Layered Electrode Coating for Adhesion and Power Density

Solution Overview

Problem

Increased carbon weight percentage in the conductive surface coating of electrode active materials decreases battery power density and reduces adhesion between the electrode and the current collector, leading to potential peeling off of the electrode active material.

Innovation Solution

Incorporating a layer between the electrode active material and the current collector, where the second layer contains a greater amount of electrode active material than the first layer, improving electrical conductivity and adhesion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If carbon weight percentage in the conductive surface coating is increased, then electrical conductivity is improved, but adhesion between the electrode active material and the current collector is reduced

Engineering Contradiction:

ImproveadhesionVSAvoidpower density

Core Design Contradiction:

ReliabilityVSPower

Solution Approach 1:

The electrode active material is divided into two distinct layers: a first layer with lower carbon content (0.5-5 wt%) applied directly to the current collector for strong adhesion, and a second layer with higher carbon content (1-10 wt%) applied over the first layer for enhanced electrical conductivity. This segmentation allows each layer to optimize its carbon content for its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the electrode active material have different carbon concentrations tailored to their specific requirements. The first layer near the current collector has lower carbon content to maximize adhesion strength, while the second layer at the outer surface has higher carbon content to maximize electrical conductivity and power density.

Inventive Principle:

Principle #3Local quality

2Reliability

If carbon weight percentage in the conductive surface coating is increased, then electrical conductivity is improved, but the electrode active material peels off the current collector

Engineering Contradiction:

Improveelectrical conductivityVSAvoidadhesion strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The electrode active material is divided into two distinct layers: a first layer with lower carbon content (0.5-5 wt%) applied directly to the current collector for strong adhesion, and a second layer with higher carbon content (1-10 wt%) applied over the first layer for enhanced electrical conductivity. This segmentation allows each layer to optimize its carbon content for its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

3Device complexity

If a single layer of electrode active material is used, then the structure is simple, but adhesion and power density cannot be simultaneously optimized

Engineering Contradiction:

Improvelayer structureVSAvoidoverall performance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The electrode active material is divided into two distinct layers: a first layer with lower carbon content (0.5-5 wt%) applied directly to the current collector for strong adhesion, and a second layer with higher carbon content (1-10 wt%) applied over the first layer for enhanced electrical conductivity. This segmentation allows each layer to optimize its carbon content for its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12537189B2Systems and methods for adhesion of electrodes

Publication Date: 2026.01.27 RIVIAN HOLDINGS LLC

AI summary

Provided herein is an electrode. The electrode can include a current collector. The electrode can include a first layer on a first surface of the current collector. The first layer can include a first electrode active material and an electrically conductive material. The electrode can include a second layer on the first layer. The second layer can include a second electrode active material. An amount of the second electrode active material in the second layer can be greater than an amount of the first electrode active material in the first layer.