Patent Description:
In recent years, with the increasingly broader application range of lithium-ion batteries, the lithium-ion batteries are extensively applied to an energy storage power supply system such as a water power station, a firepower station, a wind power station, a solar power station, as well as a plurality of fields, e.g., a power tool, an electric bicycle, an electric motorcycle, an electric vehicle, military equipment, aerospace. Among various battery types, lithium iron phosphate batteries draw people's attention due to large capacity and good safety performance thereof. However, with the popularity of secondary batteries, people have increasingly higher requirements for dynamic performance and cycle performance of the lithium iron phosphate batteries. Therefore, it is still an urgent problem for those skilled in the art to develop a lithium iron phosphate battery having good dynamic and cycle performances. Among the prior art, <CIT> provides a lithium iron phosphate positive pole piece and a preparation method and application thereof. Moreover, <CIT> discloses a positive electrode material comprising lithium iron phosphate single crystal particles and lithium iron phosphate secondary particles.

In view of the above project, the present disclosure aims to provide a lithium iron phosphate positive electrode plate, a secondary battery related to the lithium iron phosphate positive electrode plate, a battery module, a battery pack, and an electric device. The secondary battery using the positive electrode plate has good dynamic performance and cycle performance.

A first aspect of the present disclosure provides a lithium iron phosphate positive electrode plate according to claim <NUM>. The lithium iron phosphate positive electrode plate includes a positive electrode current collector, and a positive electrode active material located on the positive electrode current collector. The positive electrode active material includes: first lithium iron phosphate particles having a volume average diameter D50 of <NUM> to <NUM>, optionally <NUM> to <NUM>, and a specific surface area greater than <NUM><NUM>/g, optionally <NUM><NUM>/g to <NUM><NUM>/g; and second lithium iron phosphate particles having a volume average diameter D50 greater than <NUM>, optionally <NUM> to <NUM>, and a specific surface area smaller than <NUM><NUM>/g, optionally <NUM><NUM>/g to <NUM><NUM>/g, and asecond lithium iron phosphate particle layer is disposed on a surface of the positive electrode current collector, and a first lithium iron phosphate particle layer is disposed on a surface, opposite to the positive electrode current collector, of the second lithium iron phosphate particle layer.

The positive electrode plate according to the first aspect of the present disclosure includes two types of lithium iron phosphate particles having different particle diameters and specific surface areas, which can fully exert their respective advantages, thereby improving the dynamic performance and cycle performance of the secondary battery using the positive electrode plate.

In any embodiment, optionally, a content of the first lithium iron phosphate particles ranges from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, and further optionally from <NUM>% to <NUM>%, based on a total weight of a positive electrode film layer in the lithium iron positive electrode plate; and a content of the second lithium iron phosphate particles ranges from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, and further optionally from <NUM>% to <NUM>%, based on the total weight of the positive electrode film layer in the lithium iron phosphate positive electrode plate.

When the contents of the two types of the lithium iron phosphate particles are within the above-mentioned ranges, the secondary battery prepared with the positive electrode plate according to the first aspect of the present disclosure has good dynamic performance and cycle performance.

In any embodiment, optionally, in an active substance layer of the lithium iron phosphate positive electrode plate, a weight ratio of the first lithium iron phosphate particles to the second lithium iron phosphate particles is <NUM>: <NUM> to <NUM>, optionally <NUM>: <NUM> to <NUM>, and further optionally <NUM>: <NUM> to <NUM>.

By adjusting the weight ratio of the first lithium iron phosphate particles to the second lithium iron phosphate particles, the dynamic performance and cycle performance of the corresponding battery can be further improved.

In any embodiment, optionally, a carbon content of the first lithium iron phosphate particles ranges from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, and further optionally from <NUM>% to <NUM>%, based on a total weight of the first lithium iron phosphate particles; and a carbon content of the second lithium iron phosphate particles ranges from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, and further optionally from <NUM>% to <NUM>%, based on a total weight of the second lithium iron phosphate particles.

When the carbon contents of the two types of the lithium iron phosphate particles are within the above-mentioned ranges, the performances of the corresponding secondary battery can be further improved.

In any embodiment, optionally, a positive electrode film layer in the lithium iron phosphate positive electrode plate has a compacted density of <NUM>/cm<NUM> to <NUM>/cm<NUM>, optionally <NUM>/cm<NUM> to <NUM>/cm<NUM>, and further optionally <NUM>/cm<NUM> to <NUM>/cm<NUM>.

According to the invention, the first lithium iron phosphate particles and the second lithium iron phosphate particles are distributed in layers in an active substance layer in the lithium iron phosphate positive electrode plate.

According to the invention, a second lithium iron phosphate particle layer comprising the second lithium iron phosphate particles is disposed on a surface of the positive electrode current collector, and a first lithium iron phosphate particle layer comprising the first lithium iron phosphate particles is disposed on a surface, opposite to the positive electrode current collector, of the second lithium iron phosphate particle layer.

By adjusting the distribution of the first lithium iron phosphate particle layer and the second lithium iron phosphate layer, especially when the second lithium iron phosphate particle layer is disposed on the surface of the current collector and when the first lithium iron phosphate particle layer is disposed on an upper portion of the second lithium iron phosphate particle layer, the dynamic performance and cycle performance of the corresponding secondary battery can be further improved.

In any embodiment, optionally, the first lithium iron phosphate particle layer has a thickness of <NUM> to <NUM>, optionally <NUM> to <NUM>, and further optionally <NUM> to <NUM>; and the second lithium iron phosphate particle layer has a thickness of <NUM> to <NUM>, optionally <NUM> to <NUM>, and further optionally <NUM> to <NUM>.

When the thickness of each lithium iron phosphate particle layer is within the above-mentioned range, on the one hand, the cycle performance of the secondary battery can be improved; and on the other hand, the dynamic performance of the secondary battery can be prevented from deteriorating due to an excessively great thickness of the respective layers.

