Patent Application
20130078518
This invention relates to electrode materials for electrochemical cells and batteries. Such cells and batteries are used widely to power numerous devices, for example, portable electronic appliances and medical, transportation, aerospace, and defense systems.
This invention relates to positive electrode materials (cathodes) for electrochemical cells and batteries. More specifically, the invention relates to lithium-metal-oxide electrode materials, predominantly those having layered-type structures, rock salt-type structures, or spinel-type structures, or combinations or modifications thereof, that contain manganese ions. The invention extends to include lithium-metal-oxide electrode materials with surface protection, for example, with metal-oxide, metal-fluoride or metal-phosphate layers or coatings to protect the electrodes from highly oxidizing potentials in the cells and from other undesirable effects, such as electrolyte oxidation, oxygen loss, and/or dissolution. Such surface protection enhances the surface stability, rate capability and cycling stability of the electrodes of this invention. The invention also extends to electrode precursor materials comprising manganese ions and to methods for fabricating lithium-metal-oxide electrode materials and structures using these precursor materials. The electrodes of this invention can be used either in primary cells and batteries or rechargeable cells and batteries, notably for lithium cells and batteries.
In one aspect, the present invention provides a positive electrode for an electrochemical cell. The electrode is formed by contacting a hydrogen-lithium-manganese-oxide material with one or more metal ions (e.g., in an aqueous or a non-aqueous solution or a solid state reaction) to insert the one or more metal ions into the hydrogen-lithium-manganese-oxide precursor material; heat-treating the resulting product (e.g., at a temperature in the range of about 300 to about 1000° C., preferably about 400 to about 950° C.) to form a powdered metal oxide composition; and forming an electrode from the powdered metal oxide composition (e.g., by casting a composition comprising the metal oxide powder and a binder onto a substrate, such as a metal foil). The hydrogen-lithium-manganese-oxide material preferably has a layered-type structure that comprises hydrogen, lithium, manganese, and oxygen ions, wherein the oxygen ions are preferably arranged in alternating layers forming octahedra and trigonal prisms in the crystal structure of the material. The powdered metal oxide product composition that results from the hydrogen-lithium-manganese-oxide precursor material can have, for example, a layered-type structure, a spinel-type structure, a rock salt-type structure, or an integrated/composite structure, comprising one or more of these structure types.
For this invention, layered compounds and structures refer broadly to lithium metal oxides LiMO2 or substituted derivatives, in which M is one or more metal ions, the structures of which comprise alternating layers of lithium ions interspersed with layers containing other metal ions, M. The layers containing the M metal ions can also contain lithium ions. Typical non-limiting examples of layered materials include LiCoO2 in which layers of lithium ions alternate with layers of cobalt ions in a close-packed oxygen array; and Li2MnO3 in which layers of lithium alternate with layers of manganese and lithium ions in a close-packed oxygen array. Rock salt compounds and structures refer broadly to metal oxides, MO, in which M is one or more metal ions (including lithium) that have close-packed structures typified, for example by NiO or substituted derivatives thereof. Spinel compounds and structures refer broadly to the family of close-packed lithium metal oxide spinels, LiM2O4, or substituted derivatives thereof in which M is one or more metal ions, as typified by the spinel system Li1+xMn2-xO4 (0≦x≦0.33). It is to be understood that, in practice, deviations from ideal crystallographic behavior of these structure types are commonplace, such as variations in composition, in atomic positions and coordination sites within crystal structures, as well as in the site occupancy of atoms and in the structural disorder of atoms on different sites. Such crystallographic deviations and imperfections are therefore necessarily included within the definitions provided above and within the spirit and scope of this invention.
In one embodiment, a positive electrode of the invention is formed from a lithium-manganese-oxide precursor compound that comprises lithium, manganese, and oxygen ions in a layered-type structure wherein lithium ions occupy octahedral sites in lithium-rich layers, and lithium and manganese ions occupy octahedral sites in manganese-rich layers that alternate with the lithium-rich layers within a close-packed oxygen array. In this embodiment, the precursor compound is contacted with an aqueous or non-aqueous solution that contains an acid and the one or more metal ions to be inserted. The formation of the hydrogen-lithium-manganese-oxide material by hydrogen donation from the acid, occurs concurrently with the insertion of the one or more metal ions. Next, the resulting product is heat-treated to form a powdered metal oxide composition, and then an electrode is formed from the powdered metal oxide composition. As described above, the hydrogen-lithium-manganese-oxide precursor material comprises hydrogen, lithium, manganese and oxygen ions, in which the oxygen ions may be arranged in alternating layers of octahedra and trigonal prisms in the crystal structure of the material or, alternatively, in some other packing arrangement of the ions. The extent to which a hydrogen-lithium-manganese-oxide material is formed as an intermediate product from the lithium-manganese-oxide precursor compound during the formation of the powdered metal oxide electrode composition depends on a number of factors, such as the extent of hydrogen ion exchange, the conditions of the processing treatment, and the like. Nevertheless, it is believed that an intermediate hydrogen-lithium-manganese-oxide material plays an important role in effecting ion-exchange reactions and the subsequent formation of the powdered metal oxide electrode composition and structure during its synthesis.
Preferably, the precursor compound comprises Li2MnO3 or Li[Li1/3Mn2/3]O2. In some preferred embodiments, the Li2MnO3 precursor is cation or anion deficient. In some preferred embodiments, the first precursor compound also includes up to 25 atom percent of one or more other metal ions, preferably transition metal ions, replacing manganese ions and/or lithium ions in the manganese-rich layer of the material. For example, the one or more other transition metal ions replacing the manganese ions can comprise a Ti ion, a Zr ion, or both.
In the positive electrodes of the present invention the manganese and non-lithium metal ions can be partially disordered between lithium-rich layers and manganese-rich layers.
Preferably, the one or more metal ions utilized in forming a positive electrode of the present invention are selected from an alkali metal ion (e.g., Li, Na, or K), an alkaline earth metal ion (e.g., Mg or Ca), a transition metal ion (e.g., Ti, V, Mn, Fe, Co, Ni, Zr, or Mo), or other suitable metal ions (e.g., Al).
Preferably, the lithium and manganese ions in the hydrogen-lithium-manganese-oxide material are located in oxygen octahedra, while the hydrogen ions may be coordinated to the oxygen ions in some other configuration, for example when the hydrogen ions are located in trigonal prisms defined by the oxygen ions. A preferred hydrogen-lithium-manganese-oxide material comprises H[Li1/3Mn2/3]O2, which can be cation or anion deficient. In some preferred embodiments, the hydrogen-lithium-manganese-oxide material may also include up to 25 atom percent of one or more other metal ions replacing manganese ions and/or lithium ions in the manganese-rich layer of the material. For example, the one or more other metal ions can comprise a transition metal ion such as a Ti ion, a Zr ion, or both. In a preferred embodiment, the one or more metal ions are contacted with the hydrogen-lithium-manganese-oxide material during the formation thereof, as described above.
The powdered metal oxide composition preferably has a disordered or partially disordered structure, and can include stacking faults, dislocations, or a combination thereof. The stacking faults can exist between cubic-closed-packed structures, hexagonal-close-packed structures, trigonal prismatic stacking structures, or a combination thereof.
In some embodiments, individual particles of the powdered metal oxide composition, a surface of the formed electrode, or both, are coated in situ during synthesis, for example, with a metal oxide, a metal fluoride, a metal polyanionic material, or a combination thereof, e.g., at least one material selected from the group consisting of (a) lithium fluoride, (b) aluminum fluoride, (c) a lithium-metal-oxide in which the metal is selected preferably, but not exclusively, from the group consisting of Al and Zr, (d) a lithium-metal-phosphate in which the metal is selected from the group consisting preferably, but not exclusively, of Fe, Mn, Co, and Ni, and (e) a lithium-metal-silicate in which the metal is selected from the group consisting preferably, but not exclusively, of Al and Zr. In a preferred embodiment of the invention, the constituents of the coating, such as the aluminum and fluoride ions of an AlF3 coating, the lithium and phosphate ions of a lithium phosphate coating, or the lithium, nickel and phosphate ions of a lithium-nickel-phosphate coating can be incorporated in the solution that is contacted with the hydrogen-lithium-manganese-oxide material or the lithium-manganese-oxide precursor when forming the electrodes of this invention. Alternatively, as taught hereinafter, the surface may be coated with fluoride ions, for example, using NH4F, in which case, the fluoride ions may substitute for oxygen at the surface or at least partially within the bulk of the electrode structure.
Preferably, the formed positive electrode comprises at least about 50 percent by weight (wt %) of the powdered metal oxide composition, and an electrochemically inert polymeric binder (e.g. polyvinylidene difluoride; PVDF). Optionally, the positive electrode can comprise up to about 40 wt % carbon (e.g., carbon back, graphite, carbon nanotubes, carbon microspheres, carbon nanospheres, or any other form of particulate carbon).
