Electroplated Metal Oxide Coating for Li-ion Battery Electrodes

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Solution Overview

Problem

LiCoO2 cathode active materials in Li-ion batteries suffer from low gravimetric capacity and structural deformation when charged to high potentials, leading to capacity failures, while LiMn2O4 spinel cathodes experience capacity fade due to structural deformation during cycling.

Innovation Solution

Electroplating a transition metal oxide coating, such as Mn-based oxides, onto Li-ion battery electrodes using an aqueous media at room temperature, which is fast, cost-effective, and non-damaging to existing binders and conductive additives, allowing for control of porosity and texture without the need for high-temperature heat treatments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If LiCoO2 is charged to high potentials greater than 4.3V to attain full theoretical capacity, then gravimetric capacity is improved, but structural deformation and parasitic surface reactions occur leading to capacity failures

Engineering Contradiction:

Improvegravimetric capacityVSAvoidcycle life

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

A transition metal oxide coating layer is applied as an intermediary between the LiCoO2 cathode and the electrolyte. This coating layer mediates the interaction by providing a protective barrier that prevents direct contact between the high-potential cathode surface and the electrolyte, thereby suppressing parasitic reactions and structural deformation while allowing ionic transport for maintaining high gravimetric capacity

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If conventional coating techniques are used to protect LiCoO2 at high potentials, then cycle life is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvecycle lifeVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces complex mechanical coating systems (such as physical vapor deposition, chemical vapor deposition, or sol-gel processes requiring precise control) with a simple electrochemical deposition method. This substitution uses electric current to drive the formation of the protective coating, eliminating the need for complex equipment and multi-step procedures while achieving uniform coverage and controlled thickness

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes parameter changes in the electrochemical deposition process, specifically controlling voltage, current density, and deposition time, to optimize the coating formation. By adjusting these parameters, the process achieves protective coating with desired thickness and morphology without requiring complex manufacturing conditions, thereby simplifying production while maintaining reliability

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If high-temperature heat treatments are applied to form metal oxide coatings, then coating quality is improved, but processing time and energy consumption increase

Engineering Contradiction:

Improvecoating qualityVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces thermal processing (heat treatment) with electrochemical processing to form the metal oxide coating. Instead of using high temperatures to drive coating formation and quality improvement, the method uses electrochemical reactions at ambient or moderate temperatures, eliminating the time-consuming and energy-intensive heating step while maintaining coating quality through controlled electro deposition

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 electroplated metal oxide coating significantly enhances the cycle life and gravimetric capacity of Li-ion battery electrodes by mitigating structural deformation and parasitic reactions, reducing capacity fade, and maintaining energy output stability during high-voltage cycling.

Implementation Method 1

electroplating a transition metal oxide coating, such as Mn-based oxides, onto Li-ion battery electrodes using an aqueous media

Methodology Applied

Scientific EffectElectrochemical reduction: Electrodeposition

Data Source

PatentUS11276848B2Electroplating transition metal oxides as protective coating agents for Li-ion battery materials

Publication Date: 2022.03.15 XERION ADVANCED BATTERY CORP

AI summary

A method of electrodepositing a transition metal oxide on to the surface of cathode or anode active materials used in Li-ion batteries, using an aqueous media. The transition metal oxide coating protects the cathode or anode active materials once they are fully delithiated or fully lithiated, respectively. The protective coating may be used also in gas sensors, biological cell sensors, supercapacitors, catalysts for fuel cells and metal air batteries, nano and optoelectronic devices, filtration devices, structural components, and energy storage devices.