Lithium iron thiophosphate compound, process for producing the compound, and lithium battery using the compound

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to a lithium iron thiophosphate compound, more specifically, to a lithium iron thiophosphate compound which is particularly useful as an electrode active material of a lithium battery, a process for producing the compound, and a lithium battery using the compound.

[0003] 2. Description of the Prior Art

[0004] In recent years, with the development of portable devices such as personal computers and portable telephones, demand of batteries has been becoming very large as power sources thereof. Lithium batteries are particularly actively researched, as being capable of giving a high energy density, in various fields since lithium is a material having a small atomic weight and a large ionization energy.

[0005] In the so-called lithium ion battery, LiCoO2 is used as its cathode active material and a carbon material is used as its anode active material. Electrode reactions in these active materials are an insertion reaction of lithium ions between crystal layers and an elimination reaction from the layers. In the case that the insertion-elimination reaction of lithium ions is used as electrode reaction, a change in crystal structure caused by the electrode reaction becomes small so that very good battery characteristics such as a decrease in capacity-drop resulting from the repetition of charge and discharge are obtained.

[0006] Such insertion-elimination reaction of lithium ions into or from crystal layers was found out for the first time in TiS2. Thereafter, similar reactions were observed in various sulfides, selenides, oxides and so on. Furthermore, it has been found out that lithium ions are inserted into and eliminated from one-dimensional tunnel structure or three-dimensional network structure, and the application thereof to electrode active materials has been investigated.

[0007] In the insertion-elimination reaction, inserted or eliminated lithium ions may be called guests and an oxide or the like having lamellar structure, tunnel structure and network structure which receives the lithium ions may be called an intercalation host.

[0008] Researches on the intercalation host were made mainly about sulfides including TiS2. In recent years, the researches have been made mainly about oxides including LiCoO2. Shift of the researches from sulfides to oxides is made because the oxides make it possible to develop batteries having a high energy density because of a nobler electrode voltage of the oxides. When an oxide type host is used, the insertion-elimination voltage of lithium ions is, for example, 3 V in the case of V2O5, 4 V in the case of LiCo2O, and about 5 V in the case of LiNi½Mn{fraction (3/2)}O4 and so on. On the other hand, the insertion-elimination reaction of lithium ions in the case of almost all of sulfide type hosts takes place at 2.5 V or less on the basis of lithium. Therefore, the voltage of lithium batteries using a sulfide as a cathode active material becomes 2.5 V or less.

[0009] For an electrode active material, it is important not only that the energy density thereof is made as high as possible, bit also that a larger output current is taken out. In order to make the output current property high, it is necessary to make the diffusion of lithium ions in an intercalation host speedy.

[0010] In sulfide type hosts, a sulfide ion coordinates to a lithium ion. In oxide type hosts, an oxide ion coordinates to a lithium ion. In the case that an oxide ion coordinates to a lithium ion, in general, electrostatically attractive force acts intensely between the two so that the oxide ion tends to disturb the diffusion of the lithium ion. On the other hand, a sulfide ion has a higher polarizing ability than an oxide ion, and thus, the sulfide ion has a small effect of disturbing the diffusion of a lithium ion. That is, in order to make the energy density of a battery high, it is preferred to use an oxide type host, and in order to make the output of the battery high, it is preferred to use a sulfide type host.

[0011] However, the electromotive force of the sulfide type host is generally small. The electromotive force measured in TiS2, which is most known, is about 2.3 V, and that of almost all sulfide type hosts is 2.5 V or less. Thus, the sulfide type hosts have a problem that it is difficult to make the energy density high.

SUMMARY OF THE INVENTION

[0012] An object of the present invention is to provide a lithium iron thiophosphate compound represented by a general formula Li2xFe1-xPS3 which is capable of enhancing the diffusion of lithium ion and exhibiting a high electromotive force.

[0013] Another object of the present invention is to provide a process for producing the above-mentioned lithium iron thiophosphate compound.

[0014] Still another object of the present invention is to provide a lithium battery using the above-mentioned lithium iron thiophosphate compound as an electrode active material.

[0015] That is, a first aspect of the present invention is to provide a lithium iron thiophosphate compound represented by a general formula: Li2xFe1-xPS3 wherein x is more than 0 and less than 1.

[0016] A preferred embodiment is the above-mentioned lithium iron thiophosphate compound wherein x is not less than 0.4 and not more than 0.6 in the general formula Li2xFe1-xPS3.

[0017] A preferred embodiment is the above-mentioned lithium iron thiophosphate compound wherein x is 0.5 in the general formula Li2xFe1-xPS3.

