Lithium Battery Electrode Composite Layer for Separator-Free Stability

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Solution Overview

Problem

Conventional rechargeable lithium batteries face challenges in achieving high energy density and capacity, and the manufacturing process is complex due to the need for laminating separate organic and inorganic layers, which increases costs and complexity.

Innovation Solution

An organic-inorganic composite layer, integrating boron nitride nanosheets and nanotubes with a polyimide or polyamic acid polymer matrix, is used to replace conventional separators, forming a single layer that enhances puncture strength, adhesion, and reduces heat shrinkage, thereby simplifying the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional separators are used with separate organic and inorganic layers, then basic separation function is achieved, but manufacturing complexity and cost increase due to lamination process

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidstructure complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines separate organic and inorganic layers into a single integrated organic-inorganic composite layer. The inorganic material is dispersed within the organic polymer matrix, creating a unified structure that performs both separation functions simultaneously, thereby eliminating the lamination process and reducing manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent creates an organic-inorganic composite material where inorganic particles are embedded in an organic polymer matrix. This composite structure integrates the thermal stability of inorganic materials with the flexibility and processability of organic polymers, achieving both functional requirements in a single material system that simplifies manufacturing.

Inventive Principle:

Principle #40Composite materials

2Strength

If conventional separators are used, then basic separation function is achieved, but puncture strength and heat shrinkage resistance are insufficient

Engineering Contradiction:

Improvepuncture strengthVSAvoidseparator performance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The organic-inorganic composite structure combines the mechanical flexibility of organic polymers with the thermal stability and structural rigidity of inorganic materials. The inorganic particles act as reinforcement within the polymer matrix, significantly enhancing puncture strength while maintaining low heat shrinkage rates, thus improving overall separator reliability.

Inventive Principle:

Principle #40Composite materials

3Strength

If inorganic material content is increased in nanofibers, then puncture strength improves, but dispersibility and processing difficulty worsen

Engineering Contradiction:

Improvepuncture strengthVSAvoiddispersibility

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent optimizes the local distribution of inorganic materials within the organic matrix, ensuring uniform dispersion at appropriate concentrations. By controlling the spatial arrangement and concentration of inorganic particles locally within the composite structure, the patent achieves enhanced mechanical properties while maintaining good dispersibility and processability.

Inventive Principle:

Principle #3Local quality

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

This integration results in improved stability and lifetime of the lithium battery by reducing resistance and eliminating the need for lamination, leading to a more economical and efficient production method.

Implementation Method 1

An organic-inorganic composite layer, integrating boron nitride nanosheets and nanotubes with a polyimide or polyamic acid polymer matrix, is used to replace conventional separators

Methodology Applied

Scientific EffectComposite materials: Composite Materials

Implementation Method 2

enhances puncture strength, adhesion, and reduces heat shrinkage

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 3

The inorganic material includes one or more of boron nitride nanosheets and boron nitride nanotubes, the matrix includes one or more of a polyimide (PI)-based polymer and a polyamic acid (PAA)-based polymer

Methodology Applied

Scientific EffectThermal stability: Thermal Insulation

Data Source

PatentUS20250336933A1Electrode for rechargeable lithium battery and rechargeable lithium battery including the same

Publication Date: 2025.10.30 SAMSUNG SDI CO LTD

AI summary

The present disclosure relates to an electrode for a rechargeable lithium battery, and a rechargeable lithium battery including the electrode. The electrode includes an active material layer for a rechargeable lithium battery, and an organic-inorganic composite layer integrated with the active material layer. The organic-inorganic composite layer includes nanofibers, the nanofibers include an inorganic material and a matrix, the inorganic material includes one or more of boron nitride nanosheets and boron nitride nanotubes, the matrix includes one or more of a polyimide-based polymer and a polyamic acid-based polymer, and the inorganic material is included in an amount of about 0.1 wt % to about 7 wt % in the nanofibers.