In any embodiment, optionally, a thickness ratio of the first lithium iron phosphate particle layer to the second lithium iron phosphate particle layer is <NUM>: <NUM> to <NUM>, optionally <NUM>: <NUM> to <NUM>, and further optionally <NUM>: <NUM> to <NUM>.

When the thickness ratio of the first lithium iron phosphate particle layer to the second lithium iron phosphate particle layer is within the above-mentioned range, the dynamic performance and cycle performance of the corresponding secondary battery can be further improved.

In any embodiment, optionally, the first lithium iron phosphate particle layer has a surface density of <NUM> to <NUM>/<NUM><NUM>, optionally <NUM> to <NUM>/<NUM><NUM>, and further optionally <NUM> to <NUM>/<NUM><NUM>; and the second lithium iron phosphate particle layer has a surface density of <NUM> to <NUM>/<NUM><NUM>, optionally <NUM> to <NUM>/<NUM><NUM>, and further optionally <NUM> to <NUM>/<NUM><NUM>.

A second aspect of the present disclosure provides a secondary battery. The secondary battery includes the lithium iron phosphate positive electrode plate according to the first aspect of the present disclosure. The secondary battery can be prepared by a common method in the art.

A third aspect of the present disclosure provides a battery module. The battery module includes the secondary battery according to the second aspect of the present disclosure. The battery module can be prepared by a common method in the art.

A fourth aspect of the present disclosure provides a battery pack. The battery pack includes the battery module according to the third aspect of the present disclosure. The battery module can be prepared by a common method in the art.

A fifth aspect of the present disclosure provides an electrical device. The electrical device includes at least one of the secondary battery according to the second aspect of the present disclosure, the battery module according to the third aspect of the present disclosure, or the battery pack according to fourth aspect of the present disclosure. The electrical device can be prepared by a common method in the art.

In the lithium iron phosphate positive electrode plate according to the present disclosure, the first lithium iron phosphate particles having the volume average particle diameter D50 of <NUM> to <NUM> and the specific surface area greater than <NUM><NUM>/g, as well as the second lithium iron phosphate particles having the volume average particle diameter D50 greater than <NUM> and the specific surface area smaller than <NUM><NUM>/g are included. On the one hand, the respective advantages of the first lithium iron phosphate particles and the second lithium iron phosphate particles can be fully exerted, thereby improving the dynamic performance and cycle performance of the secondary battery including the positive electrode plate. On the other hand, in the present disclosure, the lithium iron phosphate particles are distinguished based on the specific surface area, thereby avoiding the failure of distinguishing based on a single parameter of the particle diameter, which may be caused by easy agglomeration of the first lithium iron phosphate particles.

According to the present disclosure, the battery module, the battery pack, and the electric device include the secondary battery provided by the present disclosure, and thus they at least have the same advantages as those of the secondary battery.

<NUM> battery pack; <NUM> upper box body; <NUM> lower box body; <NUM> battery module; <NUM> secondary battery; <NUM> housing; <NUM> electrode assembly; <NUM> top cover assembly.

Hereinafter, embodiments of a lithium iron phosphate positive electrode plate, a preparation method thereof, a secondary battery, a battery module, a battery pack, and an electrical device according to the present disclosure are described in detail and specifically explained with reference to the accompanying drawings as appropriate. However, unnecessary detailed illustrations may be omitted in some instances. For example, detailed description of well-known items and repeated description of actually identical structures may be omitted in some instances, in order to avoid the following description being unnecessarily redundant, facilitating understanding by those skilled in the art. Moreover, the accompanying drawings and the following description are provided for enabling those skilled in the art to fully understand the present disclosure, rather than limiting the subject matters recited in claims.

The "ranges" disclosed in the present disclosure are defined in the form of lower and upper limits. A given range is defined by selection of a lower limit and an upper limit, and the selected lower and upper limits defining the boundaries of the particular range. The ranges defined in such a manner may be inclusive or exclusive, and may be arbitrarily combined. That is, any lower limit may be combined with any upper limit to form a range. For example, if the ranges of <NUM>-<NUM> and <NUM>-<NUM> are specified for a particular parameter, it should be understood that the ranges of <NUM>-<NUM> and <NUM>-<NUM> can also be expected. Additionally, if the minimum range values <NUM> and <NUM> and the maximum range values <NUM>, <NUM>, and <NUM> are specified, the following ranges can be expected: <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM>. In the present disclosure, unless stated otherwise, the numerical range "a-b" denotes an abbreviated representation of any combination of real numbers between a and b, where both a and b are real numbers. For example, the numerical range "<NUM>-<NUM>" means that all real numbers between "<NUM>-<NUM>" have been listed herein, and "<NUM>-<NUM>" is just an abbreviated representation of combinations of these numerical values. In addition, when a parameter is expressed as an integer of ≥ <NUM>, it is equivalent to disclose that the parameter is, for example, an integer of <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, etc..

All technical features and optional technical features of the present disclosure can be combined with one another to form a new technical solution, unless otherwise stated.

Unless otherwise stated, all the steps of the present disclosure can be performed sequentially or randomly, preferably sequentially. For example, the method including steps (a) and (b) indicates that the method may include steps (a) and (b) performed sequentially, or the method may include steps (b) and (a) performed sequentially. For example, reference to "the method may further include step (c)" indicates that step (c) may be added to the method in any order, e.g., the method may include steps (a), (b) and (c), or steps (a), (c) and (b), or steps (c), (a) and (b), etc..

The terms "comprise", "contain", and "include" mentioned in the present disclosure are open-ended or closed-ended, unless otherwise stated. For example, the terms "comprise", "contain", and "include" may mean that other components not listed may also be comprised or included, or only the listed components may be comprised or included.

The phrases "above a number" and "below a number" the present disclosure include the present number, unless otherwise stated.

In the present disclosure, the term "or" is inclusive unless otherwise stated. For example, the phrase "A or B" means "A, B, or both A and B". More specifically, a condition "A or B" is satisfied by any one of the following: A is true (or present) and B is false (or not present); A is false (or not present) and B is true (or present); or both A and B are true (or present).

