Patent Application
20230387459
The present invention relates to a solid electrolyte and an active material layer, an electrolyte layer, and a secondary battery containing the electrolyte.
All-solid-state secondary batteries containing solid electrolytes can have higher heat resistance and improved safety because electrolytes do not leak or volatilize. Thus, it is possible to reduce module costs and increase energy densities.
As one of such solid electrolytes, a sulfide-based solid electrolyte has been reported. However, the sulfide-based solid electrolyte has a problem in terms of workability because a sulfide is used as a raw material for their production. Thus, oxide-based solid electrolytes have been reported as non-sulfide-based solid electrolytes.
As Li-containing solid electrolytes, NASICON-type Li1+xAlxTi2−x (PO4)3 (LATP), perovskite-type Li3+xLa2/3-xTiO3 (LLT) and garnet-type cubic Li7La3Zr2O12 (LLZ) have been reported. As Na-containing solid electrolytes, B″-alumina-type Na2O·(5-7)Al2O3 and NASICON-type Na3Zr2Si2PO12 have been reported. However, these solid electrolytes have the following problems: usable cathode materials are limited, and sintering at a high temperature of higher than 1,000° C. is required in order to improve conductivity by bringing interfaces between solid electrolytes and between a solid electrolyte and an active material into close contact with each other. In particular, sintering at a high temperature may lead to the formation of a high-resistance phase between solid electrolytes and at the interface between a solid electrolyte and an active material, limiting the improvement of ionic conductivity.
For these reasons, attempts have recently been made to lower the sintering temperature. Japanese Patent Laid-Open No. 5-54712 discloses that the post baking temperature can be reduced to about 900° C. by using a solid electrolyte containing lithium borate, such as Li2+xC1-xBxO3.
Japanese Patent Laid-Open No. 2013-37992 states that mixing Li3BO3 with LLZ-type oxides can reduce the sintering temperature to 650° C. to 800° C. when a solid electrolyte is formed.
In secondary batteries containing the respective solid electrolytes disclosed in Japanese Patent Laid-Open Nos. 5-54712 and 2013-37992, lower sintering temperatures were used, and high-resistance phases were not easily formed as intermediate layers at interfaces with other materials. However, regions occupied by the respective solid electrolytes have an ionic conductivity GSE of lower than 1×10−7 S/cm at room temperature, in some cases. There has been a demand for an oxide-based solid electrolyte having an enhanced ionic conductivity.
The present invention aims to provide a high-ionic-conductivity solid electrolyte that can be produced by sintering at a low temperature, and an electrolyte layer, an active material layer, and a secondary battery containing the solid electrolyte.
A solid electrolyte according to an embodiment of the present invention contains an oxide represented by the general formula Li6-xR1-xM1x (BO3)3.
However, R is at least one or two elements selected from a group including trivalent elements Yb, Er, Ho, and Tm, M1 is a tetravalent element, and x is a real number satisfying 0<x<1. A solid electrolyte according to an embodiment of the present invention contains a borate containing Li, an element R selected from a group including Yb, Er, Ho, Tm, La, Nd, and Sm, and an element M selected from a group including Zr, Ce, and Sn.
A solid electrolyte according to an embodiment of the present invention contains a borate containing Li, an element R selected from a group including Yb, Er, Ho, Tm, La, Nd, and Sm, and an element M selected from a group including Zr, Ce, and Sn, in which the solid electrolyte exhibits two diffraction peaks in a diffraction angle 20 range of 27.4° or more and 29.0° or less in an X-ray diffraction analysis using a K-alpha emission line in copper, and a difference 2θd in diffraction angle between a higher-angle diffraction peak and a lower-angle diffraction peak is 0.43° or more.
A solid electrolyte according to an embodiment of the present invention contains an oxide represented by the general formula Li6-xR1-xMx (BO3)3, where in the formula, R contains a rare-earth element selected from a group including Yb, Er, Ho, Tm, La, Nd, and Sm and is at least one or two elements, M is a tetravalent element, and x is a real number satisfying 0<x<1. A solid electrolyte contains an oxide represented by the general formula Li6-xR1-xMx (BO3)3, where in the formula, R is a rare-earth element selected from a group including Yb, Er, Ho, Tm, La, Nd, and Sm, M is an element selected from a group including Zr, Ce, and Sn, and x is a real number satisfying 0<x<1.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
Preferred embodiments of the present invention are described in detail below with reference to the drawings.
A solid electrolyte according to the present embodiment contains an oxide represented by the general formula Li6-xR1-xM1x (BO3)3.
In the formula, R is at least one or two elements selected from a group including trivalent elements Yb, Er, Ho, and Tm, and M1 is a tetravalent element. In the formula, x is a real number satisfying 0<x<1.
In the formula, when R contains at least two elements selected from the group including the trivalent elements Yb, Er, Ho, and Tm, a combination of the elements selected from the group including Yb, Er, Ho, and Tm may be used, and a combination with another trivalent element having an ionic radius close to these elements may also be used.
In other words, the solid electrolyte according to the present embodiment contains an oxide represented by the general formula Li6-xR1-xMx (BO3)3.
In the formula, R is at least one or two rare-earth elements selected from a group including Yb, Er, Ho, Tm, La, Nd, and Sm, and M is an element selected from a group including Zr, Ce, and Sn. In the formula, x is a real number satisfying 0<x<1.
In the formula, when R contains at least two elements selected from the group including rare-earth elements Yb, Er, Ho, Tm, La, Nd, and Sm, a combination of the rare-earth elements in the group may be used, and a combination with another rare-earth element having an ionic radius close to these elements may also be used.
