Nickel-Rich Cathode Particles Inlaid With Nano-Particles for Thermal Stability

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Nickel-rich cathode active materials in battery cells are thermally unstable, decomposing below 300°C and generating molecular oxygen, which increases the risk of thermal runaway.

Innovation Solution

Mechanically inlaying thermally stable nano-particles, such as LMFP, on the outer surfaces of nickel-rich cathode active material particles to enhance thermal stability, while also applying a carbon coating layer for additional stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If nickel-rich cathode active material is used to increase capacity, then battery capacity is improved, but thermal stability deteriorates causing decomposition below 300°C and oxygen generation

Engineering Contradiction:

Improvebattery capacityVSAvoidthermal stability

Core Design Contradiction:

Quantity of substanceVSStability of the object's composition

Solution Approach 1:

Thermally stable nano-particles (olivine or spinel type) are embedded within the nickel-rich cathode active material particles, creating a core-shell structure where the stable particles are nested inside the capacity-providing nickel-rich material, thus maintaining thermal stability while preserving high capacity

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The cathode active material is formulated as a composite containing both nickel-rich material (for capacity) and thermally stable olivine or spinel type particles (for stability), creating a multi-component system that simultaneously achieves high capacity and thermal stability

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If nickel-rich cathode active material is used to increase capacity, then battery capacity is improved, but safety deteriorates due to increased risk of thermal runaway

Engineering Contradiction:

Improvebattery capacityVSAvoidsafety

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

Thermally stable nano-particles are incorporated into the nickel-rich cathode active material before battery operation, providing a protective buffer that prevents thermal runaway by stabilizing the material structure and preventing oxygen release at elevated temperatures

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The thermally stable olivine or spinel type particles act as intermediary structures between the nickel-rich cathode material and the electrolyte, mediating thermal interactions and preventing direct harmful reactions that would lead to thermal runaway

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If carbon coating layer is applied to enhance stability, then thermal stability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal stabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The carbon coating layer is applied in advance during the cathode material preparation process, before electrode fabrication, integrating the coating step into the existing manufacturing workflow and minimizing additional process complexity

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250158039A1Nickel-rich cathode materials with inlaid thermally-stable nano-particles

Publication Date: 2025.05.15 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A cathode electrode includes a cathode current collector and a cathode active material layer comprising a plurality of cathode active material particles including nickel and a plurality of nano-particles that are mechanically inlaid on outer surfaces of the plurality of cathode active material particles to form a plurality of inlaid cathode active material particles.