Ceramic Particle-Surfactant Mixtures for Uniform Electrochemical Coatings
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Solution Overview
Problem
Existing methods for producing powder particles for electrochemical cell components, such as milling of solid electrolytes, often result in particles that are too large or have wide size distributions, leading to difficulties in coating techniques and agglomeration issues, while alternative methods may produce particles that are too small or use inappropriate additives.
Innovation Solution
A mixture comprising ceramic particles and a polymeric surfactant is milled to achieve particles with a median diameter of 600 nanometers to 6 microns and a polymeric surfactant with a molecular weight of 300 g/mol or higher, which improves particle size distribution and reduces agglomeration, facilitating coating processes like aerosol deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If milling is used to produce powder particles for electrochemical cell components, then the particles can be produced in bulk, but the particles become too large or have wide size distributions causing coating difficulties and agglomeration
Solution Approach 1:
The patent changes the chemical composition parameters of the milling medium by introducing a polymeric surfactant with specific molecular weight (≥300 g/mol). This parameter change in the milling environment modifies the particle size distribution outcome, achieving median diameters of 600 nm to 6 microns with narrow distribution, resolving the contradiction between bulk production capability and particle size precision.
2Productivity
If milling is used to produce powder particles, then particles can be produced efficiently, but agglomeration occurs making them difficult to use with coating techniques
Solution Approach 1:
The polymeric surfactant acts as an intermediary substance during milling that prevents particle agglomeration by adsorbing onto particle surfaces. This intermediary agent enables efficient bulk particle production while maintaining individual particle separation, making the particles suitable for coating techniques like aerosol deposition.
3Length of moving object
If alternative milling techniques are used to produce smaller particles, then particle size can be reduced, but particles become too small or inappropriate additives are used
Solution Approach 1:
The patent optimizes the particle size parameter to a specific range (median diameter 600 nm to 6 microns) that is suitable for electrochemical cell applications. The polymeric surfactant with molecular weight ≥300 g/mol enables achieving this size range without using inappropriate additives, maintaining particle reliability for electrochemical cell use while controlling particle dimensions.
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 milled mixture enables the formation of layers with improved characteristics, enhancing the cycle life and thermal stability of electrochemical cells by providing a protective layer that reduces ion conductivity drop and improves mechanical robustness.
Implementation Method 1
A mixture comprising ceramic particles and a polymeric surfactant is milled to achieve particles with a median diameter of 600 nanometers to 6 microns and a polymeric surfactant with a molecular weight of 300 g/mol or higher, which improves particle size distribution and reduces agglomeration
Data Source
AI summary
Mixtures and/or layers comprising ceramic particles and a polymeric surfactant are generally described. Related articles (e.g., electrodes, separators, and/or electrochemical cells) and related methods (e.g., methods of forming them and/or methods of using them) are also described.