[0018] A second aspect of the present invention is to provide a process for producing the above-mentioned lithium iron thiophosphate compound, comprising the steps of:

[0019] introducing Li, Fe, P, S and/or a sulfide of Li, Fe, P to an airtight container filled with inert atmosphere, and

[0020] heating the resultant mixture at a temperature between 400 to 800° C.

[0021] A third aspect of the present invention is to provide a lithium battery wherein the above-mentioned lithium iron thiophosphate compound is used as an electrode active material.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022]
FIG. 1 is an X-ray diffraction pattern of a lithium iron thiophosphate compound in Example 1 according to the present invention;

[0023]
FIG. 2 is a graph showing a characteristic of an electrode active material of the lithium iron thiophosphate compound in Example 1 according to the present invention;

[0024]
FIG. 3 is an X-ray diffraction pattern of a lithium iron thiophosphate compound in Example 2 according to the present invention; and

[0025]
FIG. 4 is a graph showing a characteristic of an electrode active material of the lithium iron thiophosphate compound in Example 2 according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0026] A host structure causing insertion-elimination reaction generally contains transition metal ions, the valence of which is changed by insertion-elimination of ions. It has been found out that in known sulfides, various transition metal ions cause a change in their valence. However, any element in the fourth period, which has a small atomic weight, is preferred as the transition metal in the host structure since it is possible to make capacity density high when used as an active material. From the industrial viewpoint, it is preferred to use an inexpensive element. As an element for satisfying these requirements, it is considered that an iron sulfide is preferred.

[0027] As the iron sulfide acting as an electrode active material in a lithium battery, FeS2, Li2FeS2 and so on are reported. The voltage generated when lithium ions are inserted in FeS2 is about 1.7 V, and the voltage generated when the lithium ions are eliminated from Li2FeS2 is as low as 2.3 V. As other iron sulfides, it is reported that FePS3 has a lamellar structure and ions can be inserted in the layers. However, it is reported that this material exhibits an electrode voltage of about 3 V before the insertion of lithium ions therein but the voltage drops drastically by the insertion of the lithium ions so that the insertion voltage of the lithium ions becomes as low as 2 V or less (R. Brec, Solid State Ionics, vol. 22, p.3 (1986)).

[0028] The valence of the iron ions in this compound FePS3 is +2. In redox reaction in the insertion of lithium ions, the iron ions change into a lower oxidation number. As a result, a very low voltage would be exhibited. Accordingly, in order to make the voltage higher, it is necessary to make the oxidation number of the iron ions higher in the insertion-elimination reaction of the lithium ions. In the Li2xFe1-xPS3 of the present invention, the oxidation number of the iron ions is +2 and the oxidation number changes to +3 with the elimination of the lithium ions.

[0029] A different example of a sulfide generating a voltage by a redox pair of Fe2+/Fe3+ is Li2FeS2 described above. The iron ions in this sulfide are in a +2 valence state. By eliminating lithium ions electrochemically to become a composition of Li2-δ FeS2 wherein δ is the elimination quantity of the lithium ions, the redox pair of Fe2+/Fe3+ exhibits a voltage of about 2.3 V.

[0030] In the Li2xFe1-xPS3 compound according to the present invention, its redox pair generating a voltage is a redox pair of Fe2+/Fe3+ in the same way as in Li2FeS2. However, the lithium iron thiophosphate compound generates about 3V, which is significantly higher than Li2FeS2. It is known that in the oxide type hosts, the redox voltage thereof changes dependently on the kind of cations adjacent to transition metal ions acting as a redox pair (A. K. Padhi, K. S. Nanjundaswamy, C. Masquelier, and J. B. Goodenough, J. Electrochemical Society, vol. 144, 2581 (1997)). It is considered that in Li2xFe1-xPS3 according to the present invention, a part (x) of Fe2+ in FePS3 is substituted with Li+ and lithium ions, the number of which is x are present between its layers. Consequently, the redox pair of Fe2+/Fe3+ is affected by P4+ in a P2S6 octahedron which shares a side with an FeS6 octahedron so that such a high voltage is exhibited.

[0031] Li2xFe1-xPS3 according to the present invention has a structure similar to FePS3 or Li2FeS3. The structures of FePS3 and Li2PS3 are already reported in Z. Anorg. Allig. Chem, 401, 97 (1973) and J. Solid State Chem., 43, 151 (1982). Li2PS3 belongs to a hexagonal system (space group: P63/mcm), and has a lamellar structure wherein lithium ions are present between layers of PS3. That is, the lamellar structure is represented by PS3—Li—PS3. On the other hand, FePS3 belongs to a prismatic crystal system (space group: C2/m), which is slightly distorted from the hexagonal system, and has a structure wherein iron ions are present in alternate spaces between PS3 layers similar to Li2PS3. Namely, FePS3 has a lamellar structure of PS3—Fe—PS3—( )—PS3, wherein ( ) represents a space having no cations between layers. It is considered that Li2xFe1-xPS3 according to the present invention has a lamellar structure PS3—(Fe1-xLi)—PS3—Lix—PS3 wherein a part of the iron ions in FePS3 is substituted with lithium ions and further the lithium ions occupy sites containing no Fe ions between PS3 layers.

