WO2007140014A2 - Lithium batteries with high power and high energy density - Google Patents
Lithium batteries with high power and high energy density Download PDFInfo
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- WO2007140014A2 WO2007140014A2 PCT/US2007/012691 US2007012691W WO2007140014A2 WO 2007140014 A2 WO2007140014 A2 WO 2007140014A2 US 2007012691 W US2007012691 W US 2007012691W WO 2007140014 A2 WO2007140014 A2 WO 2007140014A2
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- WIPO (PCT)
- Prior art keywords
- active material
- positive electrode
- material particles
- battery
- particles
- Prior art date
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- 229910052744 lithium Inorganic materials 0.000 title claims description 12
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 title claims description 8
- 239000002245 particle Substances 0.000 claims abstract description 103
- 239000011149 active material Substances 0.000 claims abstract description 39
- 238000000034 method Methods 0.000 claims abstract description 19
- HBBGRARXTFLTSG-UHFFFAOYSA-N Lithium ion Chemical compound [Li+] HBBGRARXTFLTSG-UHFFFAOYSA-N 0.000 claims abstract description 8
- 229910001416 lithium ion Inorganic materials 0.000 claims abstract description 8
- 239000008187 granular material Substances 0.000 claims description 23
- 229910052748 manganese Inorganic materials 0.000 claims description 12
- 238000009826 distribution Methods 0.000 claims description 11
- 238000005245 sintering Methods 0.000 claims description 10
- 229910052759 nickel Inorganic materials 0.000 claims description 9
- 239000011230 binding agent Substances 0.000 claims description 8
- 239000007774 positive electrode material Substances 0.000 claims description 7
- 239000002002 slurry Substances 0.000 claims description 6
- 239000003792 electrolyte Substances 0.000 claims description 5
- 239000011163 secondary particle Substances 0.000 claims description 5
- 229910052719 titanium Inorganic materials 0.000 claims description 5
- 230000002902 bimodal effect Effects 0.000 claims description 4
- 229910052804 chromium Inorganic materials 0.000 claims description 4
- 229910052742 iron Inorganic materials 0.000 claims description 4
- 229910052697 platinum Inorganic materials 0.000 claims description 4
- 239000011164 primary particle Substances 0.000 claims description 4
- 229910052702 rhenium Inorganic materials 0.000 claims description 4
- 229910052707 ruthenium Inorganic materials 0.000 claims description 4
- 239000002904 solvent Substances 0.000 claims description 4
- 229910052720 vanadium Inorganic materials 0.000 claims description 4
- 229910052726 zirconium Inorganic materials 0.000 claims description 4
- 229910052493 LiFePO4 Inorganic materials 0.000 claims description 3
- 229910011125 LiM1O2 Inorganic materials 0.000 claims description 3
- 229910002097 Lithium manganese(III,IV) oxide Inorganic materials 0.000 claims description 3
- 238000001694 spray drying Methods 0.000 claims description 3
- 229910032387 LiCoO2 Inorganic materials 0.000 claims 1
- 229910013191 LiMO2 Inorganic materials 0.000 claims 1
- 229910014143 LiMn2 Inorganic materials 0.000 claims 1
- 229910000625 lithium cobalt oxide Inorganic materials 0.000 description 10
- BFZPBUKRYWOWDV-UHFFFAOYSA-N lithium;oxido(oxo)cobalt Chemical compound [Li+].[O-][Co]=O BFZPBUKRYWOWDV-UHFFFAOYSA-N 0.000 description 10
- SECXISVLQFMRJM-UHFFFAOYSA-N N-Methylpyrrolidone Chemical compound CN1CCCC1=O SECXISVLQFMRJM-UHFFFAOYSA-N 0.000 description 6
- 239000000843 powder Substances 0.000 description 5
- 239000007921 spray Substances 0.000 description 5
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 238000012856 packing Methods 0.000 description 4
- 239000002033 PVDF binder Substances 0.000 description 3
- 239000004372 Polyvinyl alcohol Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 229920002451 polyvinyl alcohol Polymers 0.000 description 3
- 229920002981 polyvinylidene fluoride Polymers 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 2
- 239000004810 polytetrafluoroethylene Substances 0.000 description 2
- 239000011877 solvent mixture Substances 0.000 description 2
- 239000010936 titanium Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000010960 commercial process Methods 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 235000012489 doughnuts Nutrition 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000002086 nanomaterial Substances 0.000 description 1
- 239000002105 nanoparticle Substances 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- -1 polytetrafluoroethylene Polymers 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
- H01M4/131—Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/36—Selection of substances as active materials, active masses, active liquids
- H01M4/48—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides
- H01M4/485—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of mixed oxides or hydroxides for inserting or intercalating light metals, e.g. LiTi2O4 or LiTi2OxFy
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/36—Selection of substances as active materials, active masses, active liquids
- H01M4/48—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides
- H01M4/50—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of manganese
- H01M4/505—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of manganese of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/36—Selection of substances as active materials, active masses, active liquids
- H01M4/48—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides
- H01M4/52—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron
- H01M4/525—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M2004/021—Physical characteristics, e.g. porosity, surface area
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
Definitions
- the present invention relates to lithium batteries with high power and high energy density.