A possible reason for improved ionic conductivities of the solid electrolytes containing the oxides represented by the above general formula will be described below.
When the rare-earth elements Yb, Er, Ho, Tm, La, Nd, and Sm are partially replaced with a tetravalent element M, the charge balance is adjusted in such a manner that the crystal as a whole is neutral, thereby producing a state deficient in Li+ in the crystal lattice. A portion lacking an element is generally referred to as a vacancy. A phenomenon in which Li+ around the vacancy moves to the vacancy, which is generally called hopping, occurs in a concerted manner, thereby improving the ionic conductivity.
In other words, the solid electrolyte of the present embodiment is a solid electrolyte containing a borate that contains Li, an element R selected from a group including Yb, Er, Ho, Tm, La, Nd, and Sm, and an element M selected from a group including Zr, Ce, and Sn.
The solid electrolyte of the present embodiment preferably has a monoclinic crystal structure.
In an X-ray diffraction analysis (hereinafter, referred to as “XRD”) using a K-alpha emission line in copper, a diffraction peak at a diffraction angle 20 of about 280 changes in accordance with the composition of the solid electrolyte.
The solid electrolyte of the present embodiment in which R in the oxide represented by the general formula Li6-xR1-xMx(BO3)3 is Yb preferably exhibits a diffraction peak in the range of 2θ=28.07° or more and 28.20° or less in XRD using the K-alpha emission line in copper. More preferably, the solid electrolyte has a peak in the range of 2θ=28.10° or more and 28.20° or less.
The solid electrolyte of the present embodiment in which R in the oxide represented by the general formula Li6-xR1-xMx(BO3)3 is Er preferably exhibits a diffraction peak in the range of 2θ=27.940 or more and 28.10° or less in XRD using the K-alpha emission line in copper. More preferably, the solid electrolyte has a peak in the range of 2θ=28.0° or more and 28.20° or less.
In XRD using the K-alpha emission line in copper, the position of a diffraction peak at about 2θ=280 can be controlled by adjusting the value of x in the general formula and changing the element represented by M.
M in the above general formula is a tetravalent element. M is at least one element selected from a group including Zr, Ce, and Sn.
As elements substituted for Yb, Er, Ho, Tm, La, Nd, and Sm, which are trivalent elements R, elements having similar ionic radii are easily substituted therefor. Specific examples thereof include Zr4+, Ce4+, Sn4+, Ti4+, Nb4+, Pb4+, Pr4+, and Nb5+ as candidates. Among them, Zr4+ and Ce4+ are more easily substituted.
In the above general formula, x is a real number satisfying 0<x<1. As x corresponding to the amount of substitution element M substituted for the element R, a value of 0.025 or more and 0.60° or less is used. More preferably, a value of 0.075 or more and 0.40° or less is used.
The reasons why the above range of x is preferred are inferred as follows: When the value of x is less than 0.025, a sufficient structural change does not occur because of a small amount of element R replaced, and paths through which ions pass are not sufficiently formed, thereby resulting in no improvement in ionic conductivity. When the value of x is more than 0.600, the amount of substitution element M is too large. Thus, the excess element M, which does not contribute to substitution for the element R in the crystal, contributes as an inhibition component for ionic conduction rather than the substitution effect in the crystal.
A method for producing the solid electrolyte of the present embodiment will be described below.
The method for producing a solid electrolyte of the present embodiment includes a post baking step of heating Li, R, and M, which are elements constituting a solid electrolyte containing an oxide represented by the general formula Li6-xR1-xMx(BO3)3, or oxides thereof in an oxygen-containing atmosphere (where in the formula, R is at least one or two elements selected from a group including rare-earth elements Yb, Er, Ho, Tm, La, Nd, and Sm, and M is a tetravalent element).
The method for producing a solid electrolyte of the present embodiment includes a prebaking step of performing heat treatment at a temperature lower than the melting point of the oxides to perform solid-phase synthesis of the oxide represented by the above general formula, and a step of densifying the resulting oxide by heat treatment.
While the method, including the prebaking step and the post baking, for producing a solid electrolyte of the present embodiment will be described in detail below, the present invention is not limited to the following production method.
In the prebaking step, reagent-grade raw materials, such as Li3BO3, H3BO3, Yb2O3, Er2O3, Ho2O3, Tm2O3, ZrO2, and CeO2, are weighed with reference to a predetermined stoichiometric ratio as an index and mixed together to form Li6-xR1-xMx(BO3)3. Other raw materials to be weighed so as to achieve a predetermined stoichiometric ratio include SnO2, Nb2O3, La2O3, Nd2O3, and Sm2O3. Here, R is at least one or two elements selected from a group including rare-earth elements Yb, Er, Ho, Tm, La, Nd, and Sm. As M, a tetravalent element is used.
As a device used for mixing, a mixer such as a ball mill can be used, in addition to a mortar and pestle.
After a mixed powder of the above raw materials is prepared by the mixing treatment, the resulting mixed powder is pressure-molded into pellets. Here, as the pressure-molding method, a known pressure-molding method, such as a cold uniaxial molding method or a cold isostatic pressure molding method, can be used. As the conditions for pressure molding in the prebaking step, the pressure can be, but is not particularly limited to, 100 to 300 MPa, for example.
The resulting pellets are prebaked at 500° C. to 800° C. with, for example, an atmospheric post baking apparatus to perform solid-phase synthesis. The time of the prebaking step can be, but is not particularly limited to, for example, about 700 to 750 minutes (such as, 720 minutes).
