Coated Active Material With Spray-Dried Li-P-O Layer for Low Resistance
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Solution Overview
Problem
The increase in particle size of coated active materials due to granulation during the formation of a coating layer containing phosphorus compounds leads to higher battery resistance, which can cause deformation and cracking of the electrode layer, thereby increasing overall battery resistance.
Innovation Solution
A coated active material is developed with a particle size (D50) of 5.5 μm or less, utilizing an oxide solid electrolyte containing Li, P, and O elements, and a spray drying method with a gas-liquid ratio of 5.0×10−3 or less to suppress granulation and maintain a uniform, thin coating layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phosphorus compound is used as coating material, then chemical stability and ionic conductivity are improved, but particle size increases due to granulation
Solution Approach 1:
The patent changes the physical and chemical parameters of the coating process by controlling the gas-liquid ratio to 5.0×10^-3 or less and using a spray drying method, which prevents granulation while maintaining the chemical stability benefits of phosphorus compound coating
Solution Approach 2:
The patent applies pneumatic principles by using spray drying with atomized air to deliver the coating material. The gas-liquid ratio control ensures proper atomization and distribution of the phosphorus compound coating without causing particle aggregation
2Reliability
If phosphorus compound is used as coating material, then ionic conductivity is improved, but battery resistance increases due to particle size increase
Solution Approach 1:
The patent changes the coating process parameters by controlling gas-liquid ratio and using spray drying, which maintains small particle size (D50 ≤ 5.5 μm) while preserving the ionic conductivity benefits of phosphorus compound coating
Solution Approach 2:
The patent replaces conventional coating methods with spray drying technology, which uses aerosolization and rapid evaporation instead of mechanical mixing and drying, thereby preventing granulation and maintaining small particle size for low battery resistance
3Ease of manufacture
If coating layer is formed by conventional method, then coating is applied, but granulation occurs and particle size increases
Solution Approach 1:
The patent uses spray drying with controlled gas-liquid ratio to deliver the coating material through aerosolization. This pneumatic method ensures uniform coating application while preventing particle aggregation and maintaining size uniformity
Solution Approach 2:
The patent utilizes the phase transition from liquid slurry to solid coating through rapid evaporation during spray drying. This phase change occurs so quickly that it prevents granulation while ensuring uniform coating formation on the particles
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 reduces battery resistance by maintaining a small particle size and preventing electrode deformation, thus enhancing the battery's performance and stability.
Implementation Method 1
forming the coating layer by a spray drying method of jetting the slurry with atomized air to be dried
Implementation Method 2
forming the coating layer by a spray drying method of jetting the slurry with atomized air to be dried
Data Source
AI summary
The coated active material includes an electrode active material and a coating layer covering the electrode active material, wherein the coating layer includes an oxide solid electrolyte containing a Li element, a P element, and an O element, and a particle size (D50) of the coated active material is 5.5 μm or less.