Electrodepositable Lithium Battery Coatings via Aqueous Suspension

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for depositing lithium-containing compositions on metal foils for lithium ion batteries, such as slot die coaters, use environmentally undesirable solvent-borne slurries and result in coatings with high resin content, which is not environmentally friendly and inefficient.

Innovation Solution

An electrodepositable composition comprising an aqueous medium, an ionic resin, lithium-containing particles, and electrically conductive particles, with a weight ratio of solid particles to ionic resin of at least 17:1 and lithium-containing particles to electrically conductive particles of at least 3:1, is used to create a battery electrode through electrodeposition, reducing the need for high resin content and environmentally harmful solvents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If solvent-borne slurries are used for depositing lithium-containing compositions, then the coating can be applied on metal foils, but the method is environmentally undesirable and uses harmful solvents

Engineering Contradiction:

Improvecoating applicationVSAvoidenvironmental harm from solvents

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the fundamental parameter of the deposition medium from organic solvent-based slurry to aqueous suspension. This substitution eliminates environmentally harmful solvents while maintaining the coating application capability on metal foils through electrodeposition technology.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical slot die coating method with an electrochemical electrodeposition process. This substitution enables coating application without requiring harmful solvents, as the aqueous suspension can be deposited through electrochemical means directly onto the metal foil substrate.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If slot die coaters are used to deposit lithium-containing active material, then the coating process is efficient, but the resin content in the slurry is high relative to active material

Engineering Contradiction:

Improvecoating efficiencyVSAvoidresin to active material ratio

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent replaces slot die coating with electrodeposition, enabling efficient coating deposition while achieving a dramatically improved solid particle to resin ratio of at least 17:1. This electrochemical approach allows high productivity with minimal resin content, as the aqueous suspension can be deposited efficiently through electrochemical means.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If high resin content slurry is used for coating, then the coating can be applied uniformly, but the method is not environmentally friendly due to solvent usage

Engineering Contradiction:

Improvecoating uniformityVSAvoidenvironmental impact

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent changes the deposition medium from organic solvent-based slurry to aqueous suspension, eliminating environmental harm while maintaining coating uniformity. The electrodeposition process ensures uniform coating deposition from the aqueous suspension, achieving manufacturing precision without compromising environmental friendliness.

Inventive Principle:

Principle #35Parameter changes

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 allows for the production of lithium ion battery electrodes with a solid uniform coating of suitable film thickness and limited porosity, suitable for use as a cathode, while minimizing environmental impact and improving manufacturing efficiency.

Implementation Method 1

Electrodeposition as a coating application method involves the deposition onto an electrically conductive substrate of a composition under the influence of an applied electrical potential

Methodology Applied

Scientific EffectElectrodeposition: Electrodeposition

Implementation Method 2

the coating being applied to the substrate as electric current is passed between the electrodes

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS11646126B2Electrodepositable compositions and electrically conductive substrates prepared therewith

Publication Date: 2023.05.09 PPG INDUSTRIES OHIO INC

AI summary

The present invention is directed to electrodepositable compositions comprising: (a) an aqueous medium; (b) an ionic resin; and (c) solid particles comprising: (i) lithium-containing particles, and (ii) electrically conductive particles, wherein the composition has a weight ratio of the solid particles to the ionic resin of at least 17:1, and wherein the weight ratio of the lithium-containing particles to the electrically conductive particles is at least 3:1. The present invention is additionally directed to a battery electrode comprising a substrate and a coating applied to a surface of the substrate. The coating is deposited from the electrodepositable composition described above.