The resulting prebaked body is the oxide represented by the general formula Li6-xR1-xMx (BO3)3. The prebaked body can be ground with, for example, a mortar and pestle, to prepare a prebaked powder.
In the post baking step, at least one selected from a group including the prebaked body prepared in the prebaking step and the prebaked powder is subjected to pressure molding and post baking to prepare a dense sintered body.
The pressure molding and the post baking may be performed simultaneously by, for example, discharge plasma sintering or hot pressing. Alternatively, after pellets are produced by cold uniaxial molding, post baking may be performed in an air atmosphere, for example. As the conditions for pressure molding in the post baking step, the pressure can be, but is not particularly limited to, 100 to 300 MPa, for example.
The post baking temperature is preferably 800° C. or lower, more preferably 700° C. or lower, still more preferably 680° C. or lower.
The time of the post baking step can be appropriately changed in accordance with, for example, the temperature of the post baking, and can be, for example, about 700 to 750 minutes (such as 720 minutes).
The cooling method in the post baking step is not particularly limited. Natural cooling may be used. Cooling slower than natural cooling may also be used.
A secondary battery of the present embodiment will be described below.
A typical secondary battery includes an anode containing an anode active material, a cathode containing a cathode active material, an electrolyte containing a solid electrolyte disposed between the anode and the cathode, and if necessary, a current collector.
The secondary battery of the present embodiment is a secondary battery including at least an anode containing an anode active material, a cathode containing a cathode active material, and an electrolyte, and at least one selected from a group including the anode, the cathode, and the electrolyte contains the solid electrolyte of the present embodiment.
In the secondary battery of the present embodiment, the electrolyte may contain the solid electrolyte of the present embodiment, or may contain another solid electrolyte. Examples of another solid electrolyte that may be contained include, but are not particularly limited to, Li3PO4, Li7La3Zr2O12, Li0.33La0.55TiO3, and Li1.5Al0.5Ge1.5(PO4)3. The solid electrolyte of the present embodiment is preferably contained in the electrolyte of the secondary battery of the present embodiment in an amount of 25% or more by mass, more preferably 50% or more by mass, still more preferably 75% or more by mass, particularly preferably 100% by mass.
The secondary battery of the present embodiment can be produced by a known method, for example, by lamination of an anode, a solid electrolyte, and a cathode, shaping, and heat treatment. The solid electrolyte of the present embodiment can be produced by heat treatment at a lower temperature than in the conventional technique, thereby reducing the formation of a high-resistance phase caused by the reaction between the solid electrolyte and the electrode active material. This can result in a secondary battery having excellent output characteristics. The “solid” used in the present specification includes an object having self-supporting properties to the extent that a certain shape and volume are maintained even if the posture of the object is changed. In other words, the object is not flowable and has a viscosity of less than 1×107 cP (less than 1×104 Pa·s).
A method for measuring physical properties according to the present disclosure will be described below. Identification of R and M
When the collected sample is not a mixture with other materials, after the collected sample is treated into a solution, the composition ratio of the sample can be identified by, for example, inductively coupled high-frequency plasma atomic emission spectroscopy (ICP-AES) or wavelength dispersive X-ray fluorescence spectrometry (WDXRF). WDXRF may also be referred to as WDX.
When there is a high probability that the collected sample is a mixture, a scanning analyzer that can provide elemental mapping images, such as an X-ray photoelectron spectrometer (XPS, ESCA) or a scanning electron microscope equipped with an energy dispersive X-ray fluorescence analyzer (EDXRF), can be used. Hereinafter, the scanning electron microscope equipped with the energy dispersive X-ray fluorescence spectrometer (EDXRF) may be abbreviated as SEM/EDX. When there is a high probability that the collected sample is a mixture, the crystal structure may be identified using a transmission electron microscope equipped with an electron beam diffraction function (TEM-ED). EDXRF may also be referred to as EDX.
ICP-AES and XPS are used in order to precisely determine the composition ratio of Li, which is a light element, to other elements with higher atomic numbers, such as B, O, Zr, and rare-earth elements.
When the collected sample is a mixture, pretreatment is used to selectively remove a non-target portion for analysis by a physical removal process, such as dicing or ion beam processing, chemical removal, such as dry etching or wet etching, or a combination thereof. For the pretreatment, washing, degreasing, sectioning, grinding, pelletizing, or the like may be used.
An S-4800 available from Hitachi High-Technologies Corporation can be used as an analyzer for SEM/EDX.
RINT-2100 available from Rigaku Corporation is used for X-ray diffraction analysis of solid electrolytes.
A powder prepared by grinding a solid electrolyte with a mortar and pestle is subjected to X-ray diffraction analysis using characteristic X-rays of CuKα. The temperature is room temperature, the analysis range is 10° to 70°, the step is 0.016°, and the scan speed is 0.5 steps/second.
An electrolyte layer 40 containing a solid electrolyte 44 according to the first embodiment and a secondary battery 100 including the electrolyte layer 40 will be described with reference to
As illustrated in
The current collector layer 10 is a conductor that conducts electrons to or from an external circuit (not illustrated) and the active material layer. As the current collector layer 10, a self-supporting film of a metal, such as stainless steel (SUS) or aluminum, or a laminated structure of metal foil and a resin base is used.
