Conductive Polymer Coating for Fast-Charging Battery Electrodes

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Solution Overview

Problem

Current lithium-ion batteries face challenges in achieving long driving ranges and fast charging times, especially in extreme weather conditions, while also requiring expensive metals like cobalt, limiting their widespread adoption in vehicles.

Innovation Solution

A method of coating electroactive materials with a conductive polymer, specifically PEDOT:PSS, to enhance conductivity and stretchability, which is applied by forming a slurry with the material, solvent, and additive, then drying it to create a coated electroactive material for use in electrodes, reducing the need for expensive metals and improving battery performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If expensive metals like cobalt are used in battery chemistry, then energy density and power delivery are improved, but manufacturing cost increases

Engineering Contradiction:

Improveenergy densityVSAvoidmanufacturing cost

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The patent replaces expensive noble metals (cobalt, nickel, manganese) with abundant, inexpensive iron-based materials as the electroactive material. This substitution dramatically reduces manufacturing costs while maintaining acceptable energy density through the conductive polymer coating enhancement

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent creates a composite structure consisting of iron-based electroactive material particles coated with conductive polymer. This composite approach compensates for the lower intrinsic conductivity of iron-based materials through the conductive polymer layer, achieving a cost-effective alternative to noble metal-based batteries

Inventive Principle:

Principle #40Composite materials

2Length of moving object

If conventional battery chemistries are used, then manufacturing is simpler, but driving range and charge time are limited

Engineering Contradiction:

Improvedriving rangeVSAvoidmanufacturing complexity

Core Design Contradiction:

Length of moving objectVSEase of manufacture

Solution Approach 1:

The patent modifies the surface properties and conductivity parameters of the electroactive material by applying a conductive polymer coating. This changes the electrical and electrochemical characteristics of the material, enabling faster charge rates and improved power delivery that extend driving range

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies conductive polymer specifically to the surface of the electroactive material particles, creating a localized conductive layer that enhances electron transfer at the particle surface without requiring bulk modification of the entire material structure

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If battery operation in extreme weather conditions is required, then adaptability is improved, but performance and reliability deteriorate

Engineering Contradiction:

Improveweather adaptabilityVSAvoidperformance stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The conductive polymer forms a flexible, adherent coating layer on the electroactive material particles that maintains structural integrity and electrical conductivity across a wide temperature range, enabling reliable battery operation in extreme weather conditions

Inventive Principle:

Principle #30Flexible shells and thin films

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 coated electroactive materials exhibit improved conductivity, stretchability, and cycling stability, leading to higher energy density, capacity retention, and faster charging capabilities, thus addressing the limitations of existing battery chemistries.

Implementation Method 1

Each of the plurality of particles is at least partially coated with the conductive polymer

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Implementation Method 2

The coating further includes drying the slurry to form the coated electroactive material

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS11996553B2Method of coating electroactive materials with conductive polymers

Publication Date: 2024.05.28 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

The present disclosure provides a method of preparing a coated electroactive material. The method includes providing a plurality of particles including an electroactive material. The method further includes coating the plurality of particles with a conductive polymer. The coating includes preparing a solution of water and the conductive polymer. The coating further includes forming a slurry by combining the solution with the plurality of particles. The method further includes drying the slurry to form the coated electroactive material. The coated electroactive material includes the plurality of particles. Each of the plurality of particles is at least partially coated with the conductive polymer. In certain aspects, the present disclosure provides a method of preparing an electrode including the coated electroactive material.