In one preferred embodiment, the present invention, designated herein as “Embodiment A”, provides a positive electrode for an electrochemical cell in which the electrode is formed by a method comprising: (a) contacting a hydrogen-lithium-manganese-oxide material with one or more metal ions to insert the one or more metal ions into the hydrogen-lithium-manganese-oxide material; (b) heat-treating the resulting product (e.g., at a temperature in the range of about 300 to about 1000° C.) to form a powdered metal oxide composition; and (c) forming an electrode from the powdered metal oxide composition. The powdered metal oxide composition has a layered-type structure, a spinel-type structure, a rock salt-type structure, or an integrated structure comprising one or more of these structure types. Preferably, the hydrogen-lithium-manganese-oxide material in this embodiment comprises hydrogen, lithium, manganese, and oxygen ions, and the oxygen ions are arranged in alternating layers of octahedra and trigonal prisms in the crystal structure of the material. Preferably, the one or more metal ions are selected from the group consisting of an alkali metal ion, an alkaline earth metal ion, and a transition metal ion (e.g., one or more metal ions are selected from the group of ions consisting of Li, Na, K, Mg, Ca, Ti, V, Mn, Fe, Co, Ni, Zr, Mo and Al ions). In some preferred embodiments, the one or more other transition metal ions comprises a Ti ion, a Zr ion, a Co ion, a Ni ion, or a combination thereof.
If desired, the manganese and non-lithium metal ions in Embodiment A can be partially disordered between lithium-rich layers and manganese-rich layers. The hydrogen-lithium-manganese-oxide material can be layered, with the lithium and manganese ions located in oxygen octahedra and the hydrogen ions located in oxygen trigonal prisms in the layered hydrogen-lithium-manganese-oxide material. The one or more metal ions are in Embodiment A can be present in an aqueous solution when contacting the hydrogen-lithium-manganese-oxide material therewith.
In the positive electrode of Embodiment A, a surface of the electrode, the individual particles of the powdered metal oxide composition, or both, can comprise a coating that includes at least one material selected from the group consisting of a metal oxide, a metal fluoride, and a metal polyanionic material. The coating can comprise, for example, at least one material selected from the group consisting of (a) lithium fluoride, (b) aluminum fluoride, (c) a lithium-metal-oxide in which the metal is selected from the group consisting of Al and Zr, (d) a lithium-metal-phosphate in which the metal is selected from the group consisting of Fe, Mn, Co, and Ni, and (e) a lithium-metal-silicate comprising a metal selected from the group comprising Al and Zr.
The hydrogen-lithium-manganese-oxide material in Embodiment A also can include up to 25 atom percent of one or more other transition metal ions replacing manganese ions, lithium ions, or a combination thereof in a manganese-rich layer of the material.
For example, the hydrogen-lithium-manganese-oxide material in step (a) of Embodiment A can be formed by contacting a lithium-manganese-oxide precursor compound with a solution comprising an acid and the one or more metal ions, and the one or more metal ions are inserted into the hydrogen-lithium-manganese-oxide material during the formation thereof wherein the precursor compound comprises lithium, manganese, and oxygen ions in a layered-type structure wherein lithium ions occupy octahedral sites in lithium-rich layers, and the lithium and manganese ions occupy octahedral sites in manganese-rich layers that alternate with the lithium-rich layers. The electrode can contain cation or anion defects and/or stacking faults and dislocations. Preferably, The precursor compound comprises Li2MnO3 or Li[Li1/3Mn2/3]O2, and optionally includes up to 25 atom percent of one or more other metal ions. The solution comprising the acid and the one or more metal ions also can include one or more metalloid-containing ions, non-metal containing ions, or a combination thereof. The precursor compound can be prepared by the reaction of one or more lithium salts, one or more manganese salts, and optionally one or more other metal salts at elevated temperature (e.g., in the range of about 450 to about 550° C.) in air. The salts can be selected from the group consisting of carbonates, hydroxides, nitrates, and isopropoxides.
In another aspect, the present invention provides a method for fabricating a positive electrode as described herein. The method comprises contacting a hydrogen-lithium-manganese-oxide material as described herein with one or more metal ions to insert the one or more metal ions into the hydrogen-lithium-manganese-oxide material; heat-treating the resulting metal insertion product to form the powdered metal oxide composition; and then forming an electrode therefrom.
One preferred method for fabricating a positive electrode as described herein comprises (a) contacting a hydrogen-lithium-manganese-oxide material described herein with a solution comprising an acid and one or more metal ions to insert the one or more metal ions into the hydrogen-lithium-manganese-oxide material, (b) heat-treating the resulting product to form the powdered metal oxide composition; and (c) then forming the electrode therefrom.
In some preferred embodiments, the hydrogen-lithium-manganese-oxide material in step (a) is formed by contacting a precursor compound with the solution comprising the acid and the one or more metal ions, and the one or more metal ions are inserted into the hydrogen-lithium-manganese-oxide material during the formation thereof wherein the precursor compound comprises lithium, manganese, and oxygen ions in a layered-type structure wherein lithium ions occupy octahedral sites in lithium-rich layers, and the lithium and manganese ions occupy octahedral sites in manganese-rich layers that alternate with the lithium-rich layers. A preferred precursor compound comprises Li2MnO3. Optionally, the hydrogen-lithium-manganese-oxide material and precursor compound can be contacted with one or more stabilizing ions (e.g., lithium ions, magnesium ions, aluminum ions, titanium ions, manganese ions, iron ions, cobalt ions, nickel ions, silicon ions, fluoride ions, phosphate ions, and silicate ions) during step (a). The Li2MnO3 precursor can be prepared by the reaction of one or more lithium salt and one or more manganese salt at elevated temperature (e.g., about 450° C. and about 550° C.) in air, and can include up to 25 atom percent of one or more other metal ion (e.g., Ti and or Zr), for example by inclusion of one or more salt of the other metal ion with the lithium and manganese salts. In some preferred embodiments, the salts are reacted. The lithium, manganese, and other metal salts can be, for example, carbonates, hydroxides, nitrates and isopropoxides.
A preferred positive electrode for an electrochemical cell, as described herein, delivers its initial capacity and cycling capacity above 3 V vs. metallic lithium, as reflected by the peak maximum position of the reduction processes in the dQ/dV plots of the electrochemical discharge profile. This positive electrode is formed by a method comprising (a) contacting a hydrogen-lithium-manganese-oxide material with one or more metal ions to insert the one or more metal ions into the hydrogen-lithium-manganese-oxide material; (b) heat-treating the resulting product to form a powdered metal oxide composition; and (c) forming an electrode from the powdered metal oxide composition. The powdered metal oxide composition has a layered-type structure, a spinel-type structure, a rock salt-type structure, or an integrated structure comprising two or more of these structure types, wherein the hydrogen-lithium-manganese-oxide material in step (a) is formed by contacting a lithium-manganese-oxide precursor compound with a solution comprising an acid and the one or more metal ions, and the one or more metal ions are inserted into the hydrogen-lithium-manganese-oxide material during the formation thereof. The precursor compound comprises lithium, manganese, and oxygen ions in a layered-type structure wherein lithium ions occupy octahedral sites in lithium-rich layers, and the lithium and manganese ions occupy octahedral sites in manganese-rich layers that alternate with the lithium-rich layers. In some preferred embodiments, the powdered metal oxide composition includes a Li2MnO3 component, and one or more of a layered-, spinel-, or rocksalt-type component, in addition to the Li2MnO3 component. In a particularly preferred embodiment, the powdered metal oxide composition comprises xLi2MnO3.(1−x)LiMO2 in which M comprises one or more of Mn, Ni and Co, and 0.5≦x<1.0 (e.g., about 0.7).
In yet another aspect, the present invention provides an electrochemical cell comprising a positive electrode of the invention as described herein, a negative electrode, and a suitable electrolyte, preferably a lithium containing electrolyte, therebetween. The negative electrode preferably comprises a metal selected from the group consisting of lithium, sodium, magnesium, zinc, and aluminum. The negative electrode typically consists either of the pure metal, or an alloy, an intermetallic compound, or an intercalation compound such as those that form with carbon, e.g., graphite or a hard carbon, which can operate either on their own or in combination with one another. The electrolyte can be either a non-aqueous electrolyte or an aqueous electrolyte, depending on the metal used in the electrode structure or other factors that are well known in the art. A battery of the present invention comprises a plurality of the electrochemical cells arranged in parallel, in series, or both.