The anode active material layer 20 includes anode active material layers 20a, 20b, and 20c as sublayers. The anode active material layers 20a, 20b, and 20c are distinguished by the unit of lamination in the layer thickness direction 200 before the active material particles 22 and the anode electrolyte 24 are sintered. The anode active material layers 20a, 20b, and 20c may have distributions in the layer thickness direction in terms of the volume fractions of the active material particles 22 and the anode electrolyte 24, a conductive assistant (not illustrated), and voidage (porosity). The layer thickness direction 200 is parallel or anti-parallel to the lamination direction in which the layers are laminated, and thus may also be referred to as the lamination direction 200.
The solid electrolyte 44 according to the present embodiment is used to the anode electrolyte 24 in the composite anode active material layer 20. The anode electrolyte 24 and the solid electrolyte 44 in the electrolyte layer 40 may have the same composition and particle size distribution, or may have different compositions and particle size distributions.
As a method for producing the cathode, a known method can be used. As in the second embodiment of the present application, the method for producing the anode 30 in the first embodiment may be used to the formation of the cathode with the necessary changes. Similarly to the anode 30, the cathode may have a structure in which both the cathode active material and the solid electrolyte are contained in the layer, or may be formed of a film composed of a metal, such as metal Li or In-Li.
Examples of the cathode active material include metals, metal fibers, carbon materials, oxides, nitrides, silicon, silicon compounds, tin, tin compounds, and various alloy materials. Among these, metals, oxides, carbon materials, silicon, silicon compounds, tin, tin compounds, and the like are preferred from the viewpoint of capacity density. Examples of metals include metal Li and In-Li. Examples of oxides include Li4Ti5O12 (lithium titanate: LTO). Examples of carbon materials include various natural graphites (graphites), coke, graphitizable carbon material undergoing graphitization, carbon fibers, spherical carbon, various artificial graphites, and amorphous carbon. Examples of silicon compounds include silicon-containing alloys, silicon-containing inorganic compounds, silicon-containing organic compounds, and solid solutions. Examples of tin compounds include SnOb (0<b<2), SnO2, SnSiO3, Ni2Sn4, and Mg2Sn. The cathode material may contain a conductive assistant. Examples of the conductive assistant include graphites, such as natural graphite and artificial graphite, and carbon blacks, such as acetylene black, ketjen black, channel black, furnace black, lamp black, and thermal black. Further examples of the conductive assistant include conductive fibers, such as carbon fibers, carbon nanotubes, and metal fibers, carbon fluoride, metal powders, such as aluminum, conductive metal oxides, such as conductive whiskers, e.g., zinc oxide, and titanium oxide, and organic conductive materials, such as phenylene-based dielectrics.
An example of producing and evaluating a solid electrolyte of the present embodiment as a sintered body will be described. The present disclosure is not limited to the following examples.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Yb2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), and ZrO2 (available from Nippon Denko Co., Ltd.) were provided as raw materials for a solid electrolyte. They were weighed in a predetermined stoichiometric ratio such that the composition after sintering was Li5.975Yb0.975Zr0.025(BO3)3, and mixed with a mortar and pestle.
After that, the mixed powder was subjected to cold uniaxial molding using a hydraulic press SSP-10A available from Shimadzu Corporation and heat treatment in an air atmosphere. The heating temperature was 650° C., and the holding time was 720 minutes.
The resulting prebaked body was ground with a mortar and pestle to prepare a prebaked powder.
The prebaked powder prepared as described above was molded and heat-treated in the same manner as the prebaking, thereby producing a sintered body of Example 1. The heating temperature was 670° C., and the holding time was 720 minutes.
Prebaked bodies and prebaked powders were produced in the same process as in Example 1, except that the raw materials described in Example 1 were weighed in predetermined stoichiometric ratios in such a manner that x had values given in Table 1.
The prebaked powders prepared as described above were subjected to the same post baking step as in Example 1 to produce sintered bodies.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Yb2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), ZrO2 (available from Nippon Denko Co., Ltd.), and CeO2 (available from Iwatani Corporation) were provided as raw materials for a solid electrolyte. A prebaked body and a prebaked powder were prepared in the same process as in Example 1, except that weighing was performed in a predetermined stoichiometric ratio such that the composition after sintering was Li5.875Yb0.875Zr0.100Ce0.025 (BO3)3.
The prebaked powder prepared as described above was subjected to the same post baking step as in Example 1 to produce a sintered body. The heating temperature was 650° C., and the holding time was 720 minutes.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Yb2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), ZrO2 (available from Nippon Denko Co., Ltd.), and CeO2 (available from Iwatani Corporation) were provided as raw materials for a solid electrolyte. A prebaked body and a prebaked powder were prepared in the same process as in Example 1, except that weighing was performed in a predetermined stoichiometric ratio such that the composition after sintering was Li5.850Yb0.850Zr0.100Ce0.050(BO3)3.
The prebaked powder prepared as described above was subjected to the same post baking step as in Example 1 to produce a sintered body. The heating temperature was 670° C., and the holding time was 720 minutes.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Er2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), and ZrO2 (available from Nippon Denko Co., Ltd.) were provided as raw materials for a solid electrolyte. They were weighed in a predetermined stoichiometric ratio such that the composition after sintering was Li5.975Er0.975Zr0.025(BO3)3, and mixed with a mortar and pestle.
After that, the mixed powder was subjected to cold uniaxial molding using a hydraulic press SSP-10A available from Shimadzu Corporation and heat treatment in an air atmosphere. The heating temperature was 650° C., and the holding time was 720 minutes.
The resulting prebaked body was ground with a mortar and pestle to prepare a prebaked powder.
