Lithium Battery Electrode Density Gradient for Binder Penetration

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Solution Overview

Problem

Lithium secondary batteries with protective layers face issues of increased internal resistance due to binder penetration into the electrode active material layers during charging and discharging cycles, which can lead to reduced electrical conductivity and reliability.

Innovation Solution

A lithium secondary battery configuration with a protective layer containing an insulating filler and a binder is formed on the electrode active material layers, where the layer density on the side facing the protective layer is higher than the central portion, preventing binder penetration and maintaining low internal resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a protective layer containing binder is formed on the electrode active material layer, then loss of electrode active material is prevented and reliability is improved, but binder penetrates into the electrode active material layer during charging and discharging cycles causing increased internal resistance

Engineering Contradiction:
Improveprevention of electrode active material lossVSAvoidincrease in internal resistance
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The electrode active material layer is designed with non-uniform density distribution, where the density varies from the surface toward the interior. Specifically, the density increases as one moves from the surface (facing the protective layer) toward the interior of the layer. This localized density variation creates a gradient structure that selectively prevents binder penetration from the protective layer while maintaining overall electrode functionality and preventing active material loss.

Inventive Principle:
Principle #3Local quality

2Reliability

If a protective layer is formed on the electrode active material layer, then internal short-circuiting is prevented, but electrical conductivity decreases due to binder penetration

Engineering Contradiction:
Improveprevention of internal short-circuitingVSAvoiddecrease in electrical conductivity
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The electrode active material layer employs a density gradient structure where density increases from the surface toward the interior. This localized density variation creates a barrier that specifically阻止es binder penetration into the bulk of the electrode active material layer, thereby maintaining electrical conductivity while still providing protection against internal short-circuiting through the protective layer configuration.

Inventive Principle:
Principle #3Local quality

3Duration of action of stationary object

If a protective layer is formed on the electrode active material layer, then durability is improved, but internal resistance increases due to repeated binder penetration during charging and discharging cycles

Engineering Contradiction:
Improvedurability of lithium secondary batteryVSAvoidincrease in internal resistance over time
Core Design Contradiction:
Duration of action of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The electrode active material layer is designed with a density gradient where density increases from the surface toward the interior. This localized density variation creates a stable barrier that prevents binder penetration during repeated charging and discharging cycles, thereby maintaining low internal resistance over time while improving overall battery durability through the protective layer configuration.

Inventive Principle:
Principle #3Local quality

Data Source

PatentUS8703343B2Lithium secondary battery with electrode protective layer and initial capacity ratio and manufacturing method thereof
Publication Date: 2014.04.22 TOYOTA JIDOSHA KK
  • US8703343B2 patent drawing
  • US8703343B2 patent drawing
  • US8703343B2 patent drawing

AI summary

In a lithium secondary battery provided by the present invention, the layer density on a side facing a protective layer (46) in a negative electrode active material layer (44) and/or positive electrode active material layer where the protective layer is formed, the protective layer containing an insulating filler and a binder, is higher than the layer density in a central portion and a side facing a current collector (42) in the negative electrode active material layer and/or positive electrode active material layer where the protective layer is formed.