The invention consists of certain novel features and a combination of parts hereinafter fully described, illustrated in the accompanying drawings, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
As used herein, the term “lithium-metal-oxide” and grammatical variations thereof, refers to lithium metal oxide compounds, which can optionally include lithium metal oxides in which some oxygen ions, predominantly but not exclusively at the surface, have been replaced by other anionic species, such as fluoride ions. The term “lithium-metal-polyanionic material” and grammatical variations thereof, refers to materials comprising at least one lithium cation, at least one other metal cation (e.g., a Ni or Co cation), and at least one metal-free polyvalent anion (e.g., phosphate, silicate, etc.). The term “hydrogen-lithium-manganese-oxide” refers to materials comprising hydrogen ions, lithium ions, manganese ions and oxygen ions, and optionally one or more other metal ion, arranged preferably in layers as described herein.
Conventional lithium-ion battery cathodes, such as layered LiCoO2, spinel LiMn2O4, olivine LiFePO4 and compositional variations thereof, do not deliver sufficient electrochemical capacity and power to satisfy the driving range requirements for plug-in hybrid-electric vehicles (PHEVs) and all-electric vehicles. Moreover, there is a growing demand to increase the energy and power of lithium-ion batteries for other wide-ranging applications, such as portable electronic devices, medical devices, aerospace and defense applications and for stand-alone energy storage. Conventional electrode materials such as LiCoO2, LiMn2O4 and LiFePO4 typically deliver capacities of 100-160 mAh/g between 4.2 and 3.0 V at moderate to high rates. Layered LiMO2 compounds, in which M is selected typically from electroactive metal cations, such as Mn, Co, Ni, and additional stabilizing cations such as Li and Al, provide the best opportunity to increase the electrode capacity and hence the energy of lithium-ion cells and batteries, because they offer a maximum capacity of up to approximately 280 mAh/g at potentials greater than 3.0 V vs. metallic lithium.
However, the highly oxidizing character and instability of lithium-metal-oxide electrode structures, in particular, at low lithium loadings, as well as solubility effects, have limited the extent to which this high capacity can be realized, particularly at high rates.
The loss of oxygen from lithium-metal-oxide electrodes, such as layered LiCoO2 and LiNi1-yCoyO2 electrodes can contribute to exothermic reactions with the electrolyte and with the lithiated carbon negative electrode, and subsequently to thermal runaway if the temperature of the cell reaches a critical value. Further improvements in the composition and structural stability of the bulk and the surfaces of lithium-metal-oxide electrodes are therefore still required to protect the intrinsic capacity of the electrode from decay and to improve the overall performance and safety of lithium-ion cells without compromising the rate capability of the electrode.
Lithium-metal-oxides with spinel-type structure are particularly attractive lithium-ion battery electrodes for high-power applications. Of particular significance is the lithium-manganese-oxide spinel, LiMn2O4, and its cation-substituted derivatives, LiMn2-xMxO4, in which M is one or more metal ions typically a monovalent or a multivalent cation such as Li+, Mg2+ and Al3+, as reported by Gummow et al. in U.S. Pat. No. 5,316,877 and in Solid State Ionics, Volume 69, page 59 (1994). It is well known that LiMn2O4 and metal-substituted LiMn2-xMxO4 spinel electrodes are chemically unstable in a lithium-ion cell environment, particularly at high potentials and/or when the cell operating temperature is raised above room temperature, when manganese ions from the spinel electrodes tend to dissolve in the electrolyte. This process is believed to contribute to the capacity loss of the cells at elevated temperatures. Moreover, the removal of all the lithium from LiMn2-xMxO4 spinel electrodes, notably LiMn2O4 (x=0), yields a Mn2-xMxO4 (MnO2, x=0) component, which itself is a strong oxidizing agent. The surface of such delithiated spinel electrodes can have a high oxygen activity, thereby possibly inducing unwanted oxidation reactions with the electrolyte. Although considerable progress has been made to suppress the solubility and high-temperature performance of spinel electrodes and to improve their stability by cation doping, as described for example by Gummow et al. in U.S. Pat. No. 5,316,877, or by forming oxyfluoride compounds as described by Amatucci et al. in the Journal of the Electrochemical Society, Volume 149, page K31 (2002) and by Choi et al. in Electrochemical and Solid-State Letters, Volume 9, page A245-A248 (2006), or by surface coatings as described by Kim et al. in the Journal of the Electrochemical Society, Volume 151, page A1755 (2004), these treatments have not yet entirely overcome the cycling instability of cells containing manganese-based spinel electrodes.
Considerable progress has been made over recent years to stabilize cubic-close-packed layered lithium-metal-oxide electrode systems by using lithium- and manganese-rich composite electrode structures, xLi2MnO3.(1−x)LiMO2 in which M is, for example, Mn, Ni, and/or Co, as described in U.S. Pat. No. 6,677,082 and U.S. Pat. No. 6,680,143, and by Kim et al. in Chemistry of Materials, Volume 16, page 1996 (2004), and by Thackeray et al. in the Journal of Materials Chemistry, Volume 17, page 3112 (2007). These electrodes can deliver essentially all their theoretical capacity (240-250 mAh/g) at relatively low rate, for example C/24, as reported by Johnson et al. in Electrochemistry Communications, Volume 6, page 1085 (2004). Composite electrode structures containing cubic-close-packed layered- and spinel components, such as xLi2MnO3.(1−x)LiMn2-xMxO4 in which M is a metal cation selected preferably from Li, Ni, Co, Al and Mg have also been disclosed, as described for example, by Johnson et al. in Electrochemistry Communications, Volume 7, page 528 (2005), and by Thackeray et al. in the Journal of Materials Chemistry, Volume 15, page 2257 (2005). These composite electrodes form because of the structural compatibility of the cubic-close-packed oxygen arrays of the individual lithium-metal-oxide components. The integrated structures are highly complex and are often characterized by complicated cation arrangements with short range order.
When the manganese and nickel ions are nearest neighbors in layered and spinel electrode structures and in the composite electrode structures described above, they tend to adopt tetravalent and divalent oxidation states, respectively. The lithium and transition metal ions are distributed in highly complex arrangements; the Li+ and Mn4+ ions are arranged in small localized regions to give the structure Li2MnO3-like character. Composite layered materials can be represented either in two-component notation, xLi2MnO3.(1−x)LiMO2, in which the close-packed Li2MnO3 and LiMO2 components, are structurally integrated or, alternatively, when normalized in standard layered (rock salt) notation, as Li(2+2x)/(2+x)Mn2x/(2+x)M(2−2x)/(2+x)O2. Composite layered xLi2MnO3.(1−x)LiMO2 structures are commonly referred to as ‘layered-layered’ materials, which reflects the layered character of the Li2MnO3 and LiMO2 components. The Li2MnO3 component that supplies surplus lithium to the layered structure plays a critical role in stabilizing the electrode structure at low lithium loadings; on lithium extraction, lithium ions in the transition metal layers diffuse into the lithium depleted layers to provide sufficient binding energy to maintain the integrity of the close-packed oxygen array.
Electrochemical extraction of lithium from xLi2MnO3.(1−x)LiMO2 during the initial charge occurs in two steps. When taken to completion above 4.6 V vs. Li0, the ideal reactions can be represented:
LiMO2→MO2+Li++e− (1)
Li2MnO3→MnO2+2 Li++½O2+2e− (2)
Despite the removal of lithium and oxygen from the Li2MnO3 component, the layered character of the residual MnO2 component remains remarkably intact. The highly oxidizing nature of both the MO2 and MnO2 components, however, can result in oxygen loss at the particle surface, particularly when M=Co and/or Ni, thereby damaging the electrode surface. Electrolyte oxidation can also occur at these high potentials. These factors limit the rate at which lithium can be reinserted into the charged, high-capacity xMnO2.(1−x)MO2 electrode. These electrodes also tend to lose capacity on cycling; the same holds true for ‘layered-spinel’ composite electrodes xLi2MnO3.(1−x)LiMn2-xMxO4. ‘Layered-layered’ xLi2MnO3.(1−x)LiMO2 electrodes, in particular, are also known to suffer from a voltage decay phenomenon on cycling that compromises the energy and energy efficiency of a lithium-ion cell.