The prebaked powder prepared as described above was molded and heat-treated in the same manner as the prebaking, thereby producing a sintered body of Example 7. The heating temperature was 670° C., and the holding time was 720 minutes.
Prebaked bodies and prebaked powders were produced in the same process as in Example 7, except that the raw materials described in Example 7 were weighed in predetermined stoichiometric ratios in such a manner that x had values given in Table 1.
The prebaked powders prepared as described above were subjected to the same post baking step as in Example 1 to produce sintered bodies.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), H0203 (available from Kojundo Chemical Laboratory Co., Ltd.), and ZrO2 (available from Nippon Denko Co., Ltd.) were provided as raw materials for a solid electrolyte. They were weighed in a predetermined stoichiometric ratio such that the composition after sintering was Li5.900Ho0.900 Zr0.100(BO3)3, and mixed with a mortar and pestle.
After that, the mixed powder was subjected to cold uniaxial molding using a hydraulic press SSP-10A available from Shimadzu Corporation and heat treatment in an air atmosphere. The heating temperature was 650° C., and the holding time was 720 minutes.
The resulting prebaked body was ground with a mortar and pestle to prepare a prebaked powder.
The prebaked powder prepared as described above was molded and heat-treated in the same manner as the prebaking, thereby producing a sintered body of Example 11. The heating temperature was 650° C., and the holding time was 720 minutes.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Tm2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), and ZrO2 (available from Nippon Denko Co., Ltd.) were provided as raw materials for a solid electrolyte. They were weighed in a predetermined stoichiometric ratio such that the composition after sintering was Li5.900Tm0.900Zr0.100(BO3)3, and mixed with a mortar and pestle.
After that, the mixed powder was subjected to cold uniaxial molding using a hydraulic press SSP-10A available from Shimadzu Corporation and heat treatment in an air atmosphere. The heating temperature was 650° C., and the holding time was 720 minutes.
The resulting prebaked body was ground with a mortar and pestle to prepare a prebaked powder.
The prebaked powder prepared as described above was molded and heat-treated in the same manner as the prebaking, thereby producing a sintered body of Example 12. The heating temperature was 670° C., and the holding time was 720 minutes.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), and Yb2O3 (available from Kojundo Chemical Laboratory Co., Ltd.) were provided as raw materials for a solid electrolyte. A prebaked body and a prebaked powder were prepared in the same process as in Example 1, except that weighing was performed in a predetermined stoichiometric ratio such that the composition after sintering was Li6Yb(BO3)3.
The prebaked powder prepared as described above was subjected to the same post baking step as in Example 1 to produce a sintered body. The heating temperature was 670° C., and the holding time was 720 minutes.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), and Er2O3(available from Kojundo Chemical Laboratory Co., Ltd.) were provided as raw materials for a solid electrolyte. A prebaked body and a prebaked powder were prepared in the same process as in Example 1, except that weighing was performed in a predetermined stoichiometric ratio such that the composition after sintering was Li6Er(B03)3.
The prebaked powder prepared as described above was subjected to the same post baking step as in Example 1 to produce a sintered body. The heating temperature was 670° C., and the holding time was 720 minutes.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Nd2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), and ZrO2 (available from Nippon Denko Co., Ltd.) were provided as raw materials for a solid electrolyte. They were weighed in a predetermined stoichiometric ratio such that the composition after sintering was Li5.900Nd0.900Zr0.100(BO3)3, and mixed with a mortar and pestle.
After that, the mixed powder was subjected to cold uniaxial molding using a hydraulic press SSP-10A available from Shimadzu Corporation and heat treatment in an air atmosphere. The heating temperature was 650° C., and the holding time was 720 minutes.
The resulting prebaked body was ground with a mortar and pestle to prepare a prebaked powder.
The prebaked powder prepared as described above was molded and heat-treated in the same manner as the prebaking, thereby producing a sintered body of Reference example 1. The heating temperature was 650° C., and the holding time was 720 minutes.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Sm2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), and ZrO2 (available from Nippon Denko Co., Ltd.) were provided as raw materials for a solid electrolyte. They were weighed in a predetermined stoichiometric ratio such that the composition after sintering was Li5.900Sm0.900Zr0.100(BO3)3, and mixed with a mortar and pestle.
After that, the mixed powder was subjected to cold uniaxial molding using a hydraulic press SSP-10A available from Shimadzu Corporation and heat treatment in an air atmosphere. The heating temperature was 650° C., and the holding time was 720 minutes.
The resulting prebaked body was ground with a mortar and pestle to prepare a prebaked powder.
The prebaked powder prepared as described above was molded and heat-treated in the same manner as the prebaking, thereby producing a sintered body of Reference example 2. The heating temperature was 650° C., and the holding time was 720 minutes.
The sintered bodies of Examples 1 to 12, Comparative examples 1 and 2, and Reference examples 1 and 2 were subjected to composition analysis and measurement of X-ray diffraction peaks by the above-described methods. The ionic conductivity was measured by the following method. A method for measuring the ionic conductivity is described below. Table 1 presents the obtained evaluation results.
Gold electrodes were deposited on the top and bottom surfaces of each flat sintered body obtained by the post baking step using a magnetron sputtering system MSP-10, available from Vacuum Device Co., Ltd., to produce a sample for AC impedance measurement.
A Potentiostat/Galvanostat SI 1287A and a Frequency Response Analyzer 1255b available from Solartron Analytical were used for the AC impedance measurement. The measurement conditions were room temperature and a frequency of 1 MHz to 0.1 Hz.
