Coating Uniformity Methods for EV Batteries

A simple and efficient method to coat electrode materials for lithium-ion batteries to improve stability and cycle life. The method involves mixing the electrode material with a coating precursor like dicyandiamide or PVDF in a solvent, ball milling it, and then sintering to form a uniform coating layer on the electrode surface. This coating provides a stable interface and suppresses electrode reactions with the electrolyte to enhance battery performance.

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Battery design to improve energy density, safety, and flatness without increasing cell size. The battery has electrode sheets stacked inside a case. The positive electrode sheet size is increased compared to the negative sheet. This reduces the coverage margin of the negative sheet beyond the positive edge. The positive coating thickness is increased while keeping insulator thickness constant. This improves positive active material coverage. The second (negative) coating covers the first (positive) coating projection in thickness direction. The second coating edge is within the insulator. This prevents lithium precipitation at edges. The reduced edge thickness difference improves surface flatness.

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Method for manufacturing anode for lithium secondary battery that allows polymer deposition even inside the anode mixture layer to prevent cracking and improve durability. The anode is formed by applying a lithium composite transition metal oxide slurry on a current collector, then polymer coating using iCVD at substrate temperatures above 100°C. This allows uniform polymer distribution inside the anode's lower porosity compared to other electrodes.

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Electrode design for lithium-ion batteries that prevents short circuits and improves battery life. The electrode has a coating at the edge that contacts the side surface of the electrode portion and extends to contact the insulating layer. This coating prevents short circuits if the electrode deforms during battery assembly. It also minimizes side reactions between the electrode and electrolyte, reducing capacity loss. The coating has a first region contacting the electrode edge and a second region extending onto the insulating layer. The coating thicknesses and compositions are optimized for insulation, adhesion, and heat resistance.

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Lithium-ion battery with improved safety and energy density. The battery has a modified positive electrode plate with a safety primer coating on the current collector. This coating reduces short circuiting between the negative electrode and the aluminum current collector. The electrolyte composition is optimized to improve wetting, capacity retention, and coating density. The electrolyte contains propyl propionate and fluorobenzene. This allows better uniform electrolyte penetration and reduces impedance compared to conventional electrolytes. The coating composition and electrolyte formulation balance improves safety, wetting, and capacity retention while maintaining energy density.

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A method for producing battery electrodes that reduces layer thickness variation and prevents cracking during drying. The method involves coating the current collector with a viscous raw layer containing an activated adhesive starting component. This component is stabilized to form an adhesive before drying. The adhesive stabilizes the raw layer locally to prevent material flow and thickness variations during drying. This prevents cracking and ensures consistent electrode thickness. The activated adhesive can be a monomer that polymerizes into a long-chain adhesive during stabilization.

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Method for manufacturing battery electrodes with improved flatness and reduced thickness variation of the active material layer. The key is coating the electrode slurry at a speed that exceeds the yield point of the slurry. The slurry has specific flow properties with a region where shear stress is constant and a region where shear stress increases with speed but at decreasing rate. Coating at speeds exceeding the yield point prevents sagging and improves layer uniformity.

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Battery pole piece design and manufacturing method to improve battery performance by enabling better electrolyte flow, preventing electrolyte channel clogging, and reducing expansion issues. The pole piece has a coated region with higher coating density compared to an uncoated region. This creates a channel for electrolyte diversion through the coating-free area. The channel allows electrolyte to bypass thicker regions and flow around the pole piece during expansion, preventing electrolyte trapping and channel clogging. The coating density difference and channel design improve battery performance by enabling better electrolyte flow, preventing electrolyte channel clogging, and reducing expansion issues.

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Battery design to improve initial efficiency and prevent lithium precipitation at circular arc regions. The battery has a pole piece or separator partitioned into planar and arc areas. In the planar regions, a coating with a higher lithium supplementing agent content is used. This improves initial battery efficiency. In the arc regions, the lithium supplementing agent content is lower to prevent lithium precipitation.

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Electrochemical devices like batteries with improved flatness, liquid retention, and safety. The devices have an electrode assembly with a composite layer on the current collector. This composite layer has a functional layer between the collector and insulating layer. The functional layer absorbs electrolyte and prevents uneven electrolyte distribution. The insulating layer prevents internal shorts. The functional layer thickness is 1-20x the insulating layer thickness to balance liquid retention and flatness vs safety. This configuration improves device appearance, reduces energy density loss, and prevents internal shorts.

