Silicon Negative Electrode with Conductive Carbon Layer

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Solution Overview

Problem

Conventional lithium secondary batteries face challenges with low energy density due to graphite negative electrodes and structural safety issues with high nickel-based positive electrodes, particularly during high-rate charging, leading to increased resistance and reduced battery life.

Innovation Solution

A negative electrode with a conductive carbon layer on a current collector and a silicon-based active material layer, along with a positive electrode using a nickel-based active material coated with a conductive layer, to enhance adhesive strength and reduce interfacial resistance, thereby improving fast charging performance and structural stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If a Si-based material is used as negative electrode active material to increase theoretical capacity, then energy density is improved, but volume expansion occurs during charge and discharge leading to deteriorated battery life characteristics

Engineering Contradiction:
Improvetheoretical capacityVSAvoidbattery life characteristics
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The Si-based active material particles are embedded within a porous carbon matrix structure, creating a nested configuration where the carbon matrix surrounds and contains the Si particles. This nested structure allows the Si particles to expand and contract during charge-discharge cycles while being constrained by the carbon matrix, preventing volume expansion issues and maintaining battery life characteristics while preserving high theoretical capacity.

Inventive Principle:
Principle #7Nested doll (Nesting)

Solution Approach 2:

The negative electrode is constructed as a composite material system combining Si-based active material with porous carbon matrix and conductive carbon material. This composite structure integrates the high capacity advantage of Si with the structural stability and conductivity of carbon materials, resolving the contradiction between high theoretical capacity and battery life by synergistically combining different materials with complementary properties.

Inventive Principle:
Principle #40Composite materials

2Reliability

If a conductive layer coated with conductive carbon material is applied on current collector and active material layer is applied on the conductive layer, then adhesive strength and resistance properties are improved, but device complexity increases

Engineering Contradiction:
Improveadhesive strength and resistance propertiesVSAvoiddevice complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The conductive carbon material serves multiple functions simultaneously: it acts as part of the active material layer, provides conductivity enhancement, improves adhesive strength between layers, and reduces interfacial resistance. By merging these multiple functions into a single material component, the structure achieves improved reliability without proportionally increasing device complexity.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The conductive carbon material exhibits multi-functionality by simultaneously providing electrical conductivity, mechanical adhesion, and electrochemical activity. This universal material performs multiple roles that would otherwise require separate components, thereby improving adhesive strength and resistance properties while minimizing the increase in device complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Quantity of substance

If high nickel-based oxide is used as positive electrode active material to increase capacity, then energy density is improved, but structural safety is reduced and resistance increases during high-rate charging

Engineering Contradiction:
ImprovecapacityVSAvoidstructural safety
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The positive electrode structure is designed with local quality variations, including a surface-modified layer with different composition or structure from the bulk high-nickel oxide material. This local modification at the surface or interface regions enhances structural stability and reduces resistance during high-rate charging, while the bulk material maintains high capacity, thus resolving the contradiction between capacity and structural safety.

Inventive Principle:
Principle #3Local quality

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 solution effectively maintains contact between the current collector and active material layers during expansion and contraction, reducing electrical resistance and minimizing swelling, which results in improved energy density, extended battery life, and enhanced fast charging capabilities.

Implementation Method 1

a first coating layer including a point-type conductive material and a binder, formed on the current collector

Methodology Applied
Scientific EffectAdhesion: Adhesive

Implementation Method 2

a second coating layer including a silicon-based active material, formed on the first coating layer

Methodology Applied
Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

the Si-based material as such has a disadvantage of deteriorated battery life characteristics due to large volume expansion (∼400%) in the course of repeated charge and discharge

Methodology Applied
Scientific EffectVolume expansion: Thermal Expansion

Data Source

PatentUS20220328827A1Negative Electrode for Secondary Battery and Secondary Battery Including the Same
Publication Date: 2022.10.13 SK ON CO LTD
  • US20220328827A1 patent drawing
  • US20220328827A1 patent drawing
  • US20220328827A1 patent drawing

AI summary

Provided are a negative electrode for a secondary battery including: a current collector; a first coating layer including a point-type conductive material and a binder, formed on the current collector; and a second coating layer including a silicon-based active material, formed on the first coating layer, and a lithium secondary battery including the same.