Slurry-Based Film Coating of Battery Powders Without FBR-ALD
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Solution Overview
Problem
Current methods for coating battery material powders, such as FBR-ALD, face challenges in scalability, cost-effectiveness, and precision due to issues with fluidization, agglomeration, and the use of pyrophoric precursors, leading to incomplete coverage and reduced battery performance.
Innovation Solution
A liquid-phase deposition method involving a solvent to fluidize battery material powders, followed by sequential addition of reactive substances to form thin film monolayers, which simplifies the process, improves uniformity, and avoids the need for high-temperature vapor-phase deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If FBR-ALD is used to coat battery material powders, then uniform thin film coating is achieved, but scalability and cost-effectiveness deteriorate due to complex fluidization requirements and pyrophoric precursor handling
Solution Approach 1:
The patent replaces the pneumatic fluidization system with a liquid slurry-based system. Battery material powders are suspended in liquid media (water, alcohol, or non-aqueous solvents) to form slurries, eliminating the need for gas flow and fluidization dynamics. This hydraulic approach simplifies the manufacturing process while maintaining coating uniformity through controlled slurry circulation and deposition.
Solution Approach 2:
The invention changes the physical state of precursors from vapor phase (pyrophoric, requiring vacuum and temperature control) to liquid phase (aqueous or non-aqueous solutions). This parameter change allows deposition at ambient or mild temperatures, eliminates pyrophoric safety hazards, and enables straightforward scaling by simply adjusting slurry volume and flow rate without complex reactor engineering.
2Manufacturing precision
If FBR-ALD is used for coating, then precise film thickness control is achieved, but device complexity increases due to vacuum systems and temperature control requirements
Solution Approach 1:
The patent replaces complex pneumatic vacuum systems with simple liquid slurry circulation systems. The deposition occurs in liquid media at atmospheric pressure, eliminating vacuum pumps, pressure control valves, and temperature-controlled reactor chambers. Film thickness is controlled by slurry concentration, flow rate, and deposition time—parameters that are far easier to measure and control.
Solution Approach 2:
The invention transitions from vapor-phase deposition requiring precise temperature control (to maintain precursor vapor pressure) to liquid-phase deposition at ambient or mild temperatures. This eliminates thermal management complexity while maintaining precise film thickness control through liquid-phase reaction kinetics and slurry composition adjustment.
3Manufacturing precision
If vapor-phase precursors are used in FBR-ALD, then monolayer precision is achieved, but safety infrastructure requirements increase due to pyrophoric material handling
Solution Approach 1:
The patent changes the chemical form of precursors from pyrophoric metalorganic vapors to stable liquid or aqueous solutions. The reactive metal species are delivered dissolved in liquid carriers (water, alcohol, or non-aqueous solvents), eliminating pyrophoricity while maintaining the ability to form precise monolayers through controlled surface reactions. This allows standard laboratory safety protocols to suffice without specialized inert atmosphere handling.
Solution Approach 2:
The invention introduces liquid solvents as intermediary carriers for metal precursors. Instead of direct vapor-phase metalorganic compounds, the metal species are delivered through stable liquid solutions that act as intermediaries, reducing direct handling of hazardous materials while enabling controlled deposition through solvent evaporation or chemical reaction on the powder surface.
4Productivity
If high mass-loading is applied in FBR-ALD, then coating speed increases, but precursor condensation occurs requiring higher vapor pressures
Solution Approach 1:
The patent replaces vapor-phase precursor delivery with liquid slurry circulation. High mass-loading is achieved by increasing slurry concentration and flow rate without requiring elevated temperatures or vacuum systems. The liquid phase allows high precursor loading while preventing condensation issues that plague vapor-phase systems, enabling fast coating speeds through enhanced mass transport in the liquid medium.
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 method enables precise control of film thickness and composition, enhances battery performance by reducing impedance and preventing parasitic reactions, while being more scalable and cost-effective than existing vapor-phase deposition techniques.
Implementation Method 1
introducing a solvent into the reaction vessel to fluidize the battery material powders, thereby yielding a slurry composed of the solvent and powders
Implementation Method 2
adding a second reagent into reaction vessel to react with the battery material powders comprising an adsorbed monolayer of first reagent, thereby yielding coated battery material powders comprising a thin film monolayer
Implementation Method 3
adding a first reagent into the reaction vessel to react with the slurry, thereby producing battery material powders comprising an adsorbed monolayer of first reagent
Data Source
AI summary
Disclosed herein are methods, systems, and compositions for the liquid-phase deposition of film coatings onto the surface of battery material powders. The battery material powders are introduced into a reaction vessel within which the coating is to be performed. A solvent is added to the reaction vessel to fluidize the battery material powders, thereby yielding a slurry composed of the solvent and powders. A first reagent is then added into the reaction vessel to react with the slurry to produce battery material powders comprising an adsorbed partial layer of the first reagent. A second reagent is added into reaction vessel to react with the battery material powders comprising an adsorbed monolayer of first reagent, thereby yielding coated battery material powders comprising at least one monolayer film.