- the present invention provides a positive electrode for a lithium ion battery.
- the electrode comprises active material particles with inter-particle connectivity that increases the power and energy density of a battery compared with a battery having a positive electrode comprising active material particles without inter-particle connectivity.
- the present invention provides a lithium ion battery comprising a negative electrode, an electrolyte and a positive electrode.
- the positive electrode comprises active material particles with inter-particle connectivity that increases the power and energy density of the battery compared with a battery having a positive electrode comprising active material particles without inter-particle connectivity.
- the present invention provides a method for making a positive electrode active material for a lithium battery.
- the method comprises forming dense granules of positive electrode active material particles, and sintering the granules so as to physically join the particles and provide inter-particle connectivity.
- Figure 1 outlines the process used to synthesize sintered granules.
- Figure 2 illustrates lithium cobalt oxide powder before (A) and after (B) sintering.
- Figure 3 illustrates donut-shaped positive electrode particles.
- the present invention relates to batteries having high power and high energy density constructed with a positive electrode having unique morphology.
- the positive electrode comprises active material particles that are densely packed with significant inter-particle connectivity. That is, the particles have a physical joining without an interface or boundary. Lack of inter-particle connectivity may require electrons to hop across or tunnel through to the next particle. However, inter-particle connectivity facilities electron transport.
- a positive electrode containing active material particles with inter-particle connectivity allows for a battery with increased power and energy density compared with a battery having a positive electrode comprising active material particles without inter-particle connectivity.
- the batteries of the present invention can provide, for example, a specific power up to about 4000 Watt/kg and a specific energy up to about 500 Watt-hour/kg.
- a battery can be provided which runs at a specific power of 4000 Watt/kg and a specific energy greater than 100 Watt-hour/kg.
- the active material particles for the positive electrode are subjected to a sintering process.
- particles are mixed with a binder and solvent mixture to form a slurry.
- dense granules i.e., agglomerates of particles
- the granules are sintered in a furnace to so as to bring about physical joining of the particles and provide inter-particle connectivity.
- a positive electrode active material of multimode particle size distribution such as a bimodal particle size distribution, is used to improve packing density.
- nanoparticles can be used to further increase the power density.
- Compacting of granules by equipment such as a roll mill also improves the packing density.
- These compacted, dense positive electrode active material particles still have sufficient porosity to be coated with carbon and wetted by an electrolyte.
- the particles can also be prepared by spray drying or other process so as to have a "donut" shape.
- Such donut-shaped particles are subjected to sintering to provide for inter-particle connectivity.
- any appropriate binder and solvent may be used.
- Exemplary binders include polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE) and polyvinyl alcohol (PVA).
- Exemplary solvents include N-methyl-2-pyrrolidone (NMP) and an ethanol/water mixture.
- Granules can be sintered under any conditions which result in the physical joining of active material particles so as to provide inter-particle connectivity.
- Typical sintering temperatures range form 40O 0 C to 1000 0 C for 1 to 48 hours. In general, a longer sintering time is required at a lower temperature, and vice versa.
- the active material may have any particle size which allows for its use as a positive electrode material.
- the particle size ranges from 10 nm to 200 micrometer. Fluffiness of the bulk active material can be reduced by using a particle size greater than 1 micrometer.
