Layered Lithium Battery Electrode for Uniform High-Loading Distribution

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Solution Overview

Problem

Lithium batteries with high loading electrodes exhibit non-uniform component distribution, leading to performance deterioration and reduced efficiency.

Innovation Solution

An electrode design with distinct layers of electrode active materials and binders, each with controlled vertical relative force (FVR) variations, ensuring uniform component distribution and improved binding strength, thereby facilitating better electrolyte impregnation and reducing internal resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If high loading electrodes are used to increase battery capacity, then battery energy density is improved, but component distribution becomes non-uniform leading to performance deterioration

Engineering Contradiction:

Improvebattery capacityVSAvoidcomponent distribution uniformity

Core Design Contradiction:

Quantity of substanceVSStability of the object's composition

Solution Approach 1:

The electrode active material layer is divided into multiple sub-layers (first electrode active material layer and second electrode active material layer) with different compositions and properties. This segmentation allows each sub-layer to contribute differently to the overall electrode structure, enabling high loading while maintaining uniform component distribution throughout the electrode thickness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the electrode are designed with distinct material compositions and properties. The first electrode active material layer has different characteristics from the second electrode active material layer, allowing each region to optimize for its specific function while collectively achieving uniform overall distribution and high capacity.

Inventive Principle:

Principle #3Local quality

2Quantity of substance

If high loading electrodes are used to increase battery capacity, then battery energy density is improved, but binding strength decreases leading to performance deterioration

Engineering Contradiction:

Improvebattery capacityVSAvoidbinding strength

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The electrode is segmented into multiple layers with different binder systems. The first electrode active material layer uses a first binder while the second electrode active material layer uses a second binder, allowing optimization of binding strength in each region independently while maintaining overall structural integrity at high loading.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electrode employs a composite structure with multiple electrode active materials and multiple binders. This composite approach allows synergistic interaction between different materials, achieving both high capacity loading and sufficient binding strength through the combined properties of the various components.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12476246B2Electrode, lithium battery including the same, and method of manufacturing the same

Publication Date: 2025.11.18 SAMSUNG SDI CO LTD

AI summary

Provided are an electrode, a lithium battery including the same, and an electrode manufacturing method, the electrode including: an electrode active material layer including an electrode active material and a binder; and an electrode current collector on one surface or between two surfaces of the electrode active material layer, wherein the electrode active material layer includes: a first electrode active material layer including a first electrode active material and a first binder and contacting the electrode current collector; and a second electrode active material layer arranged on the first electrode active material layer and including a second electrode active material layer and a second binder.