Aluminum-Zinc Coated Cathode Material for High-Voltage Cycle Life

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The increasing demand for large-sized, high-capacity, or high-energy-density rechargeable lithium batteries has led to a severe insufficient supply of positive electrode active materials containing cobalt, due to its high cost and limited reserves, necessitating the development of cobalt-free or low-cobalt positive electrode active materials.

Innovation Solution

A positive electrode active material is developed, comprising layered lithium nickel-manganese-based composite oxide with a coating layer containing aluminum and zinc, which improves performance at high temperatures and high voltages, enhances capacity, and reduces production costs while ensuring long cycle-life characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If cobalt-containing positive electrode active materials are used, then battery capacity and performance are improved, but production cost increases and material supply becomes insufficient

Engineering Contradiction:

Improvebattery capacityVSAvoidproduction cost

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The patent changes the chemical composition parameters of the positive electrode active material by reducing cobalt content from conventional levels to 0.5-2 mol% while adjusting nickel (60-80 mol%) and manganese (10-30 mol%) ratios. This parameter optimization maintains high capacity while dramatically reducing production cost and supply constraints associated with cobalt

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining nickel-rich layered oxide with aluminum and zinc coating layers. This composite structure leverages nickel's high capacity, aluminum's structural stability, and zinc's surface protection properties to achieve both high performance and cost-effectiveness without relying on expensive cobalt

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If cobalt content is reduced or eliminated, then production cost decreases and material supply improves, but battery performance and stability deteriorate

Engineering Contradiction:

Improveproduction costVSAvoidbattery stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent introduces aluminum and zinc coating layers as intermediary protective barriers on the surface of the cobalt-reduced positive electrode material. These coating layers mediate between the nickel-manganese bulk material and the electrolyte, preventing direct harmful interactions while maintaining electrochemical performance and structural stability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent applies different functional properties to different regions: the nickel-rich bulk provides high capacity, while the aluminum-zinc coating layer provides surface stability and protection. This local differentiation allows cobalt reduction in the bulk without sacrificing overall battery reliability

Inventive Principle:

Principle #3Local quality

3Use of energy by moving object

If high voltage operating conditions are used, then energy density improves, but material degradation accelerates and cycle life decreases

Engineering Contradiction:

Improveenergy densityVSAvoidcycle life

Core Design Contradiction:

Use of energy by moving objectVSDuration of action of stationary object

Solution Approach 1:

The patent applies aluminum and zinc coating layers beforehand to cushion and protect the positive electrode active material from degradation during high voltage operation. This preventive coating reduces direct contact between the material and electrolyte, suppressing side reactions and maintaining structural integrity over extended cycling

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent optimizes the coating layer composition with specific aluminum (0.1-5 mol%) and zinc (0.1-5 mol%) content ratios to create a protective barrier that enables stable operation at high voltages (4.3-4.5V), thereby achieving high energy density while maintaining long cycle life

Inventive Principle:

Principle #35Parameter changes

4Power

If high temperature operating conditions are used, then power output improves, but material stability decreases and performance degrades

Engineering Contradiction:

Improvepower outputVSAvoidmaterial stability

Core Design Contradiction:

PowerVSStability of the object's composition

Solution Approach 1:

The aluminum-zinc coating layer serves as a thermal and chemical intermediary that protects the nickel-manganese bulk material from high-temperature degradation. This coating barrier prevents direct exposure to harsh thermal and electrochemical environments while allowing efficient ion transport for maintained power output

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20250192158A1Positive electrode active materials, preparation methods thereof, positive electrodes, and rechargeable lithium batteries

Publication Date: 2025.06.12 SAMSUNG SDI CO LTD

AI summary

A positive electrode active material, a method of preparing the same, and a positive electrode and rechargeable lithium battery including the same, the positive electrode active material including core particles including a layered lithium nickel-manganese-based composite oxide; and a coating layer located on the surface of the core particle and containing aluminum and zinc.