Metallization of Electrochemically Active Powders

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Solution Overview

Problem

Conventional metallization processes for electrochemically active powders in lithium-ion batteries are inefficient due to high costs, discontinuous metal coatings, and sensitivity to surface properties, leading to reduced cycle life and safety concerns.

Innovation Solution

Applying a continuous polymer coating to the electrochemically active electrode material followed by a metal catalyst for electroless deposition (ELD), resulting in a thin, uniform, and continuous metal coating that enhances adhesion and conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional metallization processes are used for electrochemically active powders, then metal coating can be applied, but the coating is discontinuous and non-uniform, leading to reduced cycle life and safety

Engineering Contradiction:

Improvecycle lifeVSAvoidcoating uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent introduces a polymer coating as an intermediary layer between the electrochemically active powder and the metal catalyst. This polymer layer modifies the surface properties to enable uniform catalyst distribution and subsequent uniform metal deposition, resolving the discontinuity issue of conventional direct metallization processes

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent applies polymer coating and catalyst deposition before the final metal coating step. This preliminary action prepares the surface with uniform properties that ensure the subsequent metal layer deposits evenly, achieving continuous and uniform coating that improves cycle life and safety

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If conventional metallization processes are used, then metal coating can be achieved, but the process is highly sensitive to surface properties, increasing manufacturing complexity

Engineering Contradiction:

Improveprocess sensitivityVSAvoidsurface preparation requirements

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent changes the surface parameters by applying a polymer coating that standardizes the surface properties. This modification makes the metallization process less sensitive to variations in the underlying powder surface, reducing manufacturing complexity and improving ease of production

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The polymer coating acts as a mediator that decouples the metallization process from the specific surface properties of the electrochemically active powder. This intermediary layer provides a consistent surface for catalyst deposition, reducing sensitivity to surface variations

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If conventional metallization processes are used, then metal coating can be applied, but the cost is high due to process complexity and material requirements

Engineering Contradiction:

Improvemanufacturing costVSAvoidcatalyst loading

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent uses a thin polymer coating layer that can be easily applied and removed or remains as a thin residual layer. This disposable-like approach reduces the need for expensive catalyst and complex processing, lowering overall manufacturing cost

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the surface parameters through polymer coating to reduce catalyst loading requirements. The modified surface enables efficient catalyst distribution at lower concentrations, reducing material costs and simplifying the manufacturing process

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

The approach reduces the cost and sensitivity of the metallization process, achieves a more continuous and uniform metal coating, improving the cycle life and safety of lithium-ion batteries by minimizing electrolyte decomposition and maintaining high energy storage capacity.

Implementation Method 1

Applying a continuous polymer coating to the electrochemically active electrode material

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

a metal catalyst for electroless deposition (ELD)

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 3

metal catalyst for electroless deposition (ELD), resulting in a thin, uniform, and continuous metal coating

Methodology Applied

Scientific EffectElectroless deposition: Deposition (physical)

Data Source

PatentUS11682758B2Process for metallization of electrochemically active powders

Publication Date: 2023.06.20 A123 SYSTEMS LLC

AI summary

Materials and methods for coating an electrochemically active electrode material for use in a lithium-ion battery are provided. In one example, an electrochemically active electrode material comprises: a polymer coating applied directly to an exterior surface of the electrochemically active electrode material; a metal plating catalyst adhered to the continuous polymer; and a continuous metal coating that completely covers the metal catalyst and continuous polymer coating. The electrochemically active electrode material may comprise a powder comprising one or more secondary particles, and the polymer and metal coatings may be applied to exterior surfaces of these secondary particles.