The resistance of the sintered body was calculated from the complex impedance plot obtained by the impedance measurement. From the calculated resistance, the thickness of the sintered body, and the electrode area, the ionic conductivity was determined using the following equation.
Ionic conductivity (S/cm)=thickness of sintered body (cm)/(resistance of sintered body (Ω)×electrode area (cm2))
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Yb2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), Tm2O3(available from Kojundo Chemical Laboratory Co., Ltd.), and ZrO2 (available from Nippon Denko Co., Ltd.) were provided as raw materials for solid electrolytes. They were weighed in predetermined stoichiometric ratios such that the compositions after sintering were Li5.900Yb0.720Tm0.180Zr0.100(BO3)3 and Li5.800Yb0.640Tm0.160Zr0.200 (BO3)3, and mixed with a mortar and pestle.
After that, the mixed powders were subjected to cold uniaxial molding using a hydraulic press SSP-10A available from Shimadzu Corporation and heat treatment in an air atmosphere. The heating temperature was 650° C., and the holding time was 720 minutes.
The resulting prebaked bodies were ground with a mortar and pestle to prepare prebaked powders.
The prebaked powders prepared as described above were molded and heat-treated in the same manner as the prebaking, thereby producing sintered bodies of Examples 13 and 14. The heating temperature was 670° C., and the holding time was 720 minutes.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Yb2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), Tm2O3(available from Kojundo Chemical Laboratory Co., Ltd.), ZrO2 (available from Nippon Denko Co., Ltd.), and CeO2 (available from Iwatani Corporation) were provided as raw materials for a solid electrolyte. They were weighed in a predetermined stoichiometric ratio such that the composition after sintering was Li5.875Yb0.700Tm0.175Zr0.100Ce0.025(BO3)3, and mixed with a mortar and pestle.
After that, the mixed powder was subjected to cold uniaxial molding using a hydraulic press SSP-10A available from Shimadzu Corporation and heat treatment in an air atmosphere. The heating temperature was 650° C., and the holding time was 720 minutes.
The resulting prebaked body was ground with a mortar and pestle to prepare a prebaked powder.
The prebaked powder prepared as described above was molded and heat-treated in the same manner as the prebaking, thereby producing a sintered body of Example 15. The heating temperature was 670° C., and the holding time was 720 minutes.
Prebaked bodies and prebaked powders were produced in the same process as in Example 15, except that the raw materials described in Example 15 were weighed in predetermined stoichiometric ratios such that R1, R2, R1 ratios, R2 ratios, M1 components, and x=x1+×2 had values given in Table 2.
The prebaked powders prepared as described above were subjected to the same post baking step as in Example 15 to produce sintered bodies.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Yb2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), Nd2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), and ZrO2 (available from Nippon Denko Co., Ltd.) were provided as raw materials for a solid electrolyte. They were weighed in a predetermined stoichiometric ratio such that the composition after sintering was L1.900Yb0.720Nd0.180Zr0.100(BO3)3, and mixed with a mortar and pestle.
After that, the mixed powder was subjected to cold uniaxial molding using a hydraulic press SSP-10A available from Shimadzu Corporation and heat treatment in an air atmosphere. The heating temperature was 650° C., and the holding time was 720 minutes.
The resulting prebaked body was ground with a mortar and pestle to prepare a prebaked powder.
The prebaked powder prepared as described above was molded and heat-treated in the same manner as the prebaking, thereby producing a sintered body of Example 18. The heating temperature was 670° C., and the holding time was 720 minutes.
Prebaked bodies and prebaked powders were produced in the same process as in Example 18, except that the raw materials described in Example 18 were weighed in predetermined stoichiometric ratios such that R1, R2, R1 ratios, R2 ratios, M1 components, and x=x1+×2 had values given in Table 2.
The prebaked powders prepared as described above were subjected to the same post baking step as in Example 18 to produce sintered bodies.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Yb2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), Nd2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), ZrO2 (available from Nippon Denko Co., Ltd.), and CeO2 (available from Iwatani Corporation) were provided as raw materials for solid electrolytes. They were weighed in predetermined stoichiometric ratios such that the compositions after sintering were Li5.875Yb0.788Nd0.088Zr0.100Ce0.025(BO3)3 and Li5.875Yb0.700Nd0.175Zr0.100Ce0.025 (BO3)3. The weighed raw materials were mixed and stirred with a mortar and pestle.
After that, the mixed powders were subjected to cold uniaxial molding using a hydraulic press SSP-10A available from Shimadzu Corporation and heat treatment in an air atmosphere. The heating temperature was 650° C., and the holding time was 720 minutes.
The resulting prebaked bodies were ground with a mortar and pestle to prepare prebaked powders.
The prebaked powders prepared as described above were molded and heat-treated in the same manner as the prebaking, thereby producing sintered bodies of Examples 22 and 23. The heating temperature was 670° C., and the holding time was 720 minutes.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Yb2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), Er2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), and ZrO2 (available from Nippon Denko Co., Ltd.) were provided as raw materials for a solid electrolyte. They were weighed in a predetermined stoichiometric ratio such that the composition after sintering was Li5.800Yb0.640Er0.160Zr0.200(BO3)3, and mixed with a mortar and pestle.
After that, the mixed powder was subjected to cold uniaxial molding using a hydraulic press SSP-10A available from Shimadzu Corporation and heat treatment in an air atmosphere. The heating temperature was 650° C., and the holding time was 720 minutes.
The resulting prebaked body was ground with a mortar and pestle to prepare a prebaked powder.