It is surprisingly found that the dynamic performance and cycle performance of the corresponding secondary battery can be effectively improved by using the lithium iron phosphate particles having different particle diameters in combination. In addition, the lithium iron phosphate particles are distinguished based on the particle diameter and the specific surface area, thereby avoiding the failure of distinguishing based on a single parameter of the particle diameter, which may be caused by easy agglomeration of the first lithium iron phosphate particles.

Further, it is found that the dynamic performance and cycle performance of the corresponding secondary battery can be further improved by changing the carbon content of the first and second lithium iron phosphate particles, by adjusting the weight ratio of the lithium iron phosphate particles, and further by coating the different lithium iron phosphate particles in different layers and adjusting the thickness of each layer.

A first aspect of the present disclosure provides a lithium iron phosphate positive electrode plate. The lithium iron phosphate positive electrode plate includes a positive electrode current collector, and a positive electrode active material located on the positive electrode current collector. The positive electrode active material includes: first lithium iron phosphate particles having a volume average diameter D50 of <NUM> to <NUM>, optionally <NUM> to <NUM>, and a specific surface area greater than <NUM><NUM>/g, optionally <NUM><NUM>/g to <NUM><NUM>/g; and second lithium iron phosphate particles having a volume average diameter D50 greater than <NUM>, optionally <NUM> to <NUM>, and a specific surface area smaller than <NUM><NUM>/g, optionally <NUM><NUM>/g to <NUM><NUM>/g.

The positive electrode plate according to the present disclosure includes the first lithium iron phosphate particles and the second lithium iron phosphate particles. Thus, the advantages of the first lithium iron phosphate particles such as small direct current resistance and good dynamic performance, as well as the advantages of the second lithium iron phosphate particles such as great pressure density and less tendency of gelling can be fully exerted, thereby effectively improving the dynamic performance and cycle performance of the corresponding secondary battery. In addition, according to the present disclosure, the lithium iron phosphate particles are distinguished based on the specific surface area, thereby the failure of distinguishing based on a single parameter of the particle diameter, which may be caused by easy agglomeration of the first lithium iron phosphate particles.

As an example, the positive electrode plate according to the present disclosure includes the positive electrode current collector and the positive electrode active material. The positive electrode current collector has two surfaces opposite to each other in a thickness direction thereof. The positive electrode active material is disposed on any one of or both of the two opposite surfaces of the positive electrode current collector.

In the present disclosure, the volume average particle diameter D50 and the specific surface area may be measured by the common methods known in the art. For example, the particle diameter of D50 may be measured based on the standard GB/T <NUM>-<NUM>/ISO <NUM>: <NUM>, and the specific surface area may be measured based on the standard GB/T <NUM>-<NUM>, "Determination of Specific Surface Area of Solids by Gas Adsorption Using the BET Method".

In some embodiments, optionally, a content of the first lithium iron phosphate particles ranges from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, and further optionally from <NUM>% to <NUM>%, based on a total weight of a positive electrode film layer in the lithium iron positive electrode plate; and a content of the second lithium iron phosphate particles ranges from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, and further optionally from <NUM>% to <NUM>%, based on the total weight of the positive electrode film layer in the lithium iron phosphate positive electrode plate.

As an example, the content of the first lithium iron phosphate particles may be <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or <NUM>%; and the content of the second lithium iron phosphate particles may be <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or <NUM>%.

When the content of the first lithium iron phosphate particles is excessively high, more first lithium iron phosphate particles may be agglomerated, which is disadvantageous to the large-scale production and the improvement of an energy density. Similarly, when the content of the second lithium iron phosphate particles is excessively high, the dynamic performance of the battery may deteriorate, and thus a battery life may be shortened. When the contents of the two types of the lithium iron phosphate particles are within the above-mentioned ranges, the corresponding secondary battery has a lower direct current resistance and a longer service life.

In some embodiments, optionally, in an active substance layer of the lithium iron phosphate positive electrode plate, a weight ratio of the first lithium iron phosphate particles to the second lithium iron phosphate particles is <NUM>: <NUM> to <NUM>, optionally <NUM>: <NUM> to <NUM>, and further optionally <NUM>: <NUM> to <NUM>. For example, the weight ratio of the first lithium iron phosphate particles to the second lithium iron phosphate particles may be <NUM>: <NUM>, <NUM>: <NUM>, <NUM>: <NUM>, <NUM>: <NUM>, <NUM>: <NUM>, or <NUM>: <NUM>.

In some embodiments, optionally, a carbon content of the first lithium iron phosphate particles ranges from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, and further optionally from <NUM>% to <NUM>%, based on a total weight of the first lithium iron phosphate particles; and a carbon content of the second lithium iron phosphate particles ranges from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, and further optionally from <NUM>% to <NUM>%, based on a total weight of the second lithium iron phosphate particles.

When the carbon contents of the two types of the lithium iron phosphate particles are within the above-mentioned ranges, the performance of the corresponding secondary battery can be further improved.

In the present disclosure, the carbon content in the lithium iron phosphate particles can be measured by a common method in the art. For example, the carbon content in the lithium iron phosphate particles can be measured by means of an infrared absorption method. Specifically, the to-be-measured sample is combusted in an oxygen flow to generate CO<NUM>. Energy of infrared rays absorbed by CO<NUM> is proportional to the concentration of CO<NUM> under a certain pressure, and thus the carbon content can be calculated based on the measured energy change before and after the CO<NUM> gas flows through an infrared absorber.

In some embodiments, optionally, the first lithium iron phosphate particle powder has a tap density of <NUM> cm-<NUM> to <NUM> cm-<NUM>, optionally <NUM> cm-<NUM> to <NUM> cm-<NUM>, and further optionally <NUM> cm-<NUM> to <NUM> cm-<NUM>.

In some embodiments, optionally, the second lithium iron phosphate particle powder has a tap density of <NUM> cm-<NUM> to <NUM> cm-<NUM>, optionally <NUM> cm-<NUM> to <NUM> cm-<NUM>, and further optionally <NUM> cm-<NUM> to <NUM> cm-<NUM>.

