WO2025023934A1

WO2025023934A1 - Recycled battery materials and traceability

Info

Publication number: WO2025023934A1
Application number: PCT/US2023/028648
Authority: WO
Inventors: James Robert Lim; Bonnie Yip; Michael HLEBASKO; Alex Wang
Original assignee: Google Llc
Priority date: 2023-07-26
Filing date: 2023-07-26
Publication date: 2025-01-30

Abstract

Various arrangements for incorporating recycled material and identifying recycled material, such as recycled cobalt, in a battery, such as a lithium-ion battery, are detailed herein. A marker material may be incorporated within the battery. The marker material may include one or more characteristics to correspond with one or more features of the recycled material. A composition, morphology, or particle size and distribution of the marker material may be associated with the recycled material. By incorporating the marker material, subsequent analysis of the battery may allow for determining characteristics of the recycled material.

Description

RECYCLED BATTERY MATERIALS AND TRACEABILITY

BACKGROUND

[0001] Conventionally, cobalt, or other materials, in cathode materials are derived from mined resources. Recently, there has been a strong push to utilize recycled materials, such as cobalt, within lithium-ion batteries, especially within cathode materials. Elementally, mined cobalt and recycled cobalt are the same. Therefore, with the use of recycled cobalt, it is challenging, if not impossible, to identify, trace, and differentiate mined cobalt versus recycled cobalt. Without being able to discern whether cobalt is mined or recycled, issues may arise with compliance or sustainability since recycled cobalt cannot be differentiated from mined cobalt. Additionally, users may not be able to confidently know whether mined cobalt or recycled cobalt is being used. Further, some instances of cobalt mining include the use of child labor and various environmental concerns. Accordingly, when possible, it is desirable to avoid cobalt mining. The same may be true for other materials including, but not limited to, lithium, nickel, and manganese.

SUMMARY

[0002] Various embodiments are described related to incorporating recycled material and identifying recycled material, such as recycled cobalt, in a battery, such as a lithium-ion battery. In some embodiments, a lithium-ion battery is described. The lithium-ion battery may further comprise a cathode. The cathode may comprise a cathode active material and a marker material. At least a portion of the cathode active material may comprise a recycled cobalt-containing material or other recycled metal-containing material. The marker material may be an electrochemically inert material. The lithium-ion battery may further comprise an anode. The lithium-ion battery may further comprise an electrolyte. The lithium-ion battery may further comprise a separator between the cathode and the anode.

[0003] Embodiments of such a battery may include one or more of the following features: the recycled cobalt-containing material may comprise lithium cobalt oxide (LCO). The marker material may comprise a lithium-containing material. The marker material may comprise a lithium super ionic conductor (LISCON), a sodium super ionic conductor (NASICON), lithium phosphorus oxynitride (LIPON), lithium lanthanum zirconium oxide (LLZO), lithium aluminum titanium phosphate (LATP), or lithium lanthanum titanium oxide (LLTO). A chemical composition, a morphology, and/or a particle size and distribution of the marker material may be associated with an amount of recycled cobalt-containing material in the cathode active material. The cathode active material may further comprise a non-recycled cobalt-containing material. The cathode active material may comprise greater than 5 wt.% recycled cobalt-containing material based on the weight of the recycled cobalt-containing material and the non-recycled cobalt- containing material.

[0004] In some embodiments, a cathode for a battery is described. The cathode may comprise a cathode current collector. The cathode may further comprise a cathode active material disposed on the cathode current collector. The cathode active material may comprise a recycled cobalt- containing material. The cathode may further comprise a marker material associated with an amount of the recycled cobalt-containing material in the cathode active material.

[0005] Embodiments of such a cathode for a battery may include one or more of the following features: the recycled cobalt-containing material may comprise lithium cobalt oxide (LCO). The marker material may be incorporated within the cathode active material. The marker material may be coated on a portion of the cathode active material. The marker material may be an electrochemically inert material. The marker material may comprise a lithium super ionic conductor (LISCON), a sodium super ionic conductor (NASICON), lithium phosphorus oxynitride (LIPON), lithium lanthanum zirconium oxide (LLZO), lithium aluminum titanium phosphate (LATP), or lithium lanthanum titanium oxide (LLTO). A chemical composition, a morphology (e.g., oval, round, bimodal, etc.), and/or a particle size and distribution of the marker material may correspond with a wt.% of the recycled cobalt-containing material in the cathode active material.

[0006] In some embodiments, a method of identifying an amount of recycled material in a battery is described. The method may comprise forming a cathode current collector on a substrate. The method may further comprise forming a cathode active material on the cathode current collector to form a cathode. The cathode active material may comprise a recycled cobalt- containing material. The method may further comprise incorporating a marker material associated with an amount of the recycled cobalt-containing material in the cathode active material. The method may further comprise incorporating the cathode with the marker material into the lithium- ion battery.

