Silicon Anode Lithium-Ion Battery Manufacturing with Stabilized Particles

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Solution Overview

Problem

Lithium-ion batteries with silicon anodes face challenges such as poor cycle performance and safety concerns due to volumetric expansion and limited high-temperature operation, which hinder their full energy density potential.

Innovation Solution

The manufacturing method involves forming a silicon-containing anode with stabilized lithium metal particles and a specific cathode material, coupled with a separator, and packaging in a rolled structure with an electrolyte, optimizing the silicon weight percentage and binder materials to enhance cycle life and high-temperature performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If silicon anode material is used to increase energy density, then gravimetric energy density is improved, but volumetric expansion occurs causing poor cycle performance

Engineering Contradiction:

Improvegravimetric energy densityVSAvoidcycle performance

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The patent changes the physical and chemical parameters of the silicon anode by reducing particle size to nanoscale (5-50 nm), controlling silicon content (1-30 wt%), and adjusting binder ratios. These parameter changes reduce volumetric expansion effects while maintaining high energy density, resolving the contradiction between energy density improvement and cycle performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates composite anode structures combining silicon particles with carbon materials (graphite, amorphous carbon) and polymer binders. This composite approach maintains the high capacity benefit of silicon while the carbon matrix and binder provide structural stability during cycling, solving the cycle performance issue

Inventive Principle:

Principle #40Composite materials

2Use of energy by moving object

If silicon anode material is used to increase energy density, then gravimetric energy density is improved, but safety concerns arise at high temperatures

Engineering Contradiction:

Improvegravimetric energy densityVSAvoidhigh temperature safety

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent introduces polymer binders (carboxymethyl cellulose, styrene-butadiene rubber) and carbon materials as intermediary substances between silicon particles and the electrolyte. These intermediaries form stable protective interfaces that prevent direct contact between silicon and electrolyte at high temperatures, eliminating safety hazards while preserving energy density benefits

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The carbon-coated silicon particles create an inert protective environment around the reactive silicon, preventing unwanted side reactions with the electrolyte and binder at elevated temperatures. This inert barrier maintains safety while allowing the high-capacity silicon to function

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Reliability

If conventional lithium-ion battery materials are used, then safety and stability are maintained, but energy density is limited

Engineering Contradiction:

Improvesafety and stabilityVSAvoidenergy density

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent applies local quality optimization by using conventional stable materials (carbon binders, polymer coatings, aluminum foil current collectors) at the interfaces and surfaces, while placing high-capacity silicon in the bulk anode structure. This local differentiation maintains safety and stability at critical interfaces while maximizing energy density in the active material region

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10424779B1Lithium-ion cells and methods of manufacture

Publication Date: 2019.09.24 GOOGLE LLC

AI summary

The present disclosure relates to lithium-ion batteries and methods for their manufacture. Specifically, the method includes forming a cathode on a first substrate and forming an anode on a second substrate. The anode material includes silicon. The method includes slitting the first substrate and the second substrate. After slitting the respective substrates, the method includes depositing stabilized lithium metal particles on the anode and forming a cathode electrode tab coupled to the cathode and an anode electrode tab coupled to the anode. The method also includes coupling the anode and the cathode to form a layered structure. The method further includes winding the layered structure to form a rolled structure and placing the rolled structure in a container. The method additionally includes placing an electrolyte in the container sealing the container with the rolled structure and electrolyte placed therein to form a battery.