Electrodepositable Battery Electrode Coating Composition

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Solution Overview

Problem

The electronics industry faces challenges in producing smaller devices with smaller batteries, as solventborne binders pose safety and environmental hazards, and waterborne binders often result in electrodes with poor adhesion and performance due to degradation of active materials during charge and discharge cycles.

Innovation Solution

An electrodepositable coating composition comprising an electrochemically active material with a protective coating, an electrodepositable binder, and an aqueous medium is used for electrodeposition, where the protective coating inhibits degradation and maintains lithium-ion mobility, improving electrode performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If solventborne binders are used for electrode production, then good adhesion and battery performance are achieved, but safety hazards, environmental pollution, and health risks increase due to toxic and flammable organic solvents

Engineering Contradiction:

Improvebattery performanceVSAvoidenvironmental pollution and safety hazards

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention changes the fundamental parameter of the binder medium from organic solvent-based to water-based. This substitution eliminates the harmful effects of toxic and flammable organic solvents while maintaining the functional performance of the electrode through careful selection of water-soluble or water-dispersible binder polymers and optimization of the slurry composition.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention converts the potential harm of water exposure to active materials into a benefit by using water as a safe, environmentally friendly solvent. The protective coating on active particles prevents water degradation, allowing the use of waterborne binders to achieve both safety and performance goals simultaneously.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Object-affected harmful factors

If waterborne binders are used for electrode production, then environmental safety is improved, but adhesion and battery performance deteriorate due to degradation of active materials from water exposure

Engineering Contradiction:

Improveenvironmental safetyVSAvoidbattery performance

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The invention introduces a protective coating as an intermediary layer between the waterborne binder and the active materials. This coating acts as a barrier that prevents direct contact between water and sensitive active materials, thereby preventing degradation while allowing the waterborne binder to provide safe, environmentally friendly adhesion.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The protective coating is applied as a thin film on the surface of active particles. This thin film provides effective protection against water exposure while maintaining the electrical and electrochemical properties of the active materials, enabling waterborne binders to be used without compromising battery performance.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If active materials are exposed to water during electrodeposition, then waterborne binder application is enabled, but degradation of active materials occurs leading to poor adhesion and performance

Engineering Contradiction:

Improveelectrodeposition processabilityVSAvoidadhesion quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The protective coating is applied to active particles before they are mixed with the waterborne binder and subjected to electrodeposition. This preliminary protection ensures that active materials are already shielded from water exposure, preventing degradation during the manufacturing process and ensuring high adhesion quality in the final electrode.

Inventive Principle:

Principle #10Preliminary 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 enhances battery performance by protecting active materials from aqueous medium exposure, ensuring improved capacity and adhesion during charging cycles without using carcinogenic materials or causing environmental pollution.

Implementation Method 1

electrophoretically depositing the electrodepositable coating composition comprising an electrochemically active material comprising a protective coating; an electrodepositable binder; and an aqueous medium onto a substrate

Methodology Applied

Scientific EffectElectrophoretic deposition: Electrophoretic Deposition

Implementation Method 2

an electrochemically active material comprising a protective coating... the protective coating inhibits degradation

Methodology Applied

Scientific EffectProtective coating barrier: Coatings

Data Source

PatentUS11611062B2Electrodepositable battery electrode coating compositions having coated active particles

Publication Date: 2023.03.21 PPG INDUSTRIES OHIO INC

AI summary

The present invention is directed towards an electrodepositable coating composition comprising an electrochemically active material comprising a protective coating; an electrodepositable binder; and an aqueous medium. Also disclosed herein is a method of coating a substrate, as well as coated substrates and electrical storage devices.