- particle sizes typically range from an average of about 1 micrometer to about 10 micrometer, although depending on desired properties, particles of about 100-150 micrometer, 60-100 micrometer, 30-50 micrometer, 2-20 micrometer, or 2-3 micrometer can be used.
- “Multi-mode” particles can also be used in which active material having two or more size distributions are used as a mixture.
- a primary particle having a size ranging from about 1-10 micrometer can be mixed with a secondary particle having a size ranging from about 10-1000 nm, or from about 10-200 nm.
- the use of secondary particles in the nanorange improves the packing density and inter-particle connectivity of the sintered active material. Any active material suitable for use in particles for a positive electrode for a lithium battery can be used.
- Examples of active materials that can be used for the particles include lithium cobalt oxide (LiCoO 2 ), LiMn 2 O 4 , LiFePO 4 , Li(MlM2Co)O 2 where Ml and M2 are selected from among Li, Ni, Mn, Cr, and Al; and XLi 2 MOa(I-X)LiM 1 O 2 where M is selected from among Mn, Ti, Zr, Ru, Re and Pt and M 1 is selected from among V, Mn, Fe, Co and Ni.
- the active material particles with inter-particle connectivity are typically coated on a current collector. Any current collector appropriate for use in a lithium battery can be used. Exemplary materials for current collectors include aluminum, copper, nickel and titanium.
- any anode and any electrolyte appropriate for use in a lithium battery can be used.
- a binder such as PVA or PVDF is dissolved in an ethanol/water mixture or an organic solvent such as NMP.
- Commercially available lithium cobalt oxide powder is added to the binder/solvent mixture and thoroughly mixed in an industrial mixer.
- a highly stable slurry results which is free of precipitation for hours.
- the slurry is fed to a spray drier which uses an atomizer to create a droplet spray from the slurry.
- the droplets are converted to granules after drying in the spray drier.
- the granules are sintered in a furnace.
- the sintered granules have significant inter-particle connectivity.
- the sintered granules are mixed with an appropriate binder and solvent and then coated on a current collector to form a positive electrode using a typical commercial process.
- Figure 1 outlines the process flow used to synthesize sintered granules.
- Figure 2(A) shows a schematic representation of as received lithium cobalt oxide powder
- Figure 2(B) shows that significant inter-particle connectivity is developed after sintering.
- Sintered dense granules obtained from the above process can also be mixed with a commercial lithium cobalt oxide powder.
- Sintered granules with nanostructures further improve the power density.
- the starting lithium cobalt oxide has a particle size in the nanometer range.
- Compacting of granules in equipment such as a roll mill also improves the packing density.
- the morphology of the granules can be changed by controlling properties of the slurry and parameters used for spray drying.
- Figure 3 shows donut-shaped particles. A three- dimensional network of donut-shaped particles can be formed which will allow high density and at the same time ensure electrolyte wettability.
- lithium cobalt oxide of two different particle size distributions is used.
- one particle size is in the nanometer range.
- the different size particles are combined with a solvent-binder solution in a mixer, spray dried to form dense granules, and then the granules are sintered to provide for inter-particle connectivity.
- lithium cobalt oxide having an average particle size of 10 microns is mixed with lithium cobalt oxide having an average particle size of 200 tun. Nanoscale powders help lower the sintering temperature and significantly improve inter-particle connectivity.
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Battery Electrode And Active Subsutance (AREA)
Abstract
Provided is a positive electrode for a lithium ion battery, the electrode comprising active material particles with inter-particle connectivity that increases the power and energy density of a battery compared with a battery having a positive electrode comprising active material particles without inter-particle connectivity. Also provided is a battery comprising the positive electrode, and a method for making the positive electrode.
Description
LITHIUM BATTERIES WITH HIGH POWER AND HIGH ENERGY DENSITY
CROSS RELATED APPLICATION
This application claims priority to U.S. Provisional Application No. 60/808,761, filed May 26, 2006, which is incorporated herein in its entirety.
FIELD OF THE INVENTION
The present invention relates to lithium batteries with high power and high energy density.
DESCRIPTION OF THE RELATED ART
In commercial lithium ion batteries, energy density decreases as power density increases.