Ion exchange reactions from Na-containing precursors to produce Li-ion battery electrode materials using non-aqueous solvents are well known. For example, in a recent development, Johnson et al. have reported in Electrochemistry Communications, Vol. 12, page 1618 (2010) that a lithium-rich nickel-manganese oxide compound Lix(Ni0.25Mn0.75)Oy (x>1) can be synthesized by Li-ion exchange in hexanol from a layered Na0.9Li0.3Ni0.25Mn0.75O6 precursor following previously described techniques as referenced therein. During this reaction, it appears that the layered structure converts from one in which the Na+ ions in the Na-rich layer are in trigonal prismatic coordination to one in which the ion-exchanged Li+ ions are in octahedral coordination and that this transformation appears to generate stacking faults in the oxygen sublattice that contribute to the good cycling stability of the electrode and its ability to discharge at high rates. The X-ray diffraction pattern of the ion-exchanged product Li1.32Na0.02Ni0.25Mn0.75Oy shows a strong peak at approximately 18° 2θ characteristic of both layered- and spinel lithium metal oxide structures, as well as broad peaks, indicative of imperfections in the structure, and a collection of weak peaks in the range 20-23° 2θ region, indicative of Li ordering in the transition metal layer, which is characteristic of the basic unit of a Li2MnO3 structure. Li/Li1.32Na0.02Ni0.25Mn0.75Oy cells provide a stable reversible capacity of 220 mAh/g at a current rate of 15 mA/g and 150 mAh/g at an extremely high rate of 1500 mA/g (i.e., a 15 C rate). The voltage profile generated by the Li1.32Na0.02Ni0.25Mn0.75Oy electrode contains features characteristic of layered and spinel components in the electrode structure.
This invention relates to positive electrode materials for lithium cells and batteries. It relates, in particular, to electrode precursor materials comprising manganese ions and to methods for fabricating lithium-metal-oxide electrode materials and structures using the precursor materials. More specifically, the invention relates to lithium-metal-oxide electrode materials with layered-type structures, spinel-type structures, rock salt-type structures, or integrated structures or combinations of structures or modifications thereof, notably those with imperfections, such as cation or anion defects and/or stacking faults and dislocations.
The invention extends to include lithium-metal-oxide electrode materials with surface protection, for example, with metal-oxide, metal-fluoride and/or metal-phosphate layers or coatings to protect the electrodes from highly oxidizing potentials in the cells and from other undesirable effects, such as electrolyte oxidation, oxygen loss and/or dissolution. Such surface protection enhances the surface stability, rate capability and cycling stability of the electrode materials of the invention.
In one embodiment, the lithium-metal-oxide materials of the invention are prepared, for example, by treating a precursor comprising Li2MnO3, which has a layered-type structure and which has an essentially cubic-close-packed oxygen array, with an acid solution. The Li2MnO3 precursor, or a precursor containing a Li2MnO3 component, is synthesized typically in the range of about 300 to 1000° C. (preferably about 400 to about 900° C.). The acid-treatment of the Li2MnO3 precursor can produce a layered lithium-hydrogen-manganese oxide product, such as H[Li1/3Mn2/3]O2 (i.e., in normalized layered LiMO2 notation in which the oxygen ions are arranged in alternating layers of octahedra and trigonal prisms) and in which the lithium ions are retained, or partially retained, in the transition metal layers. The lithium-manganese-oxide precursor, such as Li2MnO3, or lithium-hydrogen-manganese oxide precursor produced therefrom, such as H[Li1/3Mn2/3]O2, may be stoichiometric, or non-stoichiometric with anion and/or cation defects. In a second embodiment, the manganese ions in the Li2MnO3 precursor and the resulting acid-treated product, H[Li1/3Mn2/3]O2, may be partially substituted by one or more multivalent ions, such as alkaline earth metal ions and/or transition metal ions and/or other non-transition metal ions. The H[Li1/3Mn2/3]O2 product, or other compositions formed by the reaction, can react further in a second step with lithium and other metal ions to produce the lithium metal oxide electrodes of the invention after partial or complete removal of the hydrogen ions by ion-exchange and heat-treatment. Alternatively, the acid-treatment of the Li2MnO3 precursor can occur simultaneously in the presence of lithium ions and other metal ions to produce the substituted lithium metal oxide electrodes in one step, which is considered a notable advantage from processing and cost standpoints. This acid treatment process is followed by the heat-treatment step, typically between 300 and 1000° C. in air, to anneal the electrode material and to partially or completely remove the hydrogen ions from the material.
Typical lithium-metal-oxide products of this invention have layered-type structures, spinel-type structures, rock salt-type structures or combinations of these structure types, such as composite (i.e., structurally-integrated) ‘layered-layered’ structures, composite ‘layered-spinel’ structures, ‘layered-rock salt’ structures, and other complex structurally-integrated types. The invention extends specifically to include electrodes that comprise, at least as one component of the electrode, a composite Li2MnO3-MO rock salt structure in which M is a metal cation, selected preferably from the first row transition metal elements, such as Ti, Mn, Fe, Co, and Ni. In a particular embodiment, the composite Li2MnO3-MO rock salt structure may be integrated with other metal oxide components such as a layered LiMO2 component or a spinel LiM2O4 component, or both. In a further embodiment, the MO component in the electrode structure can be partially substituted by lithium, yielding rock salt components or regions of composition LixM′1-xO (0<x<0.5, and M′ is one or more metal ion other than Li) that may be either stoichiometric or lithium deficient such that the formula of the defect rock salt component is Lix-yM′1-xO in which y≦x. In a particular embodiment, the structures may be disordered and/or may preferably contain stacking faults and dislocations, such as those that exist, for example, between cubic-closed-packed (ccp) structures (i.e., with ABCABC . . . stacking), hexagonal-close-packed (hcp) structures (i.e., with ABABAB . . . stacking) and those with trigonal prismatic stacking, such as found in the H[Li1/3Mn2/3]O2 precursor of this invention that has a combination of ccp and trigonal prismatic stacking of the oxygen layers (i.e., AABBCC . . . stacking). In practice, there are more complex types of packing sequences because the stacking of oxygen layers in lithium-metal-oxide materials tends to be imperfect. All stacking deviations from ideal close packing and trigonal prismatic stacking, and irregular stacking sequences are therefore included in this invention.
In a further embodiment, the electrode materials of the invention may be surface protected by layers or coatings, the layers or coatings comprising, for example, metal oxides, metal fluorides, metal phosphates, and/or metal silicates particularly, but not exclusively, lithium-metal oxides, lithium-metal fluorides, lithium-metal phosphates and lithium metal silicates to protect the electrode material surfaces from undesirable reactions at high potentials, notably above 4 V. In a preferred embodiment of the invention, the constituents of the coating, such as the aluminum and fluoride ions of an AlF3 coating, the lithium and phosphate ions of a lithium phosphate coating, or the lithium, nickel and phosphate ions of a lithium-nickel-phosphate coating can be incorporated in the solution that is contacted with the hydrogen-lithium-manganese-oxide or lithium-manganese-oxide precursors when forming the electrodes of this invention. For example, the inventors have demonstrated by X-ray absorption spectroscopy that when electrode particles of composition 0.5Li2MnO3.0.5LiCoO2 are subjected to surface treatment in an acidic solution containing Li+, Ni2+ and PO43− ions, it appears that the phosphate ions have a tendency to leach lithium ions from the surface of the 0.5Li2MnO3.0.5LiCoO2 particles and that the nickel ions migrate into the lithium sites of the transition metal layers, characteristic of the Li2MnO3-type component in the 0.5Li2MnO3.0.5LiCoO2 structure. Lithium extraction from sites at, or near, the surface of the 0.5Li2MnO3.0.5LiCoO2 structure is likely compensated by the Ni2+ ions and the formation of vacancies. This unexpected finding has immediate implications for synthesizing a range of bulk electrode materials and structures, while simultaneously synthesizing and controlling the surface composition and structure of the final product by contacting, for example, the precursor materials comprising Li2MnO3 or substituted compounds in an acidic medium or the hydrogen-lithium-manganese-oxide materials in accordance with this invention, with one or more metal salts, preferably in solution, for example, salts containing alkali metal cations such as lithium cations, alkaline earth metals such as magnesium cations, transition metal cations such as those of titanium, vanadium, manganese, iron, cobalt, nickel and molybdenum, other metal or metalloid cations such as those of aluminum, silicon, gallium and the like, and/or stabilizing anions such as fluoride ions, phosphate ions, silicate ions or the like. The stabilizing anions, such as fluoride ions or phosphate ions, are preferably contained in solution alternatively, as a non-metal salt, such as NH4F or the like, or ammonium dihydrogen phosphate, NH4H2PO4, or the like, as taught in the Examples, hereafter. ‘Layered-layered’ xLi2MnO3.(1−x)LiMO2 electrodes, in particular, are also known to suffer from a voltage decay phenomenon on cycling that compromises the energy and energy efficiency of a lithium-ion cell.
It is clear from the principles of the invention described above, that numerous materials and compositions can be derived from these reactions with layered Li2MnO3-type precursors, as depicted schematically in
Specific advantages of this invention include, for example the following:
(1) A significant advantage of using a H[Li1/3Mn2/3]O2-type precursor that contains oxygen ions in a trigonal prismatic arrangement is that H is lost during the fabrication of the final lithium-metal-oxide product, which provides greater flexibility in controlling the structure and the electrochemical properties of the product by tailoring, for example, the degree of imperfections, stacking faults and disorder, whereas the Li-ion exchanged products from Na-based precursors always contain some Na ions which remain associated with the product during and after fabrication of the electrode.
