Cold Spray Deposition for Lithium Ion Battery Anode Coatings
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Solution Overview
Problem
Conventional methods for forming metal structures on electrodes, such as lithium ion battery anodes, often cause thermal stress and mechanical damage due to high-temperature deposition processes, leading to inefficient coating and potential electrode deterioration.
Innovation Solution
A cold spray method using a convergent-divergent nozzle to accelerate particles to high velocities while heating or cooling them to a softening temperature, allowing for the deposition of alkali metals, transition metals, and Group III-Group VI elements without thermal stress, enabling the formation of high-purity structures with controlled thickness and edge transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-temperature deposition methods (thermal evaporation, physical vapor deposition) are used to form metal structures on electrodes, then deposition efficiency is improved, but thermal stress and mechanical damage occur causing electrode deterioration
Solution Approach 1:
The invention changes the temperature parameter from high-temperature deposition to low-temperature or room temperature deposition. The plasma spray process maintains substrate temperature below the softening temperature of the anode material, eliminating thermal stress while achieving efficient deposition through kinetic energy of accelerated particles
Solution Approach 2:
The invention replaces thermal mechanisms with mechanical mechanisms. Instead of using heat to deposit material, the process uses mechanically accelerated particles (via plasma jet or electromagnetic field) that deposit through kinetic energy impact, substituting thermal energy with mechanical energy for the deposition function
2Ease of manufacture
If conventional web coating and vapor deposition methods are used, then coating process is simplified, but poorly defined coated and uncoated edge transitions are produced
Solution Approach 1:
The invention applies local quality by creating a gradient in particle deposition density across the substrate surface. The plasma jet or electromagnetic field creates a controlled distribution pattern where particles gradually decrease in density at edges, producing smooth transitions rather than abrupt boundaries between coated and uncoated regions
3Reliability
If cold spray of stabilized lithium metal powder is used, then high-capacity lithium ion batteries with long cycle life are manufactured, but electrochemically-inactive lithium carbonate contamination occurs
Solution Approach 1:
The invention changes the particle form from pre-stabilized powder with protective coating to freshly atomized liquid metal droplets. By depositing lithium from liquid state immediately before impact, the process eliminates the lithium carbonate surface layer that forms during powder storage and handling, achieving both high reliability and high purity
Solution Approach 2:
The invention performs preliminary action by atomizing and cooling lithium metal to liquid state immediately before deposition. This timing ensures the metal remains in its most reactive, purest state throughout the deposition process, preventing premature formation of inactive compounds while maintaining the benefits of cold spray technology
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 approach minimizes electrode damage, achieves precise control over coating thickness and edge transitions, and forms high-purity structures on lithium ion battery anodes, enhancing their performance and longevity.
Implementation Method 1
accelerating particles in a working gas through a convergent-divergent nozzle to a process velocity that is from about a critical velocity of the particles to an erosion velocity of the LIB anode
Implementation Method 2
heating or cooling the particles in the working gas at a softening temperature concurrent with accelerating the particles
Implementation Method 3
at least a portion of the particles are in solid phase when ejected from the convergent-divergent nozzle
Implementation Method 4
depositing a first structure on the LIB anode, the first structure comprising the alkali metal, the transition metal, the Group III element, the Group IV element, the Group V element, the Group VI element, or the combinations thereof
Data Source
AI summary
Embodiments of the present disclosure generally relate to electrode coatings and methods of coating electrodes. In an embodiment, a method of depositing a structure on a lithium ion battery (LIB) anode is provided. The method includes accelerating particles in a working gas through a convergent-divergent nozzle to a process velocity that is from a critical velocity of the particles to an erosion velocity of the LIB anode, the particles comprising a metal and/or a Group III-VI element; heating or cooling the particles in the working gas at a softening temperature; ejecting the particles in the working gas from a nozzle outlet of the convergent-divergent nozzle, the particles ejected at the process velocity, wherein at least a portion of the particles are in solid phase when ejected from the convergent-divergent nozzle; and depositing a first structure on the LIB anode, the first structure comprising the metal and/or the Group III-VI element.