Thus, available lithium ion batteries do not achieve a good, high rate discharge system. For example, U.S. Patent Nos. 6,337,156 and 6,682,849 describe certain electrodes for secondary batteries fabricated using flakes of high aspect ratio, but these electrodes do not provide for batteries with satisfactory high power and high energy density. Therefore, a need exists in the industry to address the deficiencies and inadequacies of available lithium ion batteries.
SUMMARY OF THE INVENTION In one aspect the present invention provides a positive electrode for a lithium ion battery.
The electrode comprises active material particles with inter-particle connectivity that increases the power and energy density of a battery compared with a battery having a positive electrode comprising active material particles without inter-particle connectivity.
In another aspect, the present invention provides a lithium ion battery comprising a negative electrode, an electrolyte and a positive electrode. The positive electrode comprises active material particles with inter-particle connectivity that increases the power and energy density of the battery compared with a battery having a positive electrode comprising active material particles without inter-particle connectivity.
In yet another aspect, the present invention provides a method for making a positive electrode active material for a lithium battery. The method comprises forming dense granules of positive electrode active material particles, and sintering the granules so as to physically join the particles and provide inter-particle connectivity.
Other systems, methods, features and advantages of the present invention will be or become apparent to one with skill in the art upon examination of the following drawings and
detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the present invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 outlines the process used to synthesize sintered granules.
Figure 2 illustrates lithium cobalt oxide powder before (A) and after (B) sintering.
Figure 3 illustrates donut-shaped positive electrode particles.
DESCRIPTION OF PREFERRED EMBODIMENTS
Prior to the present invention, there were batteries having a positive electrode containing active material particles, which resulted in particle-to-particle contact but with an interface, or boundary, between the particles. The present invention relates to batteries having high power and high energy density constructed with a positive electrode having unique morphology. By the present invention, the positive electrode comprises active material particles that are densely packed with significant inter-particle connectivity. That is, the particles have a physical joining without an interface or boundary. Lack of inter-particle connectivity may require electrons to hop across or tunnel through to the next particle. However, inter-particle connectivity facilities electron transport. A positive electrode containing active material particles with inter-particle connectivity allows for a battery with increased power and energy density compared with a battery having a positive electrode comprising active material particles without inter-particle connectivity. The batteries of the present invention can provide, for example, a specific power up to about 4000 Watt/kg and a specific energy up to about 500 Watt-hour/kg. For example, a battery can be provided which runs at a specific power of 4000 Watt/kg and a specific energy greater than 100 Watt-hour/kg.
In one embodiment, the active material particles for the positive electrode are subjected to a sintering process. For this process, particles are mixed with a binder and solvent mixture to form a slurry. Then dense granules (i.e., agglomerates of particles) are obtained in the green state using equipment such as a spray drier. Subsequently, the granules are sintered in a furnace to so as to bring about physical joining of the particles and provide inter-particle connectivity. In another embodiment, a positive electrode active material of multimode particle size distribution, such as a bimodal particle size distribution, is used to improve packing density. In the embodiments set forth above, nanoparticles can be used to further increase the power density. Compacting of granules by equipment such as a roll mill also improves the
packing density. These compacted, dense positive electrode active material particles still have sufficient porosity to be coated with carbon and wetted by an electrolyte. To increase porosity, the particles can also be prepared by spray drying or other process so as to have a "donut" shape. Such donut-shaped particles are subjected to sintering to provide for inter-particle connectivity. In the formation of granules for sintering, any appropriate binder and solvent may be used. Exemplary binders include polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE) and polyvinyl alcohol (PVA). ' Exemplary solvents include N-methyl-2-pyrrolidone (NMP) and an ethanol/water mixture.
Granules can be sintered under any conditions which result in the physical joining of active material particles so as to provide inter-particle connectivity. Typical sintering temperatures range form 40O0C to 10000C for 1 to 48 hours. In general, a longer sintering time is required at a lower temperature, and vice versa.