[0032] Various thiophosphate compounds represented by a general formula MePS3 wherein Me represents a metal, such as NiPS3 and MnPS3, have a lamellar structure equivalent to that of FePS3. However, only Li2NiP2S6 is reported as a compound having a composition between MePS3—Li2PS3 and no iron type compound has been reported before the present invention.

[0033] The lithium iron thiophosphate according to the present invention is represented by a general formula Li2xFe1-xPS3. In this general formula, x is 0<x<1, preferably 0.4≦x≦0.6, and most preferably x=0.5. In the case of x=0 or 1, the intended lithium iron thiophosphate compound which is an objective product of the present invention cannot be obtained.

[0034] Li2xFe1-xPS3 according to the present invention can be obtained by introducing Li, Fe and P and/or sulfides thereof and S into an airtight container filled with inert atmosphere and heating the mixture at a temperature between 400 and 800° C. Specifically, Li2xFe1-xPS3 can be obtained by mixing Li2S, Fe, FeS, P2S5, P2S3, Li, S, P and the like as starting materials to have a desired composition, putting the resultant mixture airtightly in inert atmosphere, for example, in the manner of putting the mixture airtightly into a quartz tube, and heating the mixture at a temperature of 400 to 800° C. In the case that the mixture is heated in flow of inert gas, phosphorus evaporates and scatters as the molecule of P2S5 because P2S5 is in a molecular crystal state, and thus, a compound having a desired composition cannot be obtained. When the heating temperature is lower than 400° C., the reaction rate is low so that the reaction for obtaining a desired compound requires long time. When the heating temperature is higher than 800° C., a desired compound cannot be obtained since FePS3 sublimates.

[0035] In Li2xFe1-xPS3 according to the present invention, lithium ions which can be electrochemically inserted and eliminated would be lithium ions present between layers of PS3—(Fe1-xLix)—PS3. Furthermore, the insertion-elimination reaction thereof advances simultaneously with the redox reaction of Fe2+/Fe3+. Therefore, in the composition making the capacity of Li2xFe1-xPS3 largest, x is {fraction (1/2)}. As an electrode active material, this composition (LiFe½PS3) is most preferred.

[0036] Li2xFe1-xPS3 according to the present invention is particularly useful as an electrode active material of a lithium battery, and exhibits a high voltage of about 3 V on the basis of its lithium electrode.

[0037] The present invention will be described in greater detail by way of Examples, but the present invention is not limited thereto.

EXAMPLE 1

[0038] In the present example, a lithium iron thiophosphate compound represented by LiFe½PS3 was synthesized and the electrode characteristic thereof in a lithium battery was examined.

[0039] LiFe½PS3 was synthesized by the following method.

[0040] As starting materials, metal iron (Fe) powder, iron sulfide (II) (FeS), and diphosphorus pentasulfide (P2S5) were used. These starting materials were mixed with each other at a molar ratio of 1:1:1. Thereafter, the mixture was molded into a pellet form. The pellets were put airtightly into a quartz tube whose inner surface was coated with carbon, and the tube was heated at 700° C. for 8 hours.

[0041] The X-ray diffraction pattern of the thus obtained powder of LiFe½PS3 is shown in FIG. 1. Index numbers as unit lattice of hexagonal crystal can be assigned to all diffraction peaks. Thus, LiFe½PS3 obtained in the present example can be considered to have a structure similar to that of Li2PS3 or FePS3.

[0042] Next, oxysuflide glass represented by 0.01Li3PO4-0.63Li2S-0.36SiS2 was synthesized as a lithium ion electrically-conductive solid electrolyte by the following method.

[0043] Lithium sulfide, silicon sulfide and lithium phosphate were weighed at a molar ratio of 63:36:1 and then mixed with each other. This mixture was filled into a crucible made of glassy carbon. The mixture was melted at 1000° C. in flow of argon gas for 2 hours. The melted product was super-rapidly cooled with twin rollers. In this way, a lithium ion electrically-conductive solid electrolyte was obtained.

[0044] LiFe½PS3 and 0.01Li3PO4-0.63Li2S-0.36SiS2, which were synthesized by the above-mentioned methods, were used to examine the characteristic of LiFe½PS3 as an electrode active material by the following method.