The prebaked powder prepared as described above was molded and heat-treated in the same manner as the prebaking, thereby producing a sintered body of Example 24. The heating temperature was 670° C., and the holding time was 720 minutes.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Yb2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), Sm2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), and ZrO2 (available from Nippon Denko Co., Ltd.) were provided as raw materials for a solid electrolyte. They were weighed in a predetermined stoichiometric ratio such that the composition after sintering was Li5.900Yb0.810Sm0.090Zr0.100(BO3)3, and mixed with a mortar and pestle.
After that, the mixed powder was subjected to cold uniaxial molding using a hydraulic press SSP-10A available from Shimadzu Corporation and heat treatment in an air atmosphere. The heating temperature was 650° C., and the holding time was 720 minutes.
The resulting prebaked body was ground with a mortar and pestle to prepare a prebaked powder.
The prebaked powder prepared as described above was molded and heat-treated in the same manner as the prebaking, thereby producing a sintered body of Example 25. The heating temperature was 670° C., and the holding time was 720 minutes.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Yb2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), La2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), and ZrO2 (available from Nippon Denko Co., Ltd.) were provided as raw materials for a solid electrolyte. They were weighed in a predetermined stoichiometric ratio such that the composition after sintering was Li5.900Yb0.810La0.090Zr0.100(BO3)3, and mixed with a mortar and pestle.
After that, the mixed powder was subjected to cold uniaxial molding using a hydraulic press SSP-10A available from Shimadzu Corporation and heat treatment in an air atmosphere. The heating temperature was 650° C., and the holding time was 720 minutes.
The resulting prebaked body was ground with a mortar and pestle to prepare a prebaked powder.
The prebaked powder prepared as described above was molded and heat-treated in the same manner as the prebaking, thereby producing a sintered body of Example 26. The heating temperature was 670° C., and the holding time was 720 minutes.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Yb2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), La2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), ZrO2 (available from Nippon Denko Co., Ltd.), and CeO2 (available from Iwatani Corporation) were provided as raw materials for solid electrolytes. They were weighed in a predetermined stoichiometric ratio such that the composition after sintering was Li5.88Yb0.788La0.088Zr0.100Ce0.025(BO3)3, and mixed with a mortar and pestle.
After that, the mixed powder was subjected to cold uniaxial molding using a hydraulic press SSP-10A available from Shimadzu Corporation and heat treatment in an air atmosphere. The heating temperature was 650° C., and the holding time was 720 minutes.
The resulting prebaked body was ground with a mortar and pestle to prepare a prebaked powder.
The prebaked powder prepared as described above was molded and heat-treated in the same manner as the prebaking, thereby producing a sintered body of Example 27. The heating temperature was 670° C., and the holding time was 720 minutes.
Prebaked bodies and prebaked powders were produced in the same process as in Example 27, except that the raw materials described in Example 27 were weighed in predetermined stoichiometric ratios such that R1, R2, R1 ratios, R2 ratios, the M1 components, and x=x1+×2 had values given in Table 2.
The prebaked powders prepared as described above were subjected to the same post baking step as in Example 27 to produce sintered bodies.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Yb2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), Tm2O3(available from Kojundo Chemical Laboratory Co., Ltd.), Nd2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), and La2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), were provided as raw materials for a solid electrolyte.
Prebaked bodies and prebaked powders were produced in the same process as in Example 13, except that the raw materials described in Example 13 were weighed in predetermined stoichiometric ratios such that R1, R2, R1 ratios, R2 ratios, M1 components, and x=x1+×2 had values given in Table 2.
The prebaked powders prepared as described above were subjected to the same post baking step as in Example 13 to produce sintered bodies.
Li3BO3 (available from Toshima Manufacturing Co., Ltd.), H3BO3 (available from Kishida Chemical Co., Ltd.), Er2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), La2O3 (available from Kojundo Chemical Laboratory Co., Ltd.), ZrO2 (available from Nippon Denko Co., Ltd.), and CeO2 (available from Iwatani Corporation) were provided as raw materials for solid electrolytes. They were weighed in a predetermined stoichiometric ratio such that the composition after sintering was Li5.9Er0.81La0.090Zr0.100(BO3)3, and mixed with a mortar and pestle.
After that, the mixed powder was subjected to cold uniaxial molding using a hydraulic press SSP-10A available from Shimadzu Corporation and heat treatment in an air atmosphere. The heating temperature was 650° C., and the holding time was 720 minutes.
The resulting prebaked body was ground with a mortar and pestle to prepare a prebaked powder.
The prebaked powder prepared as described above was molded and heat-treated in the same manner as the prebaking, thereby producing a sintered body of Example 30. The heating temperature was 670° C., and the holding time was 720 minutes.
Prebaked bodies and prebaked powders were produced in the same process as in Example 1, except that the raw materials described in Example 1 were weighed in predetermined stoichiometric ratios such that x had values given in Table 2.
The prebaked powders prepared as described above were subjected to the same post baking step as in Example 1 to produce sintered bodies.
A prebaked body and a prebaked powder were produced in the same process as in Example 1, except that the raw materials described in Example 1 were weighed in a predetermined stoichiometric ratio such that x had the value given in Table 2.
The prebaked powder prepared as described above was subjected to the same post baking step as in Example 1 to produce a sintered body.
The sintered bodies of Examples 13 to 33, Comparative examples 3 to 5, and Reference examples 1 to 3 were subjected to composition analysis and measurement of X-ray diffraction peaks in the same manner as in Example 1. The ionic conductivity was measured in the same manner as in Example 1.
