Nano-Engineered Battery Coatings for Interface Stability

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Solution Overview

Problem

Modern batteries face degradation issues due to SEI layer growth, increased resistance, phase transformations, reduced lithium diffusion rates, and self-discharge caused by undesirable chemical pathways at the electrode/electrolyte interface, which current technologies only partially address.

Innovation Solution

Applying nano-engineered coatings, such as those achieved through atomic layer deposition (ALD), to the anode and cathode active materials or solid-state electrolytes to block undesirable chemical pathways, inhibit side reactions, and enhance ionic and electronic conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If nano-engineered coatings are applied to active materials, then battery capacity and cycle life are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvebattery cycle lifeVSAvoidcoating process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The coating is applied to the active material particles before they are assembled into electrodes, preventing degradation pathways from the outset. This preliminary protective action addresses SEI layer growth and side reactions before they can impact battery performance during cycling.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The nano-engineered coating acts as an intermediary layer between the active material and the electrolyte, blocking undesirable chemical pathways while allowing ionic transport. This mediator prevents direct harmful interactions between the electrolyte and active material surfaces.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If nano-engineered coatings are applied to block chemical pathways, then resistance growth is reduced, but ionic conductivity may be compromised

Engineering Contradiction:

Improveresistance stabilityVSAvoidionic conductivity

Core Design Contradiction:

ReliabilityVSPower

Solution Approach 1:

The coating is implemented as an ultrathin film (nanometer scale) that provides protective functionality while maintaining ionic transport pathways. The thin film structure allows lithium ions to pass through while blocking larger molecules and preventing side reactions.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The coating structure incorporates controlled porosity that allows ionic diffusion pathways to remain open while providing protective functionality. The porous structure enables lithium ion transport while blocking electrolyte oxidation and other harmful chemical pathways.

Inventive Principle:

Principle #31Porous materials

3Reliability

If coatings are applied to inhibit side reactions, then capacity retention is improved, but manufacturing time increases

Engineering Contradiction:

Improvecapacity retentionVSAvoidmanufacturing throughput

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The coating process parameters (thickness, composition, deposition rate) are optimized to achieve the minimum necessary protective layer while maintaining manufacturing efficiency. By controlling the coating thickness at the nanometer scale and selecting appropriate deposition parameters, the process minimizes added time while ensuring adequate protection.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Traditional mechanical coating methods are replaced with vapor-phase deposition techniques (such as atomic layer deposition or chemical vapor deposition) that can apply uniform nanometer-scale coatings more efficiently and with better control, reducing overall processing time while improving coating quality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 nano-engineered coatings significantly improve battery capacity, cycle life, and power retention by preventing electrolyte oxidation, cathode cation dissolution, and SEI precursor shuttling, while maintaining mechanical stability and reducing resistance growth.

Implementation Method 1

Methodology Applied

Scientific EffectPhysical barrier (coating): Coatings

Implementation Method 2

Applying nano-engineered coatings, such as those achieved through atomic layer deposition (ALD)

Methodology Applied

Scientific EffectAtomic layer deposition: Chemical Vapour Deposition

Implementation Method 3

enhance ionic and electronic conductivity

Methodology Applied

Scientific EffectIonic conduction: Conduction (electrical)

Implementation Method 4

enhance ionic and electronic conductivity

Methodology Applied

Scientific EffectElectronic conduction: Conduction (electrical)

Implementation Method 5

preventing electrolyte oxidation, cathode cation dissolution

Methodology Applied

Scientific EffectChemical stability: Oxidation

Data Source

PatentUS11996564B2Nano-engineered coatings for anode active materials, cathode active materials, and solid-state electrolytes and methods of making batteries containing nano-engineered coatings

Publication Date: 2024.05.28 FORGE NANO INC

AI summary

The present disclosure relates to a nano-engineered coating for cathode active materials, anode active materials, and solid state electrolyte materials for reducing corrosion and enhancing cycle life of a battery, and various process for applying the disclosed coating.