[0007] Embodiments of such a method of identifying an amount of recycled material in a battery may include one or more of the following features: the recycled cobalt-containing material may comprise lithium cobalt oxide (LCO). The marker material may comprise less than or about 5 wt.% of a total weight of the cathode active material. The marker material may be characterized by a chemical composition, a morphology, and/or a particle size and distribution that is associated with an amount of recycled cobalt-containing material in the cathode active material. The methods may further comprise creating a data store to associate an amount of recycled cobalt-containing material in the cathode active material with the marker material. The marker material may comprise a lithium super ionic conductor (LISCON), a sodium super ionic conductor (NASICON), lithium phosphorus oxynitride (LIPON), lithium lanthanum zirconium oxide (LLZO), lithium aluminum titanium phosphate (LATP), or lithium lanthanum titanium oxide (LLTO).

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] A further understanding of the nature and advantages of various embodiments may be realized by reference to the following figures. In the appended figures, similar components or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

[0009] FIG. 1 illustrates a cross-sectional view of an embodiment of a battery.

[0010] FIG. 2 illustrates a cross-sectional view of an embodiment of a battery.

[0011] FIG. 3 illustrates an embodiment of a method for incorporating a marker material in a battery.

[0012] FIG. 4 illustrates an embodiment of a marker material incorporated in a battery.

[0013] FIG. 5 illustrates an embodiment of a method of identifying an amount of recycled material in a battery.

[0014] FIG. 6 illustrates an embodiment of a system for identifying an amount of recycled material in a battery.

DETAILED DESCRIPTION

[0015] Embodiments of incorporating a marker material associated with a recycled material in a battery, such as a lithium-ion battery, are detailed herein. The marker material may be included in a cathode of the battery, such as in cathode active material. The marker material or various properties thereof may be associated with recycled material content, such as an amount of recycled cobalt.

[0016] By incorporating the marker material associated with the recycled material, the recycled material may be identified, traced, and differentiated from non-recycled or mined material. Additionally, authenticity of the recycled material may be ensured, as the marker material may later be analyzed to identify and confirm various characteristics of the marker material associated with the recycled material. The marker material may also be an electrochemically inert material that does not hinder or impact electrical performance of the battery. Therefore, the incorporation of the marker material may therefore allow for the differentiation between recycled material and nonrecycled material while maintaining desired performance.

[0017] FIG. 1 illustrates a cross-sectional view of an embodiment of a battery 100, which may be a lithium-ion battery or any other cobalt-containing battery, such as a nickel manganese cobalt (NMC) battery. The battery 100 may include an anode current collector 102 and an anode 104. The anode current collector 102 may include a metal such as copper. The anode current collector 102 may additionally or alternatively include carbon nanotubes and/or metal nanowires. The anode current collector 102 may include a layer characterized by a thickness of greater than or about 1 micron, such as greater than or about 2 microns, greater than or about 3 microns, greater than or about 4 microns, greater than or about 5 microns, greater than or about 6 microns, or more, however other thicknesses are possible. The anode 104 may include lithium-containing material. The anode 104 may be a layer characterized by a thickness of greater than or about 1 micron, such as greater than or about 2 microns, greater than or about 3 microns, greater than or about 4 microns, greater than or about 5 microns, greater than or about 6 microns, or more, but other thicknesses are possible. The battery 100 may also include an anode protector 106 disposed on the anode 104. The anode protector 106 may include a lithium-containing material, such as lithium phosphorus oxynitride (LIPON). The anode protector 106 may be a layer characterized by a thickness of greater than or about 0.5 microns, such as greater than or about 0.7 microns, greater than or about 1.0 micron, greater than or about 1.2 microns, greater than or about 1.5 microns, or more, however other thicknesses are possible. In an example embodiment, the anode protector 106 material may allow lithium ion transport while preventing a short circuit between the anode 104 and the anode protector 106.

[0018] The battery 100 may include a layer of solid electrolyte 108, which may be characterized by a thickness of greater than or about 1.0 micron, such as greater than or about 1.2 microns, greater than or about 1.5 microns, greater than or about 1.7 microns, greater than or about 2.0 microns, or more, however other thicknesses are possible. The solid electrolyte 108 may include lithium sulfide glass, lithium super ionic conductor (LISCON), and a garnet-type glass. In an example embodiment, the solid electrolyte 108 may be porous and/or include pinholes. Other solid electrolyte materials configured to facilitate lithium ion transport are possible.

[0019] The battery 100 may include a separator 114 with a first gel electrolyte layer 110 and a second gel electrolyte layer 112 disposed on either side of the separator 114. The separator 114 with the gel electrolyte layers 110 and 112 may be disposed on the solid electrolyte 108. The gel electrolyte layers 110 and 112 may include a liquid and a polymer. The gel electrolyte layers 110 and 112 may each be characterized by a thickness of greater than or about 1.0 micron, such as greater than or about 1.2 microns, greater than or about 1.5 microns, or more, however other thicknesses are possible. In embodiments, the gel electrolyte layers 110 and 112 may be the same thickness. However, it is also contemplated that the gel electrolyte layers 110 and 112 may be different thicknesses.

