This technology features a multi-layer lithium-ion battery electrode created by sequentially casting a primary active material layer of lithium nickel cobalt manganese oxide (NCM) and a secondary active material layer of lithium iron phosphate (LiFePO4) onto an aluminum or copper current collector. The top LiFePO4 layer, which interfaces with the electrolyte, serves as both an active material and a protective layer for the underlying NCM layer.
When electrodes are thickened to achieve high energy density, degradation typically begins at the electrode/electrolyte interface furthest from the current collector, leading to reduced power and lifespan. To prevent this, inert materials like Al2O3 have been used to coat active material particles; however, this approach makes it difficult to create a thick protective layer and reduces energy density due to the increase in inactive components.
Instead of particle-level coating, this technology designs the electrode structure itself as a multi-layer of heterogeneous active materials. By maintaining a total thickness of 30–40㎛ and a 5:3 thickness ratio, it forms a protective layer significantly thicker than conventional inert coatings. This facilitates easier interface control and enhances active material durability while minimizing energy density loss. Applicable to portable electronics, electric vehicles, and energy storage systems for power equipment, this method allows for increased battery lifespan while utilizing existing slurry casting equipment.
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