It should be noted that the tap density of the lithium iron phosphate particle powder may be measured by a method commonly used by those skilled in the art, for example, may be measured based on standard GB/T <NUM>-<NUM>/ISO3953:<NUM>.

In some embodiments, optionally, the first lithium iron phosphate particle powder has a compacted density of <NUM>/cm<NUM> to <NUM>/cm<NUM>.

In some embodiments, optionally, the second lithium iron phosphate particle powder has a compacted density of <NUM>/cm<NUM> to <NUM>/cm<NUM>.

Similarly, the compacted density may be measured by a method commonly used by those skilled in the art. As an example, the compacted density may be measured by the following method: taking a certain amount of powder in a dedicated mold for compaction; placing the mold on a compacted density instrument; setting different pressures; reading thicknesses (the thicknesses after pressure relief) of the powder under different pressures from the instrument; and calculating the compacted density based on ρ=m/v.

In some embodiments, optionally, a positive electrode film layer in the lithium iron phosphate positive electrode plate has a compacted density of <NUM>/cm<NUM> to <NUM>/cm<NUM>, optionally <NUM>/cm<NUM> to <NUM>/cm<NUM>, and further optionally <NUM>/cm<NUM> to <NUM>/cm<NUM>. The compacted density of the positive electrode film layer can be measured by a common method in the art. As an example, the positive electrode plate of a unit area is taken to weigh its weight m1, and a weight m2 of a positive electrode foil material of a unit area is weighed, a weight of the positive electrode film layer is obtained by subtracting m2 from m1, and then the compacted density of the positive electrode film layer can be obtained by dividing the weight of the positive electrode film layer by a thickness of the positive electrode film layer (the thickness of the electrode plate minus the thickness of the foil material).

In some embodiments, optionally, the first lithium iron phosphate particles and the second lithium iron phosphate particles are distributed in layers in an active substance layer in the lithium iron phosphate positive electrode plate.

According to the invention, a second lithium iron phosphate particle layer is disposed on a surface of the positive electrode current collector; and a first lithium iron phosphate particle layer is disposed on a surface, opposite to the positive electrode current collector, of the second lithium iron phosphate particle layer.

It will be understood by those skilled in the art that a spatial structure design in terms of the electrode plate also has a significant effect on performance of a lithium secondary battery, especially the design of the electrode plate containing two or more active materials. The performance of the battery can be further improved through the spatial structure design of the electrode plate. Specifically, in the present disclosure, when the two types of the lithium iron phosphate particles are coated and distributed in layers, and particularly, when the second lithium iron phosphate particles are coated on the surface of the positive electrode current collector and the first lithium iron phosphate particles are coated on the surface of the second lithium iron phosphate particle layer to form a double-layer distribution structure, the two types of the lithium iron phosphate particles can more effectively exert their respective advantages, thereby improving the dynamic performance and cycle performance of the secondary battery.

In some embodiments, optionally, the first lithium iron phosphate particle layer has a thickness of <NUM> to <NUM>, optionally <NUM> to <NUM>, and further optionally <NUM> to <NUM>; and the second lithium iron phosphate particle layer has a thickness of <NUM> to <NUM>, optionally <NUM> to <NUM>, and further optionally <NUM> to <NUM>.

As an example, the first lithium iron phosphate particle layer may have a thickness of <NUM>, <NUM>, <NUM>, or <NUM>, and the second lithium iron phosphate particle layer may have a thickness of <NUM>, <NUM>, <NUM>, or <NUM>. The thickness of the first lithium iron phosphate particle layer and the thickness of the second lithium iron phosphate particle layer may be determined by a common method in the art. For example, the thickness of the positive electrode film layer may be measured, and then the thickness of the first lithium iron phosphate particle layer and the thickness of the second lithium iron phosphate particle layer may be determined by a weight ratio relation between the first lithium iron phosphate particles and the second lithium iron phosphate particles.

Excessively great thickness of the lithium iron phosphate particle layer may result in a deterioration of the dynamic performance of the battery. In contrast, excessively small thickness of the lithium iron phosphate particle layer, the advantages of a double-layer coating may not be fully exerted, thereby failing to further improve the performance of the battery.

In some embodiments, optionally, a thickness ratio of the first lithium iron phosphate particle layer to the second lithium iron phosphate particle layer is <NUM>: <NUM> to <NUM>, optionally <NUM>: <NUM> to <NUM>, and further optionally <NUM>: <NUM> to <NUM>. For example, a thickness ratio of the first lithium iron phosphate particle layer to the second lithium iron phosphate particle layer may be <NUM>: <NUM>, <NUM>: <NUM>, <NUM>: <NUM>, or <NUM>: <NUM>.

When the thickness ratio of the first lithium iron phosphate particle layer to the second lithium iron phosphate particle layer is within the above-mentioned ranges, it is helpful to further improve the dynamic performance and cycle performance of the corresponding secondary battery.

In some embodiments, optionally, the first lithium iron phosphate particle layer has a surface density of <NUM> to <NUM>/<NUM><NUM>, optionally <NUM> to <NUM>/<NUM><NUM>, and further optionally <NUM> to <NUM>/<NUM><NUM>; and the second lithium iron phosphate particle layer has a surface density of <NUM> to <NUM>/<NUM><NUM>, optionally <NUM> to <NUM>/<NUM><NUM>, and further optionally <NUM> to <NUM>/<NUM><NUM>.

It should be noted that, the coating method is not particularly limited in the present disclosure, and a coating method commonly used in the art may be used, for example, blade coating, roller coating, slot-die coating, etc..

In some embodiments, the positive electrode current collector may be a metal foil or a composite current collector. For example, as the metal foil, an aluminum foil may be used. The composite current collector may include a polymer material substrate and a metal layer formed on at least one surface of the polymer material substrate. The composite current collector may be formed by forming a metal material (e.g., aluminum, aluminum alloy, nickel, nickel alloy, titanium, titanium alloy, silver, silver alloy) on a polymer material substrate (e.g., polypropylene (PP), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polystyrene (PS), polyethylene (PE)).