(2) By using aqueous solutions, the approach provides the advantage of avoiding the non-aqueous Li-ion exchange step required for Na-based precursors, which although possible, is believed to be costly.
(3) The reaction method holds the possibility of making an extremely wide variety of compounds and compositions, e.g., spinel and layered compounds, composite ‘layered-layered’-type, composite ‘layered-spinel’-type and, unexpectedly, composite ‘layered-rock salt’-type structures, as well as other more complex structure types, particularly those with structural imperfections, such as stacking faults and dislocations and those with various degrees of order and disorder.
(4) A particularly significant advantage of the electrode materials described herein is that, unlike the prior art that generally teaches a one-step mixing of the lithium and metal cations during the synthesis of lithium-metal-oxide electrodes for lithium battery applications, this invention teaches the advantage of tailoring the amount of stabilizing cations in the lithium-rich layers of the product by an ion-exchange process with a Li2MnO3 precursor, which acts as a template to control the extent to which the Li2MnO3-based lithium-metal-oxide electrodes of this invention are structurally integrated with and composed of layered, spinel, and rocksalt components (and more complex disordered derivatives thereof), thereby leading to enhanced structural and electrochemical stability over typical state-of-the-art lithium-metal-oxide electrode materials.
(5) The electrodes can be used in other cell/battery types, such as those containing aqueous electrolytes, e.g., those with lithium anodes in conjunction with a solid electrolyte membrane, as well as other non-aqueous systems, e.g., those with sodium or magnesium anodes, depending on the cations and anions that can be introduced into a Li2MnO3 precursor, or a hydrogen-lithium-manganese-oxide precursor derived therefrom, as described herein.
In a further embodiment, the invention includes lithium-metal-oxide electrode materials, the surface of the individual particles being protected, for example, with metal-oxide, metal-fluoride and/or metal-polyanionic layers or coatings to protect the electrodes from highly oxidizing potentials in the cells and from other undesirable effects, such as electrolyte oxidation, oxygen loss and/or dissolution. Such surface protection enhances the surface stability, rate capability and cycling stability of the electrodes of this invention. In one embodiment, the lithium-metal-oxide particles of the electrode are protected by, and comprised of, one or more metal fluorides, metal oxides or metal-polyanionic materials, such as lithium fluoride, a lithium-metal-oxide, a lithium-metal-phosphate, a lithium-metal-silicate or the like, in which the polyanion is comprised of a negatively charged species that contains more than one atom type, for example WO3−, MoO3−, SO42−, PO43−, SiO44−. In a preferred embodiment, the metal fluorides, metal oxides or metal-polyanionic materials can act as lithium-ion conductors at or above the operating potential of the lithium-metal-oxide positive electrode to provide access of the lithium ions from the electrolyte to the electrode during discharge, and vice-versa during charge, while simultaneously protecting the surface of the electrode from undesirable effects, such as electrolyte oxidation, oxygen loss or dissolution. Such surface protection significantly enhances the surface stability, rate capability and cycling stability of the lithium-metal-oxide electrodes, particularly when charged to high potentials.
In a further embodiment of this invention, the electrodes can be protected by a modified surface, surface layer or coating comprising metal fluorides, metal oxides or metal-polyanionic materials that are stable at and/or above the operating electrochemical potential of the lithium-metal-oxide electrode. The terms ‘modified surface’, ‘surface layer’ and ‘coating’ include all forms of surface modifications that serve to stabilize the electrode surface, for example, deposited particles, deposited films, anion and cation substitutions, compositional gradients at the surface, and the like. It is desirable that the modified surface, surface layer or coating should act predominantly or exclusively as a stable lithium-ion conductor that operates preferably at or above 4 V, more preferably at or above 4.5 V and most preferably at or above 5.0 V versus metallic lithium, thereby allowing the electrode to operate repeatedly at high rates without subjecting the modified surface, surface layer or coating to potentially damaging redox reactions that might affect the electrochemical properties of the electrode.
The metal fluorides, metal oxides or metal-polyanionic materials may be comprised of one or more metals, and it may be amorphous or, alternatively, it may be poorly crystalline or strongly crystalline with either stoichiometric structures or cation and/or anion defect structures. The metal fluorides are comprised preferably of one or more of lithium fluoride, aluminum fluorides and compounds thereof, whereas, the metal oxides are comprised preferably of lithium oxide, aluminum oxide, zirconium oxide and compounds thereof, such as the family of lithium aluminum oxide compounds and lithium zirconium oxide compounds. The metal-polyanionic material is comprised preferably of one or more lithium-metal-phosphate or lithium-metal-silicate materials, for example, those selected from the family of lithium-nickel-phosphate-, lithium-cobalt-phosphate-, lithium-nickel-silicate-, and lithium-cobalt-silicate materials.
In a further preferred embodiment, the lithium-metal-polyanionic material is comprised of lithium-nickel-phosphate, lithium-cobalt-phosphate, lithium-nickel-silicate, and/or lithium-cobalt-silicate compositions and structures, including stoichiometric or defect olivine-related LiMPO4 structures (for example, M=Ni, Co), Li3PO4-related structures as well as metal-substituted Li3PO4-related structures, such as defect Li3-xMx/2PO4 (for example, M=Ni, Co; 0<x<2) structures, and Li2MSiO4-related structures such as stoichiometric Li2NiSiO4 and Li2CoSiO4 and defect Li2-xMSiO4 structures. In the stoichiometric and defect compounds of this invention, such as LiMPO4, Li3-xMx/2PO4, Li2MSiO4 and Li2-xMSiO4 compositions and structures, the M cations may be partially or completely substituted by other metal cations, for example, divalent cations, such as Mg2+ or Zn2+ ions, and trivalent cations, such as Al3+ ions, and tetravalent cations, such as Zr4+ ions, that can also form lithium-ion conducting, solid electrolyte compounds. Of particular significance is the advantage that lithium-metal-polyanionic materials containing divalent metal cations, such as LiNiPO4 and LiCoPO4, surprisingly can remain stable and electrochemically inactive to lithium extraction to a high electrochemical potential of approximately 5 V vs. lithium metal. The applicants believe that a particular advantage of having stable divalent nickel ions in the modified surface, surface layer or coating may aid to stabilize manganese-based lithium-metal-oxide electrodes because any Ni2+/Mn4+ nearest neighbor interactions would contribute further to stabilizing the lithium-metal-oxide electrode surface by suppressing surface Mn3+ species and manganese solubility.
The lithium-metal-polyanionic material of this invention may also include Li3PO4 as a component of the protective layer. In this respect, Li3PO4 may either be the major component (>50%) or the minor component (<50%) of the surface structure or, alternatively, it may be used entirely as the protective surface layer or coating of the lithium-metal-oxide electrode.
In a further embodiment, the invention extends to include Li4SiO4-related compositions and structures and substituted compositions and structures, for example, metal-substituted, defect Li4-xMx/2SiO4 structures in which M is one or more divalent cations such as Ni2+, Co2+, Mg2+ and Zn2+ and 0<x<2. In metal-substituted Li4SiO4 structures, the substituted M cations may alternatively be comprised partially of trivalent cations, such as Al3+ ions, or tetravalent cations, such as Zr4+ ions, that can form lithium-ion conducting compounds.
The invention extends to electrode precursor materials comprising manganese ions and to methods for fabricating lithium-metal-oxide electrode materials and structures using these precursor materials. In a particularly preferred embodiment, the method involves, as a first step, the acid treatment of a material comprising Li2MnO3, for example, stoichiometric, cation deficient, or anion deficient Li2MnO3, composite structures and materials such as ‘layered-layered’ xLi2MnO3.(1−x)LiMO2, ‘layered-spinel’ xLi2MnO3.(1−x)LiM2O4, and xLi2MnO3.(1−x)MO, or combinations thereof, for example, a material or structure consisting of ‘layered-layered’ xLi2MnO3.(1−x)LiMO2 and MO components, in which M is one or more suitable metal cations as known in the art, and in which 0<x<1. The Li2MnO3 precursors and those that contain up to 25% of alternative metal ions, such as Ti or Zr, as described herein, are typically prepared by well known reaction procedures, for example, by the reaction of various lithium-, manganese- and other metal salts, such as carbonates, hydroxides, nitrates, and isopropoxides in air at temperatures typically above about 450° C., and preferably below about 550° C., as described in the examples of this invention. To those skilled in the art, it will be obvious that other well known precursor salts, such as lithium-, manganese- and other metal oxyhydroxides, acetates and the like, can also be used for this purpose. The acid treatment process leaches lithium from the Li2MnO3-comprising materials, which may induce a change in the arrangement of the oxygen ion layers that sandwich the lithium layers from an octahedral arrangement of oxygen ions to a trigonal prismatic arrangement of oxygen ions. In a second step, the H[Li1/3Mn2/3]O2 product, or other compositions formed by the reaction, can react further with lithium and other metal ions to produce the lithium metal oxide electrodes of the invention after partial or complete removal of the hydrogen ions by ion-exchange and heat-treatment. Alternatively, the acid-treatment of the Li2MnO3 precursor can occur simultaneously in the presence of lithium ions and other metal ions to produce the substituted lithium metal oxide electrodes in one step; this acid treatment process is followed by the heat-treatment step, typically in the range of about 300 to 1000° C. (preferably about 400 to about 950° C.) and typically in air at ambient pressure to partially or completely remove the hydrogen ions from the electrode material. Other oxidizing, reducing or inert atmospheres and pressure conditions can alternatively be used to control the composition and electrochemical properties of the final product, if required.