[0020] The separator 114 may include, but is not limited to, polyethylene (PE) or polypropylene (PP). The separator 114 may be characterized by a thickness of greater than or about 1 micron, such as greater than or about 2 microns, greater than or about 3 microns, greater than or about 4 microns, greater than or about 5 microns, greater than or about 6 microns, or more, but other thicknesses are possible. The separator 114 may be coated on both sides with gel electrolyte layers, such as gel electrolyte layers 110 and 112, before the assembly is disposed onto the solid electrolyte 108. The separator 114 and the gel electrolyte layers 110 and 112 may be configured to reduce or eliminate the effect of pinholes in the solid electrolyte 108.

[0021] The battery 100 may include a cathode 116 disposed on the gel electrolyte layer 112. The cathode 116 may include a cathode active material. The cathode active material may include a lithium-containing material, such as lithium cobalt oxide (LCO), or nickel manganese cobalt (NMC) or another cathode material disclosed herein. In embodiments where the cathode includes LCO, at least a portion of cobalt in the LCO may be recycled cobalt. In embodiments where the cobalt in the LCO is not purely recycled cobalt, a portion of cobalt may also include a nonrecycled cobalt-containing material or a mined cobalt-containing material. In some embodiments, additionally or alternatively, a portion of the lithium in the LCO may be recycled lithium.

Similarly, where the lithium in the LCO is not purely recycled lithium, a portion of lithium may also include a non-recycled lithium-containing material or a mined lithium-containing material. In an NMC battery, the cathode active material may include a nickel-cobalt-and-manganese- containing material, and at least a portion of the cathode active material may be recycled. For example, at least a portion of the nickel and/or at least a portion of the manganese may be recycled material, with any remaining portion of the nickel or manganese being non-recycled material or mined material. The cathode 116 may be characterized by a thickness of greater than or about 40 microns, such as greater than or about 46 microns, greater than or about 47 microns, or more, however other thicknesses are possible. [0022] The battery 100 may include a cathode current collector 118. The cathode current collector 118 may include aluminum or another conductive material. Furthermore, the cathode current collector 118 may be disposed on the cathode 116.

[0023] FIG. 2 illustrates a cross-sectional view of an embodiment of a battery 200, which may be a lithium-ion battery. Similar to battery 100, battery 200 may include an anode current collector 202, an anode 204, a cathode 212, and a cathode current collector 214. Battery 200 may include a first gel electrolyte layer 206 disposed on the anode 204 and a solid electrolyte 208 disposed on the first gel electrolyte layer 206. Battery 200 may include a second gel electrolyte layer 210 disposed on the solid electrolyte 208. In other words, the solid electrolyte material may be disposed between the first gel electrolyte layer 206 and the second gel electrolyte layer 210.

[0024] The solid electrolyte 208 may be characterized by a thickness of greater than or about 15 microns, such as greater than or about 17 microns, greater than or about 20 microns, or more, however other thicknesses are possible. The first gel electrolyte layer 206 and the second gel electrolyte layer 210 may be characterized by thicknesses of greater than or about 1.0 micron, such as greater than 1.2 microns, greater than 1.5 microns, greater than 1.7 microns, greater than 2.0 microns thick, or more, however other thicknesses are possible. In embodiments, the first gel electrolyte layer 206 and the second gel electrolyte layer 210 may be the same thickness. However, it is also contemplated that the first gel electrolyte layer 206 and the second gel electrolyte layer 210 may be different thicknesses. The first gel electrolyte layer 206 and the second gel electrolyte layer 210 may include any of the gel electrolyte materials described herein. Battery 200 may also include the cathode 212 disposed on the second gel electrolyte layer 210.

[0025] A marker material, to be discussed further below, may be incorporated in cathode 116 or cathode 212, such as in the cathode active material. The marker material may be associated with an amount of the recycled cobalt-containing material (or lithium-containing material, nickel- containing material, and/or manganese-containing material) in the battery, such as in the cathode. In order to limit impact on battery performance, the marker material may be an electrochemically inert material.

[0026] As previously discussed, embodiments include incorporating a marker material associated with recycled material content in batteries. FIG. 3 illustrates an embodiment of a method 300 for incorporating a marker material in a lithium-ion battery. Method 300 may include a number of optional operations, which may or may not be specifically associated with some embodiments of methods according to the present technology. For example, many of the operations are described in order to provide a broader scope, but are not critical to the technology, or may be performed by alternative methodology.

[0027] At operation 305, method 300 may include forming a cathode current collector on a substrate. In one example, the cathode current collector may include a metal, such as aluminum, carbon, nickel, titanium, or stainless steel. However, any suitable material may be used for the cathode current collector. The cathode current collector may be characterized by a thickness of greater than 4 microns, greater than 5 microns, greater than 6 microns, or more, however other thicknesses are possible. It is noted that formation of a cathode current collector may not be a required operation, and may be an optional operation in method 300.