In some embodiments, optionally, the lithium iron phosphate positive electrode plate further includes a binder. As an example, the binder may include at least one of polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), vinylidene fluoride-tetrafluoroethylene-propylene terpolymer, vinylidene fluoride-hexafluoropropylene-tetrafluoroethylene terpolymer, tetrafluoroethylene-hexafluoropropylene copolymer, and fluorinated acrylate acid vinegar resin.

In some embodiments, optionally, the binder accounts for <NUM>% to <NUM>%, and optionally <NUM> % to <NUM>%, of a total weight of the positive electrode film layer.

In some embodiments, optionally, the lithium iron phosphate positive electrode plate further includes a conductive agent. As an example, the conductive agent may include at least one of superconducting carbon, acetylene black, carbon black, Ketjen black, carbon dots, carbon nanotubes, graphene, and carbon nanofibers.

In some embodiments, optionally, the conductive agent accounts for <NUM> % to <NUM>%, and optionally <NUM> % to <NUM>%, of the total weight of the positive electrode film layer.

In some embodiments, optionally, the lithium iron phosphate positive electrode plate further includes other additives, e.g., a surfactant, a wetting agent, a rheology modifier, etc. As an example, the additive may be selected from, for example, one or more of higher fatty acid salt, higher alkyl sulfonate, alkyl aryl sulfonate, alkali metal salts of lauric acid, myristic acid, palmitic acid, stearic acid and oleic acid, etc., such as lithium salt, perfluoroalkyl sulfonimide salt, methyl caprylate, n-butyl neopentanoate, or lauryl acetate.

In some embodiments, optionally, the other additives account for <NUM>% to <NUM>%, and optionally <NUM>% to <NUM>%, of the total weight of the positive electrode film layer.

In some embodiments, the positive electrode plate may be prepared as follows: dispersing components for preparing the positive electrode plate, for example, the first lithium iron phosphate particles and the second lithium iron phosphate particles, the conductive agent, the binder, and any other components such as the surfactant into a solvent (e.g., N-methylpyrrolidone) to form positive electrode slurry; and coating the positive electrode slurry on the positive electrode current collector; and obtaining the positive electrode plate subsequent to procedures such as drying, cold pressing.

In some embodiments, optionally, positive electrode slurry of the first lithium iron phosphate particles and positive electrode slurry of the second lithium iron phosphate particles can be separately prepared; the positive electrode slurry of the second lithium iron phosphate particles is coated on a side close to the current collector; and the positive electrode slurry of the first lithium iron phosphate particles is coated on a surface of the second lithium iron phosphate particle layer facing away from the current collector.

In some embodiments, optionally, during the preparation of the positive electrode slurry, the positive electrode slurry can be delivered immediately once the mixture is stirred to reach a viscosity of <NUM> mPa·s to <NUM> mPa·s.

A second aspect of the present disclosure provides a secondary battery. The secondary battery includes the lithium iron phosphate positive electrode plate according to the first aspect of the present disclosure. The secondary battery may be prepared by a common method in the art. For example, a positive electrode plate, a negative electrode plate, and a separator can be wound into an electrode assembly by means of a certain process, the obtained electrode assembly is injected with electrolyte, and through a procedure such as sealing, the secondary battery according to the present disclosure can be prepared.

Generally, the secondary battery includes the positive electrode plate, the negative electrode plate, the electrolyte, and the separator. In charge and discharge processes of the battery, active ions are embedded and disengaged back and forth between the positive electrode plate and the negative electrode plate. The electrolyte is configured to conduct the ions between the positive electrode plate and the negative electrode plate. The separator is disposed between the positive electrode plate and the negative electrode plate, and is mainly configured to prevent short circuits of the positive electrode and the negative electrode and enable the ions to pass through.

Other components of the secondary battery, such as the negative electrode plate, the electrolyte, and the separator, are described as follows.

The negative electrode plate includes a negative electrode current collector and a negative electrode film layer disposed on at least one surface of the negative electrode current collector. The negative electrode film layer includes a negative electrode active material.

As an example, the negative electrode current collector has two opposite surfaces in a thickness direction thereof, and the negative electrode film layer is disposed on any one or both of the two opposite surfaces of the negative electrode current collector.

In some embodiments, the negative electrode current collector may be a metal foil or a composite current collector. For example, a copper foil may be used as the metal foil. The composite current collector may include a polymer material substrate and a metal layer formed on the at least one surface of a polymer material substrate. The composite current collector may be formed by forming a metal material (copper, copper alloy, nickel, nickel alloy, titanium, titanium alloy, silver, silver alloy, etc.) on the polymer material substrate (e.g., a substrate material of polypropylene (PP), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polystyrene (PS), or polyethylene (PE)).

In some embodiments, the negative electrode active material may be the negative electrode active material for the battery known in the art. As an example, the negative electrode active material may include at least one of the following materials: artificial graphite, natural graphite, soft carbon, hard carbon, a silicon-based material, a tin-based material, or lithium titanate, etc. The silicon-based material may be selected from at least one of elemental silicon, silicon oxide, silicon-carbon composite, silicon-nitrogen composite, and silicon alloy. The tin-based material may be selected from at least one of elemental tin, tin oxide, and tin alloy. However, the present disclosure is not limited to these materials, and other conventional materials that can be used as the negative electrode active material of the battery may also be used. These negative electrode active materials may be used individually or in combination of more than two thereof.

In some embodiments, the negative electrode film layer may further optionally include a binder. The binder may be selected from at least one of styrene butadiene rubber (SBR), polyacrylic acid (PAA), sodium polyacrylate (PAAS), polyacrylamide (PAM), polyvinyl alcohol (PVA), sodium alginate (SA), polymethacrylic acid (PMAA), and carboxymethyl chitosan (CMCS).

In some embodiments, the negative electrode film layer may further optionally include a conductive agent. The conductive agent may be selected from at least one of superconducting carbon, acetylene black, carbon black, Ketjen black, carbon dots, carbon nanotubes, graphene, and carbon nanofibers.