In an additional embodiment, it has been discovered from the examples provided in this invention that electrodes with targeted composition 0.5Li2MnO3.0.5LiMn0.5Ni0.5O2 can deliver high capacities and can cycle with remarkable stability (e.g., as in Example 15 and
In an additional preferred embodiment, the cathodes of this invention deliver their initial capacity and cycling capacity above 3 V vs. metallic lithium, as reflected by the peak maximum position of the reduction processes in the dQ/dV plots of their electrochemical discharge profile, when lithium cells containing these cathodes are discharged below 3 V, for example, to 2.5 V or lower, and when charged, for example, to 5.0 V or lower, preferably 4.6 V or lower, as demonstrated in
Preferably, the electrochemical cycling behavior of the electrodes above 3 V is stable and endures for many cycles, at least over 20 cycles, preferably over 100 cycles, more preferably over 200 cycles and most preferably over 500 cycles, at least at relatively low discharge rates, for example at 15 mA per gram of cathode material, or at higher rates. For improved cycling stability above 3 V, the Li2MnO3 component in the composite structure, whether ‘layered-layered’, ‘layered-layered-spinel’ or a more complex structure type, as described herein, may comprise 50% or more of the composite electrode material. In particular, ‘layered-layered’ cathode materials of the formula xLi2MnO3.(1−x)LiMO2, such as xLi2MnO3.(1−x)LiMn0.5Ni0.5O2, with an x value equal to, or greater than about 0.5 (i.e., including more than about 50% of the Li2MnO3 component), show stable electrochemical behavior above 3 V.
For example, superior and stable performance is delivered by a ‘layered-layered’ electrode composition 0.7Li2MnO3.0.3LiMn0.5Ni0.5O2 (i.e., with 70% Li2MnO3). This composition is represented on the ‘layered-layered’ Li2MnO3—LiMO2 tie-line of the generic Li2MnO3—LiMO2—LiM′2O4 ‘layered-layered-spinel’ phase diagram in
The phase diagram in
Likewise, reducing the lithium content during the preparation of a ‘layered-layered’ 0.3Li2MnO3.0.7LiMn0.5Ni0.5O2 material in which the Mn:Ni ratio is 0.65:0.35, would drive the composition of the electrode toward the end-member spinel LiMn1.3Ni0.7O4 composition, in which the Mn:Ni ratio is 0.65:0.35, of a layered-layered-spinel phase diagram. In this case, ‘layered-layered-spinel’ compounds lying on the ‘layered-layered-0.3Li2MnO3.0.7LiMn0.5Ni0.5O2—spinel LiMn1.3Ni0.7O4 tie-line can be represented by the general formula LixMn0.65Ni0.35Oy, for which the 0.3Li2MnO3.0.7LiMn0.5Ni0.5O2 and LiMn1.3Ni0.7O4 end members have x and y values of (x=1.3; y=2.3) and (x=0.5; y=2), respectively. In this system, a value of x=1.25 and y=2.28 corresponds to the ‘layered-layered-spinel’ composition Li1.25Mn0.65Ni0.35O2.28 with approximately 94% of 0.3Li2MnO3.0.7LiMn0.5Ni0.5O2 and approximately 6% of spinel Li0.5Mn0.65Ni0.35O2 to reflect the constant Mn:Ni ratio of 0.65:0.35 (alternatively, LiMn1.3Ni0.7O4 in conventional spinel notation).
The superior cycling stability of the electrode materials of this invention above 3 V, as described above, also is observed with the electrode compositions and materials of this invention when synthesized by methods other than those described herein in which Li2MnO3 is used as a precursor compound. For example, other standard synthesis methods such as solid state reaction- or sol-gel methods using precursors besides Li2MnO3, as already taught in the art, can be employed for preparing cathode materials with this superior electrochemical potential and cycling stability. This particularly novel aspect of the composite electrode structures of this invention, which can suppress voltage fade and deliver their initial capacity and cycling capacity above 3 V on extended cycling, therefore extends to include electrode compositions within the broad scope of this invention, notably ‘layered-layered’ and ‘layered-layered-spinel’ compositions when synthesized by methods other than those using Li2MnO3 as a precursor compound.
More specifically, therefore, this invention extends to include a method for fabricating a positive electrode comprising: (a) contacting a lithium-metal-oxide material wherein the metal comprises manganese and nickel with lithium ions and optionally one or more metal ions, such as manganese ions, to insert the lithium ions and one or more metal ions into the lithium-metal-oxide material; (b) heat-treating the resulting product to form a powdered metal oxide composition; and (c) forming an electrode from the powdered metal oxide composition. In a particular embodiment, the lithium-metal-oxide material in step (a) is formed by contacting a lithium-metal-oxide precursor compound with a solution comprising an acid with lithium ions and optionally one or more metal ions, the lithium ions and one or more metal ions being inserted into the lithium-metal-oxide material during the formation thereof; wherein the precursor compound comprises lithium, manganese, one or more other metal ions and oxygen ions in a layered-type structure. In a preferred embodiment, the metal of the lithium-metal-oxide material comprises manganese, nickel and cobalt ions, such as LiMn0.5Ni0.5O2 or LiMn0.33Ni0.33Co0.33O2, in which the manganese ions have transition metal nearest neighbors or, preferably, lithium and transition metal neighbors such as in the flower pattern of an idealized LiMn0.5Ni0.5O2 structure, as described by van der Ven et al. in Electrochemistry Communications 6, Volume 6, pages 1045-1050 (2004), and Thackeray et al. in the Journal of Materials Chemistry, Volume 17, pages 3112-3125 (2007). The surface of the electrode, the individual particles of the powdered metal oxide composition thus formed, or both, may comprise a coating that includes at least one material selected from the group consisting of a metal oxide, a metal fluoride, and a metal polyanionic material to provide additional stability to the electrode when operated in an electrochemical cell.
From the principles of the invention described above, it will be clear to those skilled in the art that numerous materials, compositions and structure types can be derived from Li2MnO3-type precursors, H[Li1/3Mn2/3]O2-type precursors, or lithium metal oxide precursors by varying the reaction conditions. The lithium-metal-oxide materials produced by these reactions are particularly useful as positive electrodes for lithium-ion batteries. The principles of this invention extends to include other electrochemical cells and battery types, such as those containing aqueous electrolytes, for example those with lithium anodes in conjunction with a solid electrolyte membrane, as well as other non-aqueous systems, for example those with sodium or magnesium anodes. The electrochemical cells and batteries of this invention can be primary cells and batteries, or secondary (rechargeable) cells and batteries.
The following examples describe the principles of the invention as contemplated by the inventors, but they are not to be construed as limiting examples.
Step 1.
Li2MnO3 can be synthesized typically at about 400-500° C. and contacted with approximately 2 M sulfuric acid or nitric acid at room temperature to form a precursor of nominal composition H[Li1/3Mn2/3]O2, which is then filtered and dried. For example,
Step 2.
The H[Li1/3Mn2/3]O2 can be subsequently reacted with salts of Li, Ni, Mn, such as lithium hydroxides, nitrates, sulfates or carbonates, nickel hydroxides, nitrates, sulfates or carbonates, or manganese hydroxides, nitrates, sulfates or carbonates either in solution or in the solid state and subsequently heated, typically at 400 to 950° C., to form a powdered metal oxide composition used to prepare a positive electrode of the invention. One specific example of such a reaction is summarized in Reaction A, below:
6H[Li1/3Mn2/3]O2+5Li2CO3+2NiCO3+2MnCO3+O2→4(Li2MnO3.LiMn0.5Ni0.5O2)+9CO2+3H2O (Reaction A)
In this reaction, the conversion from trigonal prismatic configuration of the oxygen ions in the layered H[Li1/3Mn2/3]O2 precursor to octahedral configuration in the Li2MnO3.LiMn0.5Ni0.5O2 product can give rise to stacking faults to stabilize the composite structure to lithium insertion and extraction reactions without significantly impacting rate capability.