[0045] LiFe½0PS3 and 0.01Li3PO4-0.63Li2S-0.36SiS2 obtained in the above-mentioned methods were mixed with each other at a weight ratio of 1:1 and then 10 mg of this mixture was used as a working electrode. As a counter electrode, an indium-lithium alloy was used. The working electrode and the counter electrode were put together to sandwich a solid electrolyte layer so that they were integrated into a three-layer form. In this way, an electrochemical cell was produced. Constant electric current pulses (electric current value: 10 μA) in an oxidization direction were repeatedly supplied to this electrochemical cell for 2 hours. After each of the supplies of the pulses, open circuit voltage (pause time: 2 hours) was recorded. Subsequently, constant electric current pulses were repeatedly supplied thereto in a reduction direction. In the same way, open circuit voltage was recorded. The thus obtained voltage curve of LiFe½PS3 is shown in FIG. 2.

[0046] In FIG. 2, its lower transverse axis represents the electricity quantity of the electric current supplied to LiFe½PS3 per weight, and its upper transverse axis represents the elimination quantity (δ: LiFe½PS3) of lithium ions, calculated from the electricity quantity of the supplied electric current. Its left vertical axis represents the voltage between terminals of the measured cell, and its right vertical axis represents the value obtained by converting the voltage of LiFe½PS3 from terminal-terminal voltage to voltage on the basis of lithium electrode. Black spots represent a voltage change during elimination of the lithium ions. White spots represent a voltage change when the lithium ions are inserted again after the elimination of the lithium ions.

[0047] As is evident from FIG. 2, in LiFe½PS3 according to the present example, lithium ions can be eliminated at a voltage of about 3 V (on the basis of lithium electrode), and after the elimination of the lithium ions, they can be inserted again. It has also been found out that LiFe½PS3 according to the present example acts as an electrode active material exhibiting a relatively high voltage though this compound is a sulfide.

EXAMPLE 2

[0048] In the present example, a lithium iron thiophosphate compound represented by Li⅔Fe⅔PS3 was synthesized and electrode characteristic thereof in a lithium battery was examined.

[0049] Li⅔Fe⅔PS3 was synthesized by the following method.

[0050] Li⅔Fe⅔PS3 was synthesized in the same way as in Example 1 except that a composition obtained by mixing Fe powder, FeS, P2S5 and lithium sulfide (Li2S) at a molar ratio of 3:1:3:2 was used as a starting material.

[0051] The X-ray diffraction pattern of the thus obtained powder of Li{fraction (2/3)}Fe⅔PS3 is shown in FIG. 3. Index numbers as unit lattice of hexagonal crystal can be assigned to all diffraction peaks. Thus, Li⅔Fe⅔PS3 obtained in the present example can be considered to have a structure similar to that of LiFe½PS3 in Example 1.

[0052] Next, the electrode characteristic of Li⅔Fe⅔PS3 was examined by the same method as in Example 1. The results are shown in FIG. 4.

[0053] As is evident from FIG. 4, in Li⅔Fe⅔PS3 according to the present example, lithium ions can be eliminated at a voltage of about 3 V (on the basis of lithium electrode voltage), and after the elimination of the lithium ions, they can be inserted again. It has also been found out that Li⅔Fe⅔PS3 according to the present example acts as an electrode active material exhibiting a relatively high voltage though this compound is a sulfide.

[0054] In the present example, the first elimination quantity of lithium ions corresponds to 0.23 Li with respect to Li⅔Fe⅔PS3. On the other hand, the first elimination quantity of lithium ions corresponds to 0.37 Li with respect to LiFe½PS3 in Example 1. In Li⅔Fe⅔PS3, ⅓ of a lithium ion is present between Li⅓Fe⅔PS3 layers and in LiFe½PS3, ½ of a lithium ion is present between Li½Fe½PS3 layers. It can be therefore considered that the lithium ions which are inserted and eliminated at the time of charge and discharge are lithium ions present between LixFe1-xPS3 layers.

[0055] At the time of charge, the quantity of lithium eliminated from Li2xFe1-xPS3 is xLi, and the quantity of Fe2+ whose valence changes with the elimination of the lithium ions is (1-x)Fe2+. Accordingly, in the composition having a maximum elimination quantity of the lithium ions, that is, a maximum capacity when Li2xFe1-xPS3 is used as an electrode active material, x is {fraction (1/2)}. This composition is most preferred.

[0056] As described above, the lithium iron thiophosphate according to the present invention, a voltage of about 3 V can be generated on the basis of lithium electrode. For example, when the lithium iron thiophosphate is used as an electrode active material of a lithium battery, it is possible to provide a lithium battery having high output as well as high energy density.

Lithium iron thiophosphate compound, process for producing the compound, and lithium battery using the compound

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