[0028] In embodiments, cathode current collector may be formed using RF or DC sputtering of source targets. Alternatively, PVD, electron beam-induced deposition or focused ion beam deposition may be utilized to form the cathode current collector. In some embodiments, the cathode current collector may be formed by depositing a blanket material layer on a substrate. The blanket material layer may subsequently be patterned, for example by a masking and etching method or by laser ablation. An encapsulation layer may be formed over the cathode current collector. The encapsulation layer may include an inert and/or passivating material, such as silicon nitride (SiN). The encapsulation layer may include a plurality of layers. The plurality of layers may include at least one of a polymer material and a ceramic material. For example, the encapsulation layer may include a photoresist layer and an alumina layer deposited in an alternating multi-layer fashion.

[0029] Subsequent to forming the cathode current collector, method 300 may include forming a cathode active material on the cathode current collector at operation 310. By forming the cathode active material on the cathode current collector, a cathode may be produced. The cathode active material may include a cobalt-containing material, and at least a portion of the cobalt-containing material may be a recycled cobalt-containing material. The cathode active material, depending on application, may additionally or alternatively include a lithium-containing material, a nickel- containing material, and/or a manganese-containing material, with at least a portion of any of these materials being a recycled material. As previously discussed with regard to operation 305, forming a cathode current collector may not be a required operation. Accordingly, the present technology may encompass forming the cathode active material without the previous formation of a cathode current collector.

[0030] In embodiments, the cobalt-containing material (or lithium-containing material, nickel- containing material, or manganese-containing material) may be greater than 5 wt.% recycled cobalt-containing material (or recycled lithium-containing material, recycled nickel-containing material, or recycled manganese-containing material), greater than 10 wt.%, greater than 15 wt.%, greater than 20 wt.%, greater than 25 wt.%, greater than 30 wt.%, greater than 35 wt.%, greater than 40 wt.%, greater than 45 wt.%, greater than 50 wt.%, greater than 55 wt.%, greater than 60 wt.%, greater than 65 wt.%, greater than 70 wt.%, greater than 75 wt.%, greater than 80 wt.%, greater than 85 wt.%, greater than 90 wt.%, or greater than 95 wt.%, and may include 100 wt.% recycled cobalt (or recycled lithium, recycled nickel, or recycled manganese).

[0031] The cathode active material, such as LCO, may be deposited using RF sputtering or PVD, however other deposition techniques may be used to form the cathode active material. The deposition of the cathode active material may occur as a blanket over the entire cathode current collector. A subtractive process of masking and etching may remove cathode active material where unwanted. Alternatively, the deposition of the cathode active material may be masked using a photolithography-defined resist mask. The cathode active material may be deposited through a shadow mask. The cathode active material may be patterned using additive or subtractive fabrication techniques.

[0032] At operation 315, method 300 may include incorporating a marker material associated with an amount of the recycled cobalt-containing material (or recycled lithium-containing material, recycled nickel-containing material, or recycled manganese-containing material) in the cathode active material. The marker material may be an electrochemically inert material to limit any impact on the cathode and/or the battery. For example, the marker material may include one or more of a lithium super ionic conductor (LISCON), a sodium super ionic conductor (NASICON), lithium phosphorus oxynitride (LIPON), lithium lanthanum zirconium oxide (LLZO), lithium aluminum titanium phosphate (LATP), lithium lanthanum titanium oxide (LLTO). However, any other electrochemically inert material, such as other lithium-containing materials or inert solid state electrolyte materials may be used. Again, as previously discussed with regard to operation 305, forming a cathode current collector may not be a required operation. Accordingly, the present technology may encompass incorporating the marker material without the previous formation of a cathode current collector.

[0033] The marker material may be incorporated in the cathode active material in any number of manners. In one embodiment, the marker material may be coated on the material used to form the cathode active material. For example, material or particles used during the formation of cathode active material on the cathode current collector may be at least partially coated with the marker material. Additionally or alternatively, the marker material may more simply be incorporated within the cathode active material matrix.

[0034] The marker material may be characterized by one or more characteristics, which may be associated with the recycled cobalt-containing material (or recycled lithium-containing material, recycled nickel-containing material, or recycled manganese-containing material). For example, the one or more characteristics may be associated with incorporation, source, or any other feature desired to be traced of the recycled cobalt-containing material (or recycled lithium-containing material, recycled nickel-containing material, or recycled manganese-containing material). Characteristics associated with the marker material may include, but are not limited to, composition, morphology, particle size and distribution. For example, when the marker material includes LLZO, the composition may be tailored to correspond with two different features of traced recycled cobalt-containing material (or recycled lithium-containing material, recycled nickel-containing material, or recycled manganese-containing material). LivLasZnOn may correspond with a first recycled material, such as a first recycled cobalt-containing material, whereas LieLaiZnOn may correspond with a second recycled material, such as a second recycled cobalt-containing material, different from the first recycled material. Additionally, various different morphologies may be used for the marker material. For example, the marker material may have an oval, round, bimodal, or any other shape. Finally, particle size and distribution may be associated with the recycled material. In embodiments, a dio, dso, and dw particle size and distribution may be adjusted to correspond with specific values or features of the recycled material.

