Phosphorus Coating Composition for Low-Resistance Cathode Particles

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Solution Overview

Problem

Existing all-solid-state batteries face challenges in reducing initial resistance and post-endurance-test resistance increment, particularly in sulfide-type batteries, where conventional coating films like Li3PO4 increase initial resistance while niobium compounds lead to high post-endurance-test resistance.

Innovation Solution

A composite particle with a phosphorus compound coating film is used, where the coating film covers the positive electrode active material particle, with a specific composition ratio of lithium to phosphorus (CLi/CP ≤ 2.5) and a high covering rate, achieved by a coating liquid containing diphosphorus pentoxide in a mass fraction of 72% or more, to decrease initial resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional coating film material like Li3PO4 is used, then the coating film provides protection, but the initial resistance increases

Engineering Contradiction:
Improvecoating film protectionVSAvoidinitial resistance
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters of the coating film by using phosphorus compounds with specific Li/P ratio (CLi/CP ≤ 2.5) instead of conventional Li3PO4. This parameter change reduces initial resistance while maintaining protective functions, directly resolving the contradiction between protection and resistance.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent employs composite coating materials containing phosphorus compounds combined with specific ratios of lithium compounds. This composite approach creates a coating film that simultaneously achieves low initial resistance and effective protection, overcoming the limitations of single-material coatings like Li3PO4.

Inventive Principle:
Principle #40Composite materials

2Object-affected harmful factors

If a niobium compound coating film (LiNbO3) is used, then initial resistance decreases, but post-endurance-test resistance increment increases

Engineering Contradiction:
Improveinitial resistanceVSAvoidpost-endurance-test resistance increment
Core Design Contradiction:
Object-affected harmful factorsVSDuration of action of stationary object

Solution Approach 1:

The patent changes the material composition from niobium compounds to phosphorus compounds with controlled Li/P ratios. This parameter change achieves both low initial resistance and minimal resistance increment after endurance tests, resolving the time-dependent performance contradiction.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent uses phosphorus compounds that form stable, durable coating films replacing niobium compounds. Although phosphorus compounds may have different initial properties, they provide sustained performance over time with minimal resistance increment, effectively addressing the duration-based contradiction.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

3Object-affected harmful factors

If the particle surface composition ratio (CLi/CP) is increased to improve Li-ion conductivity, then initial resistance decreases, but the covering rate decreases

Engineering Contradiction:
Improveinitial resistanceVSAvoidcovering rate
Core Design Contradiction:
Object-affected harmful factorsVSArea of stationary object

Solution Approach 1:

The patent optimizes the CLi/CP ratio to be 2.5 or less, finding the optimal balance point where both adequate Li-ion conductivity (low initial resistance) and high covering rate are achieved. This precise parameter optimization resolves the contradiction between conductivity and coverage.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent applies phosphorus compounds with controlled lithium content to achieve sufficient Li-ion conductivity without excessive lithium that would reduce covering rate. This partial action approach maintains the right balance between conductivity requirements and coverage efficiency.

Inventive Principle:
Principle #16Partial or excessive action

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 solution effectively decreases initial resistance and post-endurance-test resistance increment, maintaining high lithium-ion conductivity and covering rates, thereby enhancing battery performance.

Implementation Method 1

a coating film that includes a phosphorus compound tends to have a small post-endurance-test resistance increment

Methodology Applied
Scientific EffectIonic conduction: Conduction (electrical)

Implementation Method 2

By using X-ray photoelectron spectroscopy (XPS), it is possible to identify the composition of a particle surface

Methodology Applied
Scientific EffectPhotoelectron spectroscopy: Photoelectric Effect

Data Source

PatentUS20240250264A1Composite Particle, Positive Electrode, All-Solid-State Battery, and Method of Producing Composite Particle
Publication Date: 2024.07.25 TOYOTA JIDOSHA KK
  • US20240250264A1 patent drawing
  • US20240250264A1 patent drawing
  • US20240250264A1 patent drawing

AI summary

A composite particle includes a positive electrode active material particle and a coating film. The coating film covers at least part of a surface of the positive electrode active material particle. The coating film includes a phosphorus compound. The composite particle satisfies a relationship of “CLi/CP≤2.5”. “CLi” represents a concentration of Li element measured by XPS. “CP” represents a concentration of P element measured by XPS.