Other lithium metal oxide compositions can be synthesized by selectively varying the relative amounts of the H[Li1/3Mn2/3]O2 precursor as well as the lithium and the metal salts in Step 2.
In this example, the Li2MnO3 precursor material, as described in Example 1 above, is treated typically with acid at the same time that it is reacted with the lithium, nickel and manganese nitrates in acid solution, after which it is heated to dryness and annealed at higher temperature, e.g., about 400-600° C. such that essentially all the lithium in the original precursor remains in the final 4(Li2MnO3—LiMn0.5Ni0.5O2) product. In this case, the ideal reaction can be represented as in Reaction B:
2Li2MnO3+2Li(NO3)2+Ni(NiO3)2+Mn(NO3)2+acid→2(Li2MnO3.LiMn0.5Ni0.5O2)+6NO2+O2 (Reaction B)
Other lithium metal oxide compositions can be synthesized by selectively varying the relative amounts of the H[Li1/3Mn2/3]O2 precursor as well as the lithium and the metal salts in the reaction above. Moreover, numerous metal salts can be used to prepare compounds over an extremely wide compositional range. Note that, in Reaction B, oxygen is generated by the reaction to form the Li2MnO3.LiMn0.5Ni0.5O2 product of the invention whereas in Reaction A oxygen is consumed to form the product. Reaction B is preferred to Reaction A because the product is synthesized in a one-step reaction directly from a Li2MnO3 precursor, rather than a two-step reaction with the formation of a discrete hydrogen-lithium-manganese-oxide intermediate in Reaction A.
For the electrochemical evaluation of the lithium metal oxide materials produced by the methods described herein, coin-type cells (2032, Hohsen) are typically used. The cells are constructed in an argon-filled glove box (<5 ppm O2 and H2O). The cathode consists typically of 80 wt % of the lithium metal oxide powder, 10 wt % carbon, and 10 wt % polyvinylidene difluoride (PVDF) binder on aluminum foil. The anode can be e.g. either metallic lithium or graphite (MAG-10, Hitachi with 8 wt % PVDF) on copper foil. The electrolyte is typically 1.2M LiPF6 in a 3:7 mixture of ethylene carbonate and ethylmethyl carbonate. For the cycling experiments, cells are galvanostatically charged and discharged typically between 2.0 and 4.6 V (2.0 and 4.5 V for the Li-ion cells) at different currents (0.1-2.0 mA/cm2) and trickle charged at 4.6 V for 3 hours. For typical rate tests, lithium cells are charged to 4.6 V at 0.1 mA/cm2 with a trickle charge at 4.6 V for 3 hours; cells are discharged to 2.0 V at 0.1 to 1.0 mA/cm2 with three cycles at each rate. Alternatively, electrochemical cells can be subjected to one discharge at various rates to assess the rate capability of the cathode material. Electrochemical experiments are conducted typically at room temperature and at elevated temperature (about 50° C.) and duplicated to check reproducibility.
Li2MnO3 was prepared by the following general procedure: MnCO3 was added to an aqueous solution of LiOH·H2O in the required stoichiometric amount and stirred for about 45 minutes to 1 hour. The liquid from the solution was evaporated at approximately 80° C., and a solid product was collected and ground to a powder. The powder was then annealed at about 450° C. for about 30 hours in air. The X-ray diffraction pattern of the annealed Li2MnO3 product is shown in
A Li2MnO3 product containing nickel with a targeted composition 0.5Li2MnO3.0.5LiMn0.5Ni0.5O2 was prepared as follows: the Li2MnO3 precursor produced by the method described above was reacted with the stoichiometrically required amount of nickel nitrate in a 0.1M solution of HNO3 and stirred overnight at room temperature, i.e., the Li:Mn:Ni ratio in the Li2MnO3/nitric acid solution was about 1.50:0.75:0.25. The liquid from the solution was evaporated at approximately 70° C., and the resulting solid product was collected and ground to a powder. The powder was then annealed at about 450° C. for about 6 hours in air. The X-ray diffraction pattern of the annealed nickel-containing Li2MnO3 product, labeled “Li2MnO3
In the X-ray diffraction patterns depicted in
The X-ray diffraction pattern of the “Li2MnO3
The corresponding voltage profiles and dQ/dV plots for a Li/Li2MnO3
This example therefore emphasizes that the annealing step is crucial in controlling and tailoring the electrode structures of this invention and their electrochemical properties.
A Ni-containing Li2MnO3 powder was prepared as described above in Example 4 by adjusting the amount of Ni nitrate in the acidic solution to target a product with composition 0.2Li2MnO3.0.8LiMn0.5Ni0.5O2, i.e., the Li:Mn:Ni ratio in the Li2MnO3/nitric acid solution was about 1.20:0.60:0.40. The product was annealed at about 850° C. prior to electrochemical evaluation in the lithium cell, and is labeled Li2MnO3
Li2Mn0.9Ti0.1O3 was prepared by the following general procedure: TiC12H28O4 (titanium isopropoxide) and MnCO3 precursors were added to an aqueous solution of LiOH.H2O in the required stoichiometric amount and stirred for about 45 minutes to 1 hour. The liquid from the solution was evaporated at approximately 80° C., and a solid product was collected and ground to a powder. The powder was then annealed at about 450° C. for about 30 hours in air.
The Li2Mn0.9Ti0.1O3 precursor was then reacted with nickel nitrate in a 0.1M solution of HNO3 to target a product with composition 0.5Li2Mn0.9Ti0.1O3.0.5LiMn0.5Ni0.5O2, i.e., the Li:Mn:Ni:Ti ratio in the Li2MnO3/nitric acid solution was about 1.50:0.70:0.25:0.05, and stirred overnight at room temperature. The liquid from the solution was evaporated at approximately 70° C., and the resulting solid product was collected and ground to a powder. The powder was then annealed at about 450° C. for about 6 hours in air and labeled Li2Mn0.9Ti0.1O3
The voltage profiles of a Li/Li2Mn0.9Ti0.1O3
A Ni- and Co-containing Li2MnO3 powder was prepared as described above in Example 4 by adjusting the amount of Ni and Co nitrates in the acidic solution to target a product with composition 0.5Li2MnO3.0.5LiMn0.4Ni0.4Co0.2O2, i.e., the Li:Mn:Ni:Co ratio in the Li2MnO3/nitric acid solution was about 1.50:0.70:0.20:0.10. The product was annealed at about 450° C. prior to electrochemical evaluation in the lithium cell, and is labeled Li2MnO3
The Li2MnO3 precursor of Example 4 was reacted with manganese acetate, Mn(CH3COO)2.4H2O in a 0.1M solution of HNO3 to target a ‘layered-spinel’ product with approximate composition 0.8Li2MnO3.0.2LiMn2O4 using a Li:Mn ratio in the Li2MnO3/nitric acid solution of about 1.5:1.0, and stirred overnight at room temperature. The liquid from the solution was evaporated at approximately 70° C., and the resulting solid product was collected and ground to a powder. The powder was then annealed at about 450° C. for about 6 hours in air and labeled Li2MnO3
The voltage profiles of a Li/Li2MnO3
A Co0.5Mn0.5CO3 precursor was first prepared by reacting the required amounts of cobalt sulfate heptahydrate and manganese sulfate monohydrate in an aqueous solution of ammonium hydrogen carbonate to yield a Co0.5Mn0.5CO3 precipitate that was subsequently dried overnight at about 100° C. Li2CO3 was then mechanically mixed with the dried Co0.5Mn0.5CO3 precursor using a Li:Co:Mn ratio of about 1.5:0.5:0.5 before being annealed in air at 550° C. for 24 hours. The sample was subsequently cooled to room temperature before being heated at 850° C. for 12 hours to yield a product with the targeted composition 0.5Li2MnO3.0.5LiCoO2. Thereafter, the product was immersed in a coating solution consisting of ammonium dihydrogen phosphate, glycolic acid, nickel nitrate and lithium nitrate using a Li:Ni:P ratio of about 1:1:1 and a targeted Li—Ni—PO4 mass of about 4 to 5% of the 0.5Li2MnO3.0.5LiCoO2 product, and then heated to dryness at approximately 60 to 70° C. The Li—Ni—PO4 coated product was finally annealed at about 550° C. prior to electrochemical evaluation in the lithium cell, and is labeled Li2MnO3
Alternatively, a Li2MnO3
A Li2MnO3 product containing nickel with a targeted composition of 0.5Li2MnO3.0.5LiMn0.5Ni0.5O2 was prepared as in Example 4 above with the exception that an amount of NH4F was added to the solution, simultaneously with the Ni nitrate, so that the total amount of F in the final product was about 2.5 mol % with respect to all metals (i.e. Li, Mn, Ni). The dried powders were collected, ground, and annealed at 450° C. and 850° C. for 6 hours in air. Samples are labeled as Li2MnO3