[0035] In order to further limit any impact on electrical performance of the battery, incorporation of the marker material may be minimized. For example, the marker material may be less than or about 10 wt.% of a total weight of the cathode active material. For example, the marker material may be less than or about 9 wt.%, less than or about 8 wt.%, less than or about 7 wt.%, less than or about 6 wt.%, less than or about 5 wt.%, less than or about 4 wt.%, less than or about 3 wt.%, less than or about 2 wt.%, less than or about 1 wt.%, less than or about 0.5 wt.%, or less of a total weight of the cathode active material, such as between about 0.5 wt.% and about 10 wt.% or between about 0.5 wt.% and about 5 wt.%. At marker material incorporations of much greater than 10 wt.%, performance of the battery may be impacted. Additionally, smaller amounts of marker material may be sufficient for associating the marker material with recycled material.

[0036] While illustrated as a separate operation in FIG. 3, method 300 may include simultaneously forming a cathode active material on the cathode current collector at operation 310 and incorporating a marker material in the cathode active material at operation 315. In embodiments, the marker material may be incorporated intermittently while forming the cathode active material on the cathode current collector. Additionally, it is contemplated that the marker material may be incorporated into the material used to form the cathode active material prior to producing the cathode.

[0037] At operation 320, method 300 may include incorporating the cathode with the marker material into the battery. For example, the cathode formed by method 300 may be incorporated into battery 100 or battery 200 previously described. By incorporating the marker material into the battery, recycled material content may be identified and traced.

[0038] Additionally, one or more other operations necessary to form the battery may be performed in method 300. For example, the method 300 may further include forming an electrolyte layer on the cathode active material, forming an anode layer on the electrolyte layer, and/or forming an anode current collector layer on the substrate.

[0039] FIG. 4 illustrates a scanning electron microscope (SEM) image of an embodiment of a cathode 400. Cathode 400 may include a marker material 405 and a cathode active material 410. In the embodiment shown in FIG. 4, the marker material 405 may be incorporated within the matrix of the cathode active material 410. As previously discussed, the marker material 405 may be characterized by one or more features, such as chemical composition, morphology, and/or particle size and distribution, associated with recycled material in the cathode active material 410. For example, the marker material 405 may include LLZO particles with a composition of LivLasZnOn and a particle shape of round. For example, this chemical composition and morphology of the marker material 405 may be mapped to a 100% recycled cobalt-containing material (or recycled lithium-containing material, recycled nickel-containing material, or recycled manganese- containing material) in the cathode active material 410. Therefore, at some time in the future, when the cathode active material 410 is analyzed, the cobalt (or other material) can be traced back to from where it was obtained.

[0040] In another embodiment and as illustrated in FIG. 5, a method 500 for identifying an amount of recycled material in a battery is contemplated. Method 500 may include a number of optional operations, which may or may not be specifically associated with some embodiments of methods according to the present technology. For example, many of the operations are described in order to provide a broader scope, but are not critical to the technology, or may be performed by alternative methodology. [0041] At operation 505, method 500 may include creating a data store. The data store may include characteristics of the marker material to be incorporated in the battery. The characteristics of the marker material may include, but are not limited to, chemical composition, morphology, and/or particle size and distribution. These characteristics may be associated with recycled material, such as an amount of recycled material incorporated within the battery. These characteristics may also or alternatively be associated with provenance of the recycled material or any other feature desired to be tracked of the recycled material. The data store may include, but is not limited to, random access memory (RAM), flash memory, a hard disk drive (HDD), and/or a solid-state drive (SSD). [0042] An example data store is shown below in Table 1 that associates various features of the marker material with the recycled material.

Table 1. Data Store of Marker Materials

[0043] Similar to operation 305 of method 300, method 500 may include forming a cathode current collector on a substrate at operation 510. Again, the cathode current collector may include a metal, such as aluminum, carbon, nickel, titanium, or stainless steel. However, any suitable material may be used for the cathode current collector. The cathode current collector formed at operation 510 may be formed using any of the methods and techniques previously discussed with regard to operation 305. Additionally, the cathode formed at operation 50 may include any characteristics previously discussed with regard to operation 305. Similar to operation 305, it is noted that formation of a cathode current collector may not be a required operation, and may be an optional operation in method 500.

[0044] Method 500 may include forming a cathode active material on the cathode current collector at operation 515. The cathode active material formed at operation 515 may be formed using any of the methods and techniques previously discussed with regard to operation 310. Additionally, the cathode active material formed at operation 515 may include any characteristics previously discussed with regard to operation 310. As forming a cathode current collector may not be a required operation, the present technology may encompass forming the cathode active material without the previous formation of a cathode current collector.

[0045] Subsequent to or while forming the cathode active material, method 500 may include incorporating a marker material at operation 520. Similar to method 300, the marker material may be associated with a source, a product, or an amount of the recycled material, such as the recycled cobalt-containing material, in the cathode, such as in the cathode active material. The marker material incorporated at operation 520 may be incorporated using any of the methods and techniques previously discussed with regard to operation 315. Additionally, the marker material incorporated at operation 515 may be any materials or include any characteristics previously discussed with regard to operation 315. Again, as previously discussed with regard to operation 305, forming a cathode current collector may not be a required operation. Accordingly, the present technology may encompass incorporating the marker material without the previous formation of a cathode current collector.