The active material may have any particle size which allows for its use as a positive electrode material. In general, the particle size ranges from 10 nm to 200 micrometer. Fluffiness of the bulk active material can be reduced by using a particle size greater than 1 micrometer. When using "single-mode" particles, particle sizes typically range from an average of about 1 micrometer to about 10 micrometer, although depending on desired properties, particles of about 100-150 micrometer, 60-100 micrometer, 30-50 micrometer, 2-20 micrometer, or 2-3 micrometer can be used. "Multi-mode" particles can also be used in which active material having two or more size distributions are used as a mixture. For example, a primary particle having a size ranging from about 1-10 micrometer can be mixed with a secondary particle having a size ranging from about 10-1000 nm, or from about 10-200 nm. The use of secondary particles in the nanorange improves the packing density and inter-particle connectivity of the sintered active material. Any active material suitable for use in particles for a positive electrode for a lithium battery can be used. Examples of active materials that can be used for the particles include lithium cobalt oxide (LiCoO2), LiMn2O4, LiFePO4, Li(MlM2Co)O2 where Ml and M2 are selected from among Li, Ni, Mn, Cr, and Al; and XLi2MOa(I-X)LiM1O2 where M is selected from among Mn, Ti, Zr, Ru, Re and Pt and M1 is selected from among V, Mn, Fe, Co and Ni. In making a positive electrode of the present invention, the active material particles with inter-particle connectivity are typically coated on a current collector. Any current collector appropriate for use in a lithium battery can be used. Exemplary materials for current collectors include aluminum, copper, nickel and titanium. In addition, any anode and any electrolyte appropriate for use in a lithium battery can be used.
Example 1 Sintered Granules
A binder such as PVA or PVDF is dissolved in an ethanol/water mixture or an organic solvent such as NMP. Commercially available lithium cobalt oxide powder is added to the binder/solvent mixture and thoroughly mixed in an industrial mixer. A highly stable slurry results which is free of precipitation for hours. The slurry is fed to a spray drier which uses an atomizer to create a droplet spray from the slurry. The droplets are converted to granules after drying in the spray drier. The granules are sintered in a furnace. The sintered granules have significant inter-particle connectivity. The sintered granules are mixed with an appropriate binder and solvent and then coated on a current collector to form a positive electrode using a typical commercial process.
Figure 1 outlines the process flow used to synthesize sintered granules. Figure 2(A) shows a schematic representation of as received lithium cobalt oxide powder, and Figure 2(B) shows that significant inter-particle connectivity is developed after sintering. Sintered dense granules obtained from the above process can also be mixed with a commercial lithium cobalt oxide powder. Sintered granules with nanostructures further improve the power density. In this case the starting lithium cobalt oxide has a particle size in the nanometer range. Compacting of granules in equipment such as a roll mill also improves the packing density.
The morphology of the granules can be changed by controlling properties of the slurry and parameters used for spray drying. Figure 3 shows donut-shaped particles. A three- dimensional network of donut-shaped particles can be formed which will allow high density and at the same time ensure electrolyte wettability.
Example 2 Multi-mode particle size distribution
In a second embodiment, lithium cobalt oxide of two different particle size distributions is used. Preferably, one particle size is in the nanometer range. The different size particles are combined with a solvent-binder solution in a mixer, spray dried to form dense granules, and then the granules are sintered to provide for inter-particle connectivity. In one example, lithium cobalt oxide having an average particle size of 10 microns is mixed with lithium cobalt oxide having an average particle size of 200 tun. Nanoscale powders help lower the sintering temperature and significantly improve inter-particle connectivity.
All references cited in this disclosure are incorporated by reference to the same extent as if each reference had been incorporated by reference in its entirety individually.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various variations and modifications can be made therein without departing from the sprit and scope thereof. All such variations and modifications are intended to be included within the scope of this disclosure and the present invention and protected by the following claims.
Claims
1. A positive electrode for a lithium ion battery, the electrode comprising active material particles with inter-particle connectivity that increases the power and energy density of a battery compared with a battery having a positive electrode comprising active material particles without inter-particle connectivity.
2. The positive electrode of claim 1, wherein the active material is selected from the group consisting OfLiCoO21LiMn2O4, LiFePO4, Li(MlM2Co)θ2 where Ml and M2 are selected from among Li, Ni, Mn, Cr, or Al; and XLi2MO3(I-X)LiMO2 where M is selected from among Mn, Ti, Zr, Ru, Re or Pt and M' is selected from among V, Mn, Fe, Co or Ni.