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Electrode design and assembly for lithium-ion batteries that improves safety, thermal stability, and performance. The electrode has a current collector, electrode mixture layer, and functional coating on the other side. The coating can include a heat resistance layer and/or a conductive layer with higher conductivity than the collector. The outermost electrode can also have improved conductivity. The coating and outermost electrode enhance safety by reducing thermal runaway propagation and improving stability from fire and heat. The higher conductivity electrodes also improve battery performance.

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A method to produce electrode mixtures for lithium-ion batteries that prevents granulation of the active material during coating. The method involves using a coating liquid containing both lithium and niobium precursors. This results in a coating layer on the active material particles containing lithium niobate. By also adding niobium-containing particles, granulation of the active material is suppressed during coating. The niobium particles don't contain the active material, but instead have substances similar to the coating layer. This allows forming the coated particles with the desired lithium niobate coating without excessive granulation.

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A preparation method for cathode material for lithium-ion batteries with uniform and conductive coating layers that improves cycle life and capacity retention. The method involves steps like mixing precursor powder, primary sintering, coating with modified binder, and secondary calcination. The binder is treated to optimize coating properties. The precursor powder is prepared by complex co-precipitation to form NCM313 particles. The coating agent is applied at a specific concentration. The modified binder treatment improves coating uniformity and conductivity compared to standard binder. The secondary calcination step refines the particles and coating. This results in cathode material with uniform coating layers, better conductivity, and improved cycle life and capacity retention.

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Battery design with a specialized pole piece and coating configuration to improve battery performance and longevity, especially in cylindrical lithium-ion batteries. The pole piece has a unique coating profile where the mass per area of the positive electrode coating increases progressively along the pole piece length, while the negative electrode coating decreases. This compensates for the inherent difference in coating mass between inner and outer pole piece segments during winding. This keeps the positive/negative coating ratio stable throughout the battery construction to prevent issues like local lithium precipitation, improve charging, cycle life, and safety.

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Electrochemical cell with improved energy density compared to conventional cells. The cell has a wound pole piece design with an active material layer on each surface. The active material layer on one side has an extended edge coating that overlaps and adjoins the main coating. This reduces expansion and thinning of the active material at the edge during cycling. The extended edge coating also helps prevent shrinkage at the ends of the pole piece. This increases the thickness of the active material at the edges, which improves energy density.

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Electrode pole piece for lithium-ion batteries that improves charge transfer efficiency and cycle life. The pole piece has two coatings with lower OI (intercalation) value for the second coating compared to the first. This avoids excessive thickness increase and charge transfer path lengthening from thick coatings. The lower OI second coating helps reduce charge transfer resistance. The ratio of OI values (OI1/OI2) should be between 1.1 and 2.0.

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Coating battery electrodes with artificial solid electrolyte interfaces (SEI) to improve safety and thermal stability of batteries. The artificial SEI is formed by a liquid phase deposition process that involves exposing the electrode to reactant solutions in chambers and rinsing between chambers. The coating provides protective barrier on electrode surfaces to prevent exothermic reactions, reduce gas evolution, and raise thermal runaway onset temperatures compared to uncoated electrodes.

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Partially coating lithium-ion battery cathode active materials with a thin layer of acidic alumina to reduce resistance build-up during cycling. The process involves reacting the active material with a zirconium alkoxide or amide to form a precursor. This precursor is then mixed with water and the active material to coat the particles. The coated material is dried and further mixed to homogenize the coating. The coating provides a protective barrier on the active material surface that prevents unwanted reactions during cycling, reducing resistance and improving cycle life.

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A lithium battery preparation process that improves battery performance by inhibiting electrolyte decomposition on the positive electrode. The process involves coating a primary active material layer on a foil substrate, then coating a secondary layer containing a ternary material on top. This reduces the contact area between the primary layer and electrolyte, preventing electrolyte decomposition on the primary layer. The multi-layer positive electrode improves high-temperature stability and cycle life compared to a single layer.

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A production process for new energy batteries that improves battery quality and reduces issues like electrode thickness variation, sealing problems, and electrolyte leakage. The process involves using specific materials and steps for each battery component. The positive electrode is made by coating the active material onto aluminum foil. The negative electrode uses cladding on copper sheets. The electrolyte is a mixed solvent with ammonium salt or lithium salt. The diaphragm is a microporous membrane. This combination helps ensure consistent electrode thickness, better sealing, and prevent electrolyte leakage in the battery.

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