[0046] After the cathode is formed and the marker material is incorporated, method 500 may include incorporating the cathode with the marker material into the lithium-ion battery at operation 525. Again, the cathode formed by method 500 may be incorporated into battery 100 or battery 200 previously described. By incorporating the marker material into the battery, recycled material content may be identified and traced, such as in subsequent operations described below.

[0047] At operation 530, method 500 may include analyzing the marker material within the battery. In order to analyze the marker material, the battery may be opened, and the cathode active material may be extracted. The cathode active material may be placed in a jelly roll structure, or any other structure suitable for analysis of the cathode active material. One or more analytical tools may be employed at operation 530 to identify characteristics of the cathode active material, especially the marker material incorporated in the cathode active material. Such analytical tools may identify chemical composition, morphology, and/or particle size and distribution. While the analysis performed at operation 530 may analyze the entire cathode active material, emphasis may be on analyzing the marker material.

[0048] Non-limiting examples of analytical tools may include Auger electron spectroscopy (AES) or energy-dispersive X-ray spectroscopy (EDS) for identifying chemical composition, as well as SEM or transmission electron microscopy (TEM) for identifying morphology and/or particle size and distribution. While AES, EDS, SEM, and TEM are specifically listed, it is contemplated that any suitable analytical tool or analysis method may be utilized to analyze the marker material.

[0049] With characteristics of the marker material, including chemical composition, morphology, and/or particle size and distribution, identified, method 500 may include associating the marker material with recycled material in the battery at operation 535. Specifically, operation 535 may include associating the identified characteristics of the marker material with one or more characteristics of marker materials in the data store. As previously discussed, the data store may include information of various marker materials and their corresponding information related to recycled material. As such, analyzing the marker material to identify chemical composition, morphology, and/or particle size and distribution, or any other characteristic, may allow for associating the specific marker material with the recycled material, such as with the amount of recycled cobalt-containing material (or recycled lithium-containing material, recycled nickel- containing material, or recycled manganese-containing material), in the cathode active material.

[0050] In embodiments, two or more characteristics of the marker material may be associated with the recycled material. For example, the recycled material may be associated with both a chemical composition and a morphology. By associating the recycled material with both a chemical composition and a morphology, authenticity of the cathode may be monitored. When multiple parties are involved in recycling, producing the material for the cathode, and forming the cathode, the final product can be analyzed for two or more characteristics of the marker material to ensure the recycled material is authentic. In such embodiments, a first party recycling the material and/or producing the material for the cathode may be aware of the two or more characteristics, and a second party forming the cathode may be aware of only one characteristic. For example, the first party may be aware of both the chemical composition and morphology of the marker material, and the second party may be aware of only the chemical composition. After the cathode is formed, the morphology of the marker material may be analyzed to confirm the marker material is correctly associated with the recycled material. If the morphology is not correct, the second party may have simply used the chemical composition with a different morphology, which may evidence use of non-recycled material.

[0051] FIG. 6 illustrates a block diagram of a system 600 used for manufacturing a battery with a marker material and, later, identifying a characteristic, such as an amount of recycled material in the battery. The system 600 may be operable to associate data about recycled material, such as recycled cathode active material, with a marker or identifier, manufacture a battery including the recycled material and the marker or identifier, and perform subsequent analysis to identify the marker or identifier and interpret characteristics of the recycled material. The system 600 may include a monitoring subsystem 601, a manufacturing subsystem 602, and an investigating subsystem 603. While shown as three separate subsystems which can each be operated by distinct entities or parties, it is contemplated that two or even all of the subsystems may be controlled by a single entity or party. For example, the party controlling the monitoring subsystem 601 may also control the investigating subsystem 603 while a second party controls the manufacturing subsystem 602.

[0052] The monitoring subsystem 601 may include a user interface 610, a first processing system 620, and a data store 630. The user interface 610 may be operable to receive inputs to associate characteristics of a marker material 640, such as for the marker materials previously discussed, with recycled material. The first processing system 620 may include one or more special-purpose or general-purpose processors. Such special-purpose processors may include processors that are specifically designed to perform the functions of the components detailed herein. Such special-purpose processors may be ASICs or FPGAs which are general -purpose components that are physically and electrically configured to perform the functions detailed herein. Such general-purpose processors may execute special-purpose software that is stored locally using one or more non-transitory processor-readable mediums via data store 630, which can include random access memory (RAM), flash memory, a hard disk drive (HDD) and/or a solid-state drive (SSD). In embodiments, the information housed in the data store 630 may include information of recycled material, such as amount, source, and/or product of the recycled material in the cathode active material. This information is mapped to the characteristics of the marker material. In embodiments, information housed in the data store 630 may be stored remotely and accessible via network 690. For example, a cloud-based storage accessible via the Internet may be used to access the information.

