrolyte, a conductive material, and a first binder, and the slurry includes a solvent and a second binder.The electrode active material slurry may include the clustered complex including the first binder and the slurry including the second binder so as to decrease a surface area of the overall complex, such that adhesion property with the current collector may be sufficiently secured even by using a small amount of binder, and performance of the all-solid secondary battery may be further improved.