In some embodiments, the negative electrode film layer may optionally include other additives, for example, a thickening agent (e.g., sodium carboxymethyl cellulose (CMC-Na)).

In some embodiments, the negative electrode plate may be prepared as follows: dispersing the components for preparing the negative electrode plate such as a negative electrode active material, a conductive agent, a binder, and any other components into a solvent (e.g., deionized water) to form negative electrode slurry; coating the negative electrode slurry on the negative electrode current collector; and obtaining the negative electrode plate subsequent to procedures such as drying, cold pressing.

The electrolyte plays a role in conducting the ions between the positive electrode plate and the negative electrode plate. The type of the electrolyte is not specifically limited in the present disclosure, and the electrolyte may be selected based on actual requirements. For example, the electrolyte may be in a liquid state, a gel state, or an all-solid state.

In some embodiments, the electrolyte is an electrolyte solution. The electrolyte solution includes an electrolyte salt and a solvent.

In some embodiments, the electrolyte salt may be selected from at least one of lithium hexafluorophosphate, lithium tetrafluoroborate, lithium perchlorate, lithium hexafluoroarsenate, lithium bis(fluorosulfonyl)imide, lithium bis(trifluoromethanesulfonyl)imide, lithium trifluoromethanesulfonate, lithium difluorophosphate, lithium difluoro(oxalate)borate, lithium bis(oxalato)borate, lithium bis(oxyaly)difluorophosphate, and lithium tetrafluoro(oxalato)phosphate.

In some embodiments, the solvent may be selected from at least one of ethylene carbonate, propylene carbonate, methyl ethyl carbonate, diethyl carbonate, dimethyl carbonate, dipropyl carbonate, methyl propyl carbonate, ethyl propyl carbonate, butylene carbonate, fluoroethylene carbonate, methyl formate, ethyl formate, ethyl acetate, propyl acetate, methyl propionate, ethyl propionate, propyl propionate, methyl butyrate, ethyl butyrate, <NUM>,<NUM>-butyrolactone, sulfolane, dimethyl sulfone, methyl ethyl sulfone, or diethyl sulfone.

In some embodiments, the electrolyte solution may further optionally include an additive. For example, the additive may include a negative electrode film-forming additive and a positive electrode film-forming additive. The additive may further include an additive capable of improving certain performances of the battery, for example, an additive capable of improving overcharge performance of the battery, an additive capable of improving high-temperature or low-temperature performance of the battery, etc..

In some embodiments, the secondary battery further includes a separator. A type of the separator is not specifically limited in the present disclosure, and any well-known porous structure separator with good chemical stability and mechanical stability may be selected.

In some embodiments, a material of the separator may be selected from at least one of glass fiber, non-woven fabric, polyethylene, polypropylene, or polyvinylidene fluoride. The separator may be a single-layer thin film or a multi-layer composite thin film, which is not particularly limited. When the separator is the multi-layer composite thin film, the materials of the layers may be the same or different, which is not particularly limited.

A third aspect of the present disclosure provides a battery module. The battery module includes the secondary battery according to the second aspect of the present disclosure.

A fourth aspect of the present disclosure provides a battery pack. The battery pack includes the battery module according to the third aspect of the present disclosure.

A fifth aspect of the present disclosure provides an electrical device. The electrical device includes at least one of the secondary battery according to the second aspect of the present disclosure, the battery module according to the third aspect of the present disclosure, or the battery pack according to the fourth aspect of the present disclosure. The secondary battery, the battery module, or the battery pack may be used as a power supply of the electric device, and may also be used as an energy storage unit of the electric device. The electric device may include, but not limited to, a mobile apparatus (e.g., a mobile phone, a notebook computer), an electric vehicle (e.g., a pure electric vehicle, a hybrid electric vehicle, a plug-in hybrid electric vehicle, an electric bicycle, an electric scooter, an electric golf cart, an electric truck), an electrical train, a ship, a satellite, an energy storage system, etc..

The secondary battery, the battery module, or the battery pack may be selected as the electrical device based on a use demand thereof.

In addition, the secondary battery, the battery module, the battery pack, and the electrical device of the present disclosure are described below with reference to the accompanying drawings as appropriate.

In some embodiments, the secondary battery may include an outer package. The outer package may be configured to encapsulate the electrode assembly and the electrolyte.

In some embodiments, the outer package of the secondary battery may be a hard shell, such as a hard plastic shell, an aluminum shell, a steel shell, etc. The outer package of the secondary battery may also be a soft bag, such as a pouch-type soft bag. A material of the soft package may be plastics. Examples of plastics may include polypropylene, polybutylene terephthalate, polybutylene succinate, etc..

A shape of the secondary battery is not specifically limited in the present disclosure, and the secondary battery may be cylindrical, square, or any other shape. For example, <FIG> illustrates an example of a secondary battery <NUM> with a square structure.

In some embodiments, referring to <FIG>, the outer package may include a housing <NUM> and a cover plate <NUM>. The housing <NUM> may include a bottom plate and a side plate connected to the bottom plate, and an accommodating cavity is enclosed by the bottom plate and the side plate. The housing <NUM> has an opening in communication with the accommodating cavity, and the cover plate <NUM> can be disposed on and cover the opening to close the accommodating cavity. The positive electrode plate, the negative electrode plate, and the separator may be subjected to a winding process or a stacking process to form an electrode assembly <NUM>, and the electrode assembly <NUM> is encapsulated in the accommodating cavity. The electrolyte solution is infiltrated into the electrode assembly <NUM>. The electrode assembly <NUM> may include one or more the secondary batteries <NUM>, which may be selected by those skilled in the art based on the actual requirements.

In some embodiments, the secondary battery may be assembled into the battery module. The battery module may include one or more secondary batteries, and the exact number may be selected by those skilled in the art based on usage and capacity of the battery module.

<FIG> illustrates an example of a battery module <NUM>. Referring to <FIG>, in the battery module <NUM>, a plurality of secondary batteries <NUM> can be sequentially arranged in a length direction of the battery module <NUM>. The plurality of secondary batteries <NUM> may also be arranged in any other manner. The plurality of secondary batteries <NUM> may be further fixed by a fastener.