3. The positive electrode of claim 1, wherein the active material particles have an average size ranging from about 1 to about 10 micrometer.
4. The positive electrode of claim 1, wherein the active material particles have a multimode particle distribution.
5. The positive electrode of claim 4, wherein the active material particles have a bimodal particle distribution.
6. The positive electrode of claim 5, wherein the active material particles comprise primary particles having an average particle size ranging from 1-10 micrometer and secondary particles having an average particle size ranging from about 10-200 nm.
7. A lithium ion battery comprising a negative electrode, an electrolyte and a positive electrode, the positive electrode comprising active material particles with inter-particle connectivity that increases the power and energy density of the battery compared with a battery having a positive electrode comprising active material particles without inter-particle connectivity.
8. The battery of claim 7, wherein the active material is LiCoO2, LiMn2CM, LiFePO-J, Li(MlM2Co)O2 where Ml and M2 are selected from among Li, Ni, Mn, Cr, or Al; and XLi2MO3(I-X)LiM1O2 where M is selected from among Mn, Ti, Zr, Ru, Re or Pt and M' is selected from among V, Mn, Fe, Co or Ni.
9. The battery of claim 7, wherein the active material particles have an average size ranging from about 1 to about 10 micrometer.
10. The battery of claim 7, wherein the active material particles have a multimode particle distribution.
11. The battery of claim 10, wherein the active material particles have a bimodal particle distribution.
12. The battery of claim 11 , wherein the active material particles comprise primary particles having an average particle size ranging from 1-10 micrometer and secondary particles having an average particle size ranging from about 10-200 run.
13. A method for making a positive electrode active material for a lithium battery, the method comprising forming dense granules of positive electrode active material particles, and sintering the granules so as to physically join the particles and provide inter-particle connectivity.
14. The method of claim 13, wherein the active material is LiCoO21LiMn2O4, LiFePO4, Li(MlM2Co)O2 where Ml and M2 are selected from among Li, Ni, Mn, Cr, or Al; and XLi2MOa(I -X)LiM1O2 where M is selected from among Mn, Ti, Zr, Ru, Re or Pt and M1 is selected from among V, Mn, Fe, Co or Ni.
15. The method of claim 13, wherein the active material particles have an average size ranging from about 1 to about 10 micrometer.
16. The method of claim 13, wherein the active material particles have a multimode particle distribution.
17. The method of claim 16, wherein the active material particles have a bimodal particle distribution.
18. The method of claim 17, wherein the active material particles comprise primary particles having an average particle size ranging from 1-10 micrometer and secondary particles having an average particle size ranging from about 10-200 ran.
19. The method of claim 13, wherein the dense granules are formed by spray drying a slurry of active material particles in a solvent/binder solution.
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US9099738B2 (en) | 2008-11-03 | 2015-08-04 | Basvah Llc | Lithium secondary batteries with positive electrode compositions and their methods of manufacturing |
US10224565B2 (en) | 2012-10-12 | 2019-03-05 | Ut-Battelle, Llc | High energy density secondary lithium batteries |
WO2024091625A1 (en) * | 2022-10-26 | 2024-05-02 | Texpower, Inc. | Low-cobalt or cobalt-free cathode materials with bimodal particle size distribution for lithium batteries |
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US5358533A (en) * | 1992-02-19 | 1994-10-25 | Joint Medical Products Corporation | Sintered coatings for implantable prostheses |
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US20040164291A1 (en) * | 2002-12-18 | 2004-08-26 | Xingwu Wang | Nanoelectrical compositions |
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US9099738B2 (en) | 2008-11-03 | 2015-08-04 | Basvah Llc | Lithium secondary batteries with positive electrode compositions and their methods of manufacturing |
US10224565B2 (en) | 2012-10-12 | 2019-03-05 | Ut-Battelle, Llc | High energy density secondary lithium batteries |
US10930969B2 (en) | 2012-10-12 | 2021-02-23 | Ut-Battelle, Llc | High energy density secondary lithium batteries |
WO2024091625A1 (en) * | 2022-10-26 | 2024-05-02 | Texpower, Inc. | Low-cobalt or cobalt-free cathode materials with bimodal particle size distribution for lithium batteries |
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