[0053] The monitoring subsystem 601 may therefore allow for association and/or production of the marker material 640. However, it is also contemplated that the monitoring subsystem 601 may simply associate one or more characteristics of the marker material 640 with recycled material to be used in formed devices. For example, a party operating monitoring subsystem 601 may have the marker material 640 manufactured on its behalf by another entity. This information may then be kept in the data store 630 of the monitoring subsystem 601. Regardless of whether the monitoring subsystem 601 produces the marker material 640 or stores information about the marker material 640, the marker material 640 may then be used in the manufacturing subsystem 602.

[0054] In this example, the manufacturing subsystem 602 indicates the entity and systems that are used to manufacture the battery. The manufacturing subsystem 602 may use the marker material 640, recycled material 650 (e.g., recycled cobalt-containing material), and a manufacturing assembly 660 in creating the battery. As previously discussed, the marker material 640 may be incorporated with recycled material 650, such as in the manufacturing assembly 660. In embodiments, the manufacturing assembly 660 may form a cathode where cathode active material includes both the marker material 640 and the recycled material 650. It is contemplated that the marker material 640 and the recycled material 650 may be combined prior to being provided to the manufacturing assembly 660, or the marker material 640 and the recycled material 650 may be combined in the manufacturing assembly 660. Combining the marker material 640 and the recycled material 650 may include any feature of method 300 or 500 previously discussed. After forming the cathode in the manufacturing assembly 660, the cathode may be incorporated into a battery 670, which may include any feature of battery 100 or 200 or method 300 or 500 previously discussed.

[0055] In embodiments where the marker material 640 is provided to the manufacturing subsystem 602, the data store 630 may house two or more characteristics associated with the marker material 640. However, at least one of those characteristics may not be provided or readily discernable to the party responsible for the manufacturing subsystem 602. By not indicating all of the characteristics, the party overseeing the monitoring subsystem 601 may ensure the party responsible for the manufacturing subsystem 602 is utilizing the correct marker material 640 with the correct recycled material 650 and/or that the party responsible for manufacturing system 602 is not acquiring its own marker material for impermissible use. If, in later analysis, all of the characteristics associated with the marker material 640 are not present, the party overseeing the monitoring subsystem 601 may identify that the party responsible for the manufacturing subsystem 602 may be counterfeiting devices.

[0056] The battery 670, after some amount of time and/or use, may be provided to investigating subsystem 603 for analysis. Investigating subsystem 603 can be operated by a third distinct party or may be operated by the same party as monitoring system 601. Investigating subsystem 603 may include an analytical tool 680, a second processing system 625, and a second user interface 645. The battery 670 may be provided to the analytical tool 680 for determining one or more characteristics or features of the battery 670, such as characteristics or features of the marker material 640 within the battery 670. As previously discussed with regard to method 500, analytical tools may identify chemical composition, morphology, and/or particle size and distribution of the marker material 640. As such, the analytical tool 680 may include a tool or method to perform AES, EDSD, SEM, TEM, or any other analysis method. The analytical tool 680 may obtain information associated with one or more characteristics or features of the marker material 640 from the analysis performed. The analytical tool 680 may be in communication with a second processing system 625.

[0057] Similar to the first processing system 620, the second processing system 625 may include one or more special-purpose or general-purpose processors. The second processing system 625 may include any feature previously discussed with regard to the first processing system 620. The first processing system 620 may then communicate with the data store 630 via network 690 to use the information obtained from the analytical tool 680 to look up information housed in the data store 630. In embodiments, the information that is looked up may include, but is not limited to, an amount of recycled material 650, such as recycled cobalt-containing material, in the battery 670, such as in the cathode active material.

[0058] After performing the lookup in data store 630 based on the characteristics of the marker material 640, information obtained from the data store 630 may be outputted via the second user interface 645 or transmitted to a remote user via network 690. The second user interface 645 may output information regarding the recycled material 650 after analysis of the battery 670 and association with the data store 630.

[0059] As previously discussed, both mined cobalt and recycled cobalt are elementally the same and nearly impossible to differentiate. By incorporating a marker material when recycled cobalt is present, later analysis may be performed to identify characteristics of the recycled cobalt that may be included with non-recycled cobalt. While the present embodiments routinely discuss identification of recycled cobalt-containing material, the described devices, methods, and systems may be utilized to track and identify any number of recycled materials. For example and as previously discussed, the described devices, methods, and systems may be utilized to track and identify recycled lithium-containing material, recycled nickel-containing material, recycled manganese-containing material, and any other material that is nearly impossible to differentiate a recycled form from a non-recycled form.

[0060] It should be noted that the methods, systems, and devices discussed above are intended merely to be examples. It must be stressed that various embodiments may omit, substitute, or add various procedures or components as appropriate. For instance, it should be appreciated that, in alternative embodiments, the methods may be performed in an order different from that described, and that various steps may be added, omitted, or combined. Also, features described with respect to certain embodiments may be combined in various other embodiments. Different aspects and elements of the embodiments may be combined in a similar manner. Also, it should be emphasized that technology evolves and, thus, many of the elements are examples and should not be interpreted to limit the scope of the invention.