Optionally, the battery module <NUM> may further include a casing having accommodating space, and the plurality of secondary batteries <NUM> is accommodated in the accommodating space.

In some embodiments, the battery module may also be assembled into the battery pack. The battery pack may include one or more battery modules, and the exact number may be selected by those skilled in the art based on usage and capacity of the battery pack.

<FIG> illustrate an example of a battery back. Referring to <FIG>, the battery pack <NUM> may include a battery box and a plurality of battery modules <NUM> disposed in the battery box. The battery box includes an upper box body <NUM> and a lower box body <NUM>. The upper box body <NUM> can be disposed on and cover the lower box body <NUM> to form a closed space for accommodating the battery modules <NUM>. The plurality of battery modules <NUM> may be arranged within the battery box in any manner.

<FIG> illustrates an example of an electrical device. The electric device may be a pure electric vehicle, a hybrid electric vehicle, or a plug-in hybrid electric vehicle, etc. In order to meet requirements of the electrical device for high power and high energy density of the secondary battery, the battery pack or the battery module may be used.

Another example of the device may be a mobile phone, a tablet computer, a notebook computer, etc. The device is generally required to be thin and light, and a secondary battery may be used as a power supply.

Hereinafter, the examples of the present disclosure will be explained. The examples described below are exemplary and are merely for explaining the present disclosure, and they should not be construed as limiting the present disclosure. In the examples, techniques or conditions that are not specified shall be based on the techniques or conditions described in literature in the art or according to the product introduction. The used reagents or instruments without indicating the manufacturers are all conventional and commercially available products.

The cathode active materials involved in the examples of the present disclosure are listed in the following table.

The first lithium iron phosphate particles (D50 of <NUM>, BET of <NUM><NUM>/g, and carbon content of <NUM>%), the second lithium iron phosphate particles (D50 of <NUM>, BET of <NUM><NUM>/g, carbon content of <NUM>%), polyvinylidene fluoride (PVDF) and conductive agent acetylene black were added in a weight ratio of <NUM>%: <NUM>%: <NUM>: <NUM> into a stirring tank for mixing. The mixture was stirred for <NUM> minutes at a revolution speed of <NUM> rpm and a rotation speed of <NUM> rpm. Solvent N-methylpyrrolidone (NMP) was added into the dry mixture based on a solid content of <NUM>%, and stirred for <NUM> minutes at the revolution speed of <NUM> rpm and a rotation speed of <NUM> rpm. The revolution speed was adjusted to be <NUM> rpm and the rotation speed was adjusted to be <NUM>,<NUM> rpm, and the mixture was stirred for <NUM> minutes to be dispersed uniformly. The mixture was continuously stirred at the revolution speed of <NUM> rpm and a rotation speed of <NUM> rpm, until a viscosity of the mixture was adjusted to be <NUM> mPa·s, and then the mixture was immediately delivered to obtain mixed slurry. The above mixed slurry was coated, based on a surface density of <NUM>/mm<NUM>, on both surfaces of an aluminum foil having a thickness of <NUM>. The solvent was removed by drying, and cooling was performed, such that the positive electrode film layer has a compacted density of <NUM>/cm<NUM>. The positive electrode plate of the example <NUM> was obtained after cutting.

Negative electrode active substances: artificial graphite, a conductive agent acetylene black, a binder styrene-butadiene rubber (SBR), and a dispersant sodium carboxymethyl cellulose (CMC-Na) in a weight ratio of <NUM>: <NUM>: <NUM>: <NUM> were dissolved in solvent deionized water, and stirred and mixed uniformly to prepare the negative electrode slurry. The negative electrode slurry with a coating density of <NUM>/cm<NUM> was uniformly coated on a negative electrode current collector copper foil, and the negative electrode plate was obtained by drying, cold pressing, and slicing.

In an argon atmosphere glove box (H<NUM>O <<NUM>. 1ppm, O<NUM> <<NUM>. 1ppm), organic solvents ethylene carbonate (EC)/methyl ethyl carbonate (EMC) were uniformly mixed in a volume ratio of <NUM> to <NUM>. <NUM>% by weight of LiPF<NUM> (based on a weight of the ethylene carbonate/the methyl ethyl carbonate solvent) was added to dissolve in the above organic solvent. The mixture was uniformly stirred to obtain the electrolyte solution.

Commercially available PP-PE copolymer microporous film having a thickness of <NUM> and an average pore diameter of <NUM> were used (from Advanced Electronic Technology Co. Model <NUM>).

The positive electrode plate, the separator, and the negative electrode plate were stacked in sequence, enabling the separator to be disposed between the positive electrode plate and the negative electrode plate to play a role of isolation, and they were wound to obtain a cylindrical bare cell having a height of <NUM> and a diameter from upper surface to lower surface of <NUM>. A spacing between the positive electrode plate and the negative electrode plate was <NUM>, and a spacing between the separator and each of the positive electrode plate and the negative electrode plate was about <NUM>. The bare battery cell was placed in an outer package, and <NUM> of the electrolyte solution was injected and packaged to obtain the secondary battery.

Conditions of Example <NUM> to Example <NUM> were substantially the same as those of Example <NUM>, except the differences in the particle diameter, specific surface area and carbon content of the first lithium iron phosphate particles and the second lithium iron phosphate particles and the weight of the lithium iron phosphate particles. The specific conditions are listed in Table <NUM>.

Conditions of Example <NUM> are basically the same as those of Example <NUM>, except the following differences: the first lithium iron phosphate particles were added into the stirring tank in a weight ratio of the first lithium iron phosphate particles: polyvinylidene fluoride (PVDF): the conductive agent acetylene black of <NUM>: <NUM>: <NUM> to prepare a slurry; the slurry was coated, based on a surface density of <NUM>/<NUM><NUM><NUM>, on a surface of an aluminum foil having a thickness of <NUM>, as a first active material layer; then the second lithium iron phosphate particles were added into the stirring tank in a weight ratio of the second lithium iron phosphate particles: polyvinylidene fluoride (PVDF): the conductive agent acetylene black of <NUM>: <NUM>: <NUM> to prepare a slurry; and then the slurry was coated, based on the surface density of <NUM>/<NUM>. <NUM><NUM>, on an upper surface of the first active material layer.