The voltage profiles and corresponding dQ/dV plots of a Li/Li2MnO3
The voltage profiles and corresponding dQ/dV plots of a Li/Li2MnO3
These observations, along with the excellent stability of the discharge process as demonstrated in particular by the dQ/dV data in
A precursor with a nominal composition of Li1.95Na0.05MnO3 was prepared by the following general procedure: MnCO3 and Na2CO3 were added to an aqueous solution of LiOH.H2O in the required stoichiometric amount and stirred for about 45 minutes to 1 hour. The liquid from the solution was evaporated at approximately 80° C., and a solid product was collected and ground to a powder. The powder was then annealed at about 450° C. for about 30 hours in air. Subsequently, a Ni containing product with a Ni:Mn ratio of 1:3 was prepared from the Na-containing Li2MnO3 precursor, as described in Example 4, and annealed at 850° C. in air for 6 hours. These samples are labeled as Li2MnO3
A precursor with a nominal composition of Li1-xMgx/2MnO3 (x=0.05) was prepared as in Example 11 using stoichiometric amounts of MnCO3 and Mg(NO3)2.6H2O in an aqueous solution of LiOH.H2O. The dried powder was ground and subsequently annealed at 450° C. in air for about 30 hours. A Ni containing product with a Ni:Mn ratio of 1:3 was prepared from the Mg-containing Li2MnO3 precursor, as described in Example 4, and annealed at 450° C. in air for 6 hours. Samples are labeled as Li2MnO3
The top and bottom panels in
The Li2MnO3 precursor, prepared as in Example 4, was reacted with stoichiometric amounts of Co nitrate and Ni nitrate to target a lithium-rich product having the approximate composition of Li1.05Mn0.52Ni0.32Co0.11O2. The final, dried powder was annealed in air at 450° C. for 6 hours and is labeled as Li2MnO3
This example is particularly noteworthy because it demonstrates a significantly lower first-cycle capacity loss (12%) compared to state-of-the-art composite electrode structures and compositions, such as the 38% first-cycle capacity loss of a 0.5Li2MnO3.0.5LiMn0.33Ni0.33Co0.33O2 electrode reported by Johnson et al. in Electrochemistry Communications, Volume 9, page 787 (2007). This improvement is particularly important because it illustrates that the materials of this invention can significantly minimize the extent of electrochemical activation above 4.5 V, thereby reducing surface damage to the electrode particles and enhancing electrochemical performance without compromising the exceptionally high capacities delivered by these composite electrodes relative to state-of-the art-electrode materials such as layered LiCoO2, spinel LiMn2O4, and olivine LiFePO4 and their analogues that typically provide capacities of about 160-170 mAh/g or lower.
The Li2MnO3 precursor was prepared as in Example 4 using stoichiometric amounts of MnCO3 in an aqueous solution of LiOH.H2O. The dried powder was ground and subsequently annealed at about 450° C. in air for about 30 hours. An Al containing product with a Ni:Mn ratio of 1:3 and total Al content of 2% by weight was prepared from a mixture of Ni nitrate and Al nitrate, similar to the procedure described in Example 4, and annealed at about 450° C. in air for about 6 hours; the target composition of this product was Li1.16Mn0.58Ni0.19Al0.06O2 (in standard layered notation). This sample is labeled Li2MnO3
Stoichiometrically required amounts of MnCO3 and Li2CO3 were thoroughly mixed and annealed in air at about 450° C. for about 72 hours to prepare the Li2MnO3 precursor; this sample is labeled C—Li2MnO3. A Li2MnO3 product containing nickel with a targeted composition 0.5Li2MnO3.0.5LiMn0.5Ni0.5O2, labeled C—Li2MnO3
A Li2MnO3 precursor was prepared as in Example 15 with carbonate precursors. A Li2MnO3 product 0.5Li2MnO3.0.5LiMn0.5Ni0.5O2 containing about 10% excess lithium (with respect to the precursor Li2MnO3) was prepared following the procedure described in Example 4 to give a Li:Mn molar ratio in the final composite electrode product of about 2.13 and a Li:(Mn+Ni) molar ratio of about 1.6; the targeted composition of this example, in two-component notation, is therefore about 0.476Li2MnO3.0.524Li1.09Mn0.455Ni0.455O2; this sample is labeled Li2MnO3
A ‘layered-layered’ Li2MnO3-based product containing nickel having a targeted composition 0.7Li2MnO3.0.3LiMn0.5Ni0.5O2 was prepared in a similar manner to that described in Example 4. This product was annealed in air at about 850° C. for about 6 hours. A similar material was prepared by a conventional solid state reaction as follows. A metal oxalate precursor Mn0.85Ni0.15C2O4 was prepared from an aqueous solution containing the appropriate amounts of NiSO4.6H2O and MnSO4.H2O to which a solution of sodium oxalate was added, while stirring continuously for about 3 hours in air at a constant 70° C. The resulting co-precipitated product was filtered, washed, and dried in air at 105° C. Thereafter, the powder was thoroughly mixed with the stoichiometrically-required amount of Li2CO3 (or LiOH.H2O) and calcined first at 550° C. for 12 hours in air, and then at 850° C. for 12 hours in air, to produce the targeted composition 0.7Li2MnO3.0.3LiMn0.5Ni0.5O2.
The corresponding voltage profiles and dQ/dV plots for the Li/0.7Li2MnO3.0.3LiMn0.5Ni0.5O2 cell are shown in top and bottom panels of
Suppression of the voltage fade of cells containing other high Li2MnO3 content (>50%) composite electrode structures in terms of their dQ/dV plots applies broadly to other materials compositions and structure types of this invention, including, for example, (a) substituted ‘layered-layered’ compositions, such as 0.7Li2MnO3.0.3LiMn0.5Ni0.5-xCoxO2 (0≦x≦0.5) or more specifically 0.7Li2MnO3.0.3LiMn0.375Ni0.375Co0.250O2 and (b) ‘layered-layered-spinel’ compositions such as those that have the same Mn:Ni ratio as ‘layered-layered’ materials for example, 0.9 {0.7Li2MnO3.0.3 LiMn0.5Ni0.5O2}.(0.1Li0.5Mn0.85Ni0.15O2) (alternatively, Li1.58Mn0.85Ni0.15O2.45) that has the same Mn:Ni ratio is 0.85:0.15 as ‘layered-layered’ 0.7Li2MnO3.0.3LiMn0.5Ni0.5O2 (alternatively Li1.7Mn0.85Ni0.15O2.7), and that can be synthesized by slightly reducing the lithium content of the parent ‘layered-layered’ structure, thereby endorsing the benefits of using composite electrode structures with a high Li2MnO3 content, in accordance with the principles of this invention. Note that the spinel notation Li0.5Mn0.85Ni0.15O2, given above, is equivalent to the more conventional spinel notation LiMn1.7Ni0.3O4. Note also that these are targeted compositions based on the lithium and transition metal content in the precursor materials. In practice, there are likely to be variations in the cation distribution and formulae of the layered and spinel component structures of the final electrode product as a result of processing parameters such as temperature and dwell time that can vary the oxygen content of the electrode—the invention therefore includes such cation and compositional variations of the composite electrode structures, as defined herein.
A detailed schematic illustration of an electrochemical cell 10 of the invention is shown in
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
This application is a continuation-in-part of U.S. application Ser. No. 13/440,431, filed on Apr. 5, 2012, which is a continuation-in-part of International Application No. PCT/US2011/040652, filed on Jun. 16, 2011, which is a continuation-in-part of U.S. patent application Ser. No. 13/044,038, filed on Mar. 9, 2011, now abandoned, which claims the benefit of U.S. Provisional Application Ser. No. 61/414,561, filed on Nov. 17, 2010, each of which is incorporated herein by reference in its entirety.
The United States Government has rights in this invention pursuant to Contract No. DE-AC02-06CH11357 between the United States Government and UChicago Argonne, LLC representing Argonne National Laboratory.
| Number | Date | Country | |
|---|---|---|---|
| 61414561 | Nov 2010 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13440431 | Apr 2012 | US |
| Child | 13680959 | US | |
| Parent | PCT/US2011/040652 | Jun 2011 | US |
| Child | 13440431 | US | |
| Parent | 13044038 | Mar 2011 | US |
| Child | PCT/US2011/040652 | US |