[0061] Specific details are given in the description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, well-known, processes, structures, and techniques have been shown without unnecessary detail in order to avoid obscuring the embodiments. This description provides example embodiments only, and is not intended to limit the scope, applicability, or configuration of the invention. Rather, the preceding description of the embodiments will provide those skilled in the art with an enabling description for implementing embodiments of the invention. Various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention.

[0062] Also, it is noted that the embodiments may be described as a process which is depicted as a flow diagram or block diagram. Although each may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be rearranged. A process may have additional steps not included in the figure.

[0063] Having described several embodiments, it will be recognized by those of skill in the art that various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the invention. For example, the above elements may merely be a component of a larger system, wherein other rules may take precedence over or otherwise modify the application of the invention. Also, a number of steps may be undertaken before, during, or after the above elements are considered. Accordingly, the above description should not be taken as limiting the scope of the invention.

Claims

WHAT IS CLAIMED IS:

1. A battery comprising: a cathode comprising a cathode active material and a marker material, wherein at least a portion of the cathode active material comprises a recycled cobalt-containing material, and wherein the marker material is an electrochemically inert material; an anode; an electrolyte; and a separator between the cathode and the anode.

2. The battery of claim 1, wherein the recycled cobalt-containing material comprises lithium cobalt oxide (LCO).

3. The battery of claim 1, wherein the marker material comprises a lithium- containing material.

4. The battery of claim 1, wherein the marker material comprises a lithium super ionic conductor (LISCON), a sodium super ionic conductor (NASICON), lithium phosphorus oxynitride (LIPON), lithium lanthanum zirconium oxide (LLZO), lithium aluminum titanium phosphate (LATP), or lithium lanthanum titanium oxide (LLTO).

5. The battery of claim 1, wherein a chemical composition, a morphology, and/or a particle size and distribution of the marker material is associated with an amount of recycled cobalt-containing material in the cathode active material.

6. The battery of claim 1, wherein the cathode active material further comprises a non-recycled cobalt-containing material.

7. The battery of claim 1, wherein the cathode active material comprises greater than 5 wt.% recycled cobalt-containing material based on the weight of the recycled cobalt- containing material and the non-recycled cobalt-containing material.

8. A cathode for a battery comprising: a cathode current collector; a cathode active material disposed on the cathode current collector, wherein the cathode active material comprises a recycled cobalt-containing material; and a marker material associated with an amount of the recycled cobalt-containing material in the cathode active material.

9. The cathode for a battery of claim 8, wherein the recycled cobalt-containing material comprises lithium cobalt oxide (LCO).

10. The cathode for a battery of claim 8, wherein the marker material is incorporated within the cathode active material.

11. The cathode for a battery of claim 8, wherein the marker material is coated on a portion of the cathode active material.

12. The cathode for a battery of claim 8, wherein the marker material is an electrochemically inert material.

13. The cathode for a battery of claim 8, wherein the marker material comprises a lithium super ionic conductor (LISCON), a sodium super ionic conductor (NASICON), lithium phosphorus oxynitride (LIPON), lithium lanthanum zirconium oxide (LLZO), lithium aluminum titanium phosphate (LATP), or lithium lanthanum titanium oxide (LLTO).

14. The cathode for a battery of claim 8, wherein a chemical composition, a morphology, and/or a particle size and distribution of the marker material corresponds with a wt.% of the recycled cobalt-containing material in the cathode active material.

15. A method of identifying an amount of recycled material in a battery comprising: forming a cathode current collector on a substrate; forming a cathode active material on the cathode current collector to form a cathode, wherein the cathode active material comprises a recycled cobalt-containing material; incorporating a marker material associated with an amount of the recycled cobalt- containing material in the cathode active material; and incorporating the cathode with the marker material into the lithium-ion battery.

16. The method of identifying an amount of recycled material in a battery of claim 15, wherein the recycled cobalt-containing material comprises lithium cobalt oxide (LCO).

17. The method of identifying an amount of recycled material in a battery of claim 15, wherein the marker material comprises less than or about 5 wt.% of a total weight of the cathode active material.

18. The method of identifying an amount of recycled material in a battery of claim 15, wherein the marker material is characterized by a chemical composition, a morphology, and/or a particle size and distribution that is associated with an amount of recycled cobalt- containing material in the cathode active material.

19. The method of identifying an amount of recycled material in a battery of claim 15, further comprising: creating a data store to associate an amount of recycled cobalt-containing material in the cathode active material with the marker material.

20. The method of identifying an amount of recycled material in a battery of claim 15, wherein the marker material comprises a lithium super ionic conductor (LISCON), a sodium super ionic conductor (NASICON), lithium phosphorus oxynitride (LIPON), lithium lanthanum zirconium oxide (LLZO), lithium aluminum titanium phosphate (LATP), or lithium lanthanum titanium oxide (LLTO).