The weight of the first lithium iron phosphate particles and the weight of the second lithium iron phosphate particles are the same as those of Example <NUM>, that is, the total weight of the upper and lower layers is the same as that of the Example <NUM>. On the obtained positive electrode plate, the first lithium iron phosphate particle layer has a thickness of <NUM>, and the second lithium iron phosphate particle layer has a thickness of <NUM>.

Conditions of Example <NUM> are basically the same as those of Example <NUM>, except that the second lithium iron phosphate particles were coated on the surface of the aluminum foil to serve as the first active material layer, and the first lithium iron phosphate particle layer was coated on the upper portion of the second lithium iron phosphate particle layer.

Conditions of Example <NUM> to Example <NUM> are basically the same as those of Example <NUM>, except that the weight of the lithium iron phosphate particles was changed to enable the first lithium iron phosphate particle layer/the second lithium iron phosphate particle layer to have the thicknesses of <NUM>/<NUM>, <NUM>/<NUM>, and <NUM>/<NUM>, respectively. The specific conditions are listed in the Table <NUM>.

Conditions of Comparative example <NUM> to Comparative example <NUM> are basically the same as those of Example <NUM>, except the differences in the particle diameter, specific surface area and carbon content of the first lithium iron phosphate particles and the second lithium iron phosphate particles and the weight of the lithium iron phosphate particles. The specific conditions are listed in Table <NUM>.

Conditions of Comparative example <NUM> are basically the same as those of Example <NUM>, except that the thickness of the first lithium iron phosphate particle layer/ the thickness of the second lithium iron phosphate particle layer were <NUM> and <NUM>, respectively.

A proper amount of to-be-tested lithium iron phosphate particles were prepared as samples, and the morphologies of the samples were observed with a ZEISS sigma <NUM> scanning electron microscope in accordance with the standard JY/T010-<NUM>.

The standard GB/T <NUM>-<NUM>/ISO <NUM>: <NUM>, Particle Size Distribution Laser Diffraction Method, was used as a reference. A laser particle size analyzer (MasterSizer <NUM>) was used for testing, and a helium-neon red light source was used as a primary light source. <NUM> of a to-be-tested sample was added into a small clean beaker, <NUM> of deionized water (to ensure <NUM>% to <NUM>% shade rate by concentration of the sample) was added into the beaker, and a drop of a surfactant was added into the beaker to reduce a surface tension of the water to facilitate infiltration of the particles. The sample was subjected to ultrasound for <NUM> at <NUM>/120W to ensure that the sample was completely dispersed. The laser particle size analyzer was turned on, and after an optical path system was cleaned, a background was automatically tested. The to-be-tested solution that has been subjected to the ultrasound was stirred to be uniformly dispersed, and the solution was put into a sample pool as required to start to measure the particle diameter. A measurement result can be read from the instrument.

The test method refers to the standard GB/T <NUM>-<NUM>, "Determination of Specific Surface Area of Solids by Gas Adsorption Using the BET Method.

A battery was taken for a charge and discharge test. The battery was fully charged at <NUM> first, and left to stand for <NUM> minutes after fully charged. The battery was discharged at a discharge rate of 1C for <NUM> minutes, and left to stand for <NUM> minutes when adjusted to <NUM>% SOC. A temperature of an incubator was adjusted to -<NUM>, and the battery was left to stand for <NUM> minutes to measure an initial discharge voltage. The battery was discharged for <NUM> seconds at a discharge rate of 3C, and a lowest voltage in the discharge process was recorded, and then the battery was left to stand for <NUM> minutes. The DCR was obtained by dividing a difference between the initial discharge voltage of the 3C discharge and the lowest voltage in the 3C discharge process by a current value (a discharge rate of 3C, and a current of <NUM> A).

At <NUM>, the secondary batteries prepared according to the examples and comparative examples were charged to <NUM> V at a constant current rate of 1C (i.e., a current value at which a theoretical capacity was completely released within <NUM> hour), then charged to a current of <NUM> C at a constant voltage of <NUM> V, and left to stand for <NUM> minutes, and discharged to <NUM> V at a constant current rate of 1C, and left to stand for <NUM> minutes, which was a charge and discharge cycle. A capacity C0 of the battery at this moment was recorded. The battery was charged and discharged for n cycles in this way, and a capacity of the battery after n cycles was recorded as C1. A cycle capacity retention rate of the battery at <NUM> = C1/C0× <NUM>%. A cycle number n, corresponding to that the measured cycle capacity retention rate of the battery was <NUM>%, was recorded.

Claim 1:
A lithium iron phosphate positive electrode plate, comprising:
a positive electrode current collector; and
a positive electrode active material located on the positive electrode current collector, wherein the positive electrode active material comprises:
first lithium iron phosphate particles having a volume average diameter D50 of <NUM> to <NUM>, optionally <NUM> to <NUM>, and a specific surface area greater than <NUM><NUM>/g, optionally <NUM><NUM>/g to <NUM><NUM>/g; and
second lithium iron phosphate particles having a volume average diameter D50 greater than <NUM>, optionally <NUM> to <NUM>, and a specific surface area smaller than <NUM><NUM>/g, optionally <NUM><NUM>/g to <NUM><NUM>/g, characterized in that:
the first lithium iron phosphate particles and the second lithium iron phosphate particles are distributed in layers in an active substance layer in the lithium iron phosphate positive electrode plate, and
a second lithium iron phosphate particle layer comprising the second lithium iron phosphate particles is disposed on a surface of the positive electrode current collector; and
a first lithium iron phosphate particle layer comprising the second lithium iron phosphate particles is disposed on a surface, opposite to the positive electrode current collector, of the second lithium iron phosphate particle layer.