Positive electrode for non-aqueous electrolyte, rechargeable battery, and non-aqueous electrolyte rechargeable battery

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Solution Overview

Problem

Conventional intermediate layers in non-aqueous electrolyte rechargeable batteries, such as those used in lithium ion batteries, are insufficient in effectively reducing or suppressing short-circuits caused by foreign objects piercing the positive electrode, leading to potential safety hazards due to high Joule heating.

Innovation Solution

Incorporating an intermediate layer between the positive electrode current collector and the positive electrode mixture layer, composed of first particles made of boron nitride with an aspect ratio of 3.0 to 30 and second particles comprising metal hydroxides and metal oxides with a flame retardant component, which together capture active oxygen and suppress decomposition reactions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an intermediate layer is installed between the positive electrode current collector and the positive electrode mixture layer, then the exposure of the positive electrode current collector is reduced when pierced by foreign substances, but the conventional intermediate layer materials (metal oxide particles and solid electrolyte particles) provide insufficient short-circuit reduction effect

Engineering Contradiction:

Improveshort-circuit reduction effectVSAvoidexposure of positive electrode current collector

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent uses a composite intermediate layer consisting of boron nitride particles (insulating material) and aluminum hydroxide particles (flame retardant material). This composite structure combines the electrical insulation properties of boron nitride with the flame retardant and oxygen-capturing capabilities of aluminum hydroxide, achieving superior short-circuit prevention and thermal safety compared to conventional single-material intermediate layers.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent specifies precise particle size parameters for the intermediate layer materials: boron nitride particles with D50 of 0.01-8 μm and aluminum hydroxide particles with D50 of 0.01-8 μm. By optimizing these particle size parameters, the intermediate layer achieves better filling density, improved adhesion to the current collector, and enhanced effectiveness in preventing foreign object penetration while maintaining electrical insulation.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If the positive electrode mixture layer is peeled off from the positive electrode current collector due to deformation, then sharp foreign substances may pierce the battery and cause short-circuit, but conventional intermediate layers do not sufficiently suppress this exposure

Engineering Contradiction:

Improveprotection against foreign substance piercingVSAvoidJoule heating from short-circuit

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The intermediate layer acts as an intermediary barrier between the positive electrode current collector and foreign substances. The boron nitride particles provide electrical insulation to prevent current flow, while the aluminum hydroxide particles provide mechanical cushioning and flame retardancy. This intermediary layer effectively blocks the harmful effects of foreign object piercing, including short-circuit current flow and subsequent Joule heating.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent converts the potential harmful effect of foreign object piercing into a beneficial protective mechanism. When a foreign object pierces the battery, the intermediate layer undergoes controlled deformation and potential decomposition of aluminum hydroxide (releasing water vapor), which creates a physical and chemical barrier that prevents direct contact between the current collector and foreign substance, thereby converting the harmful piercing event into a protected state.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 proposed configuration significantly reduces the exposure of the positive electrode current collector, minimizing temperature rise and enhancing safety by capturing active oxygen and suppressing endothermic reactions, thereby improving battery safety.

Implementation Method 1

the first particles include boron nitride and has insulating properties... capturing active oxygen and suppressing decomposition reactions

Methodology Applied

Scientific EffectOxygen capture: Absorption (physical)

Implementation Method 2

the second particles include at least one of a metal hydroxide and a metal oxide... suppressing endothermic reactions

Methodology Applied

Scientific EffectEndothermic reaction: Endothermic Reaction

Implementation Method 3

a flame retardant component... capturing active oxygen and suppressing decomposition reactions

Methodology Applied

Scientific EffectFlame retardation:

Data Source

PatentUS20260058163A1Positive electrode for non-aqueous electrolyte, rechargeable battery, and non-aqueous electrolyte rechargeable battery

Publication Date: 2026.02.26 SAMSUNG SDI CO LTD

AI summary

The present disclosure improves a short-circuit reduction or suppression effect of a non-aqueous electrolyte rechargeable battery more effectively by reducing or suppressing exposure of a positive electrode current collector when pierced by a foreign substance such as a nail. Example embodiments include a positive electrode for a non-aqueous electrolyte rechargeable battery including a positive electrode current collector, a positive electrode mixture layer, an intermediate layer between the positive electrode current collector and the positive electrode mixture layer.