Table 1 presents the stoichiometric amounts of raw materials and the heating temperature during the post baking when the solid electrolytes according to Examples 1 to 12, Comparative examples 1 and 2, and Reference examples 1 and 2 were produced, the diffraction peak positions, and the ionic conductivity. Table 2 presents the stoichiometric amounts of raw materials and the heating temperature during post baking when the solid electrolytes according to Examples 13 to 33, Comparative examples 3 to 5, and Reference example 3 were produced, the diffraction peak positions, and the ionic conductivity.
The results of the above composition analysis indicated that each sintered body (solid electrolyte) had the elements of the raw materials described in Tables 1 and 2. The sintered bodies (solid electrolytes) according to Examples 1 to 33 were each a solid electrolyte that was successfully densified at a low temperature of lower than 700° C. and that exhibited high ionic conductivity.
In the solid electrolytes according to Examples 1 to 33 in which the ion conductivity σ was 1×10-? S/cm or more, as presented in Tables 1 and 2, the peak shift of the bimodal diffraction peaks to higher angles was observed along with the shift of the X-ray diffraction angle peaks to higher angles. That is, it can be read that in the range of 27.4° or more and 29.0° or less, the difference 2θd in diffraction angle between a higher-angle diffraction peak observed at 28.3° to 29.0° and a lower-angle diffraction peak observed at 27.4° to 28.3° is increased to 0.43° or more. In other words, the solid electrolyte according to the present embodiment contains a borate containing Li, an element R selected from a group including Yb, Er, Ho, Tm, La, Nd, and Sm, and an element M selected from a group including Zr, Ce, and Sn. Furthermore, the solid electrolyte of the present embodiment is, in other words, an electrolyte that exhibits two diffraction peaks in the diffraction angle 20 range of 27.4° or more and 29.0° or less in XRD using the K-alpha emission line in copper, in which the difference 2θd in diffraction angle between the higher-angle diffraction peak and the lower-angle diffraction peak is 0.43° or more.
The two diffraction peaks observed in the diffraction angle 20 range of 27.4° or more and 29.0° or less may further include multimodal peaks including trimodal or tetramodal peaks depending on the crystallinity. In the present specification, the two diffraction peaks are represented as having one peak on the lower angle side and one peak on the higher angle side, respectively, bordering a diffraction angle 2θ of 28.3°. In this way, the diffraction peaks are separated by fitting to a bimodal diffraction profile.
Such high-angle diffraction peaks are broadened and shift to higher angles more remarkably than low-angle diffraction peaks as the component of the substitution element M increases or as the ionic conductivity increases. These results indicate that the solid electrolyte 44 of the present embodiment has a different crystal structure than the non-substituted comparative examples, such that multiple crystal structures having distributions in lattice spacing and crystallite size are mixed.
The solid electrolytes according to Examples 13 to 33 described in Table 2 and
The solid electrolytes of Examples 14 to 16, 18, 22, 23, and 26 to 33 exhibit an ionic conductivity of 1E-5 (S/cm) or more as in Examples 2 to 6 and 12, and can be used for the anodes of all-solid-state batteries by being combined with anode active material particles, such as LCO, to form a composite structure.
In the solid electrolytes having an ionic conductivity of 1E-7 (S/cm) or more according to Examples 1 to 33, the atomic concentration ratio [M]/[R] of the substitution element M to the rare-earth element R was 0.026 or more and 1.500 or less. In the solid electrolytes having an ionic conductivity of 1E-6 (S/cm) or more according to Examples 2 to 6, 8 to 10, and 12 to 33, the atomic concentration ratio [M]/[R] of the substitution element M to the rare-earth element R was 0.056 or more and 1.500 or less. In the solid electrolytes having an ionic conductivity of 2E-5 (S/cm) or more according to Examples 2 to 6, 12, 14 to 16, 18, 22, 23, 26 to 30, and 32, the atomic concentration ratio [M]/[R] of the substitution element M to the rare-earth element R was 0.081 or more and 0.667 or less.
Among the solid electrolytes containing multiple rare-earth elements according to Examples 13 to 33, the solid electrolytes having an ionic conductivity of 1E-5 (S/cm) or more had an atomic concentration ratio ([R]-[Yb])/[R] of 0.063 or more and 0.200 or less.
The atomic concentration ratio [M]/[R] of the substitution element M to the rare-earth element R is algebraically described as [M]/[R]=(x1+x2)/(R1 ratio+R2 ratio) using the R1 ratio, the R2 ratio, x1, and x2 described in Table 2. Similarly, the atomic concentration ratio [M]/[R] of the substitution element M to the rare-earth element R is algebraically described as [M]/[R]=(x1+x2)/(1-x1-x2) using x1 and x2 described in Table 1.
The atomic concentration ratio ([R]-[Yb])/[R] is algebraically described as (R2 ratio)/(R1 ratio+R2 ratio) using the R1 ratio and the R2 ratio described in Table 2.
In Tables 1 and 2, the atomic concentration ratio [M]/[R] of the substitution element M is described as the atomic concentration ratio [M1]/[R] of the substitution element M1.
The present invention is not limited to the above embodiments and various changes and modifications can be made within the spirit and scope of the present invention. Therefore, to apprise the public of the scope of the present invention, the following claims are made.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2021-028807 | Feb 2021 | JP | national |
| 2021-101742 | Jun 2021 | JP | national |
| 2022-007354 | Jan 2022 | JP | national |
This application is a Continuation of International Patent Application No. PCT/JP2022/007439, filed Feb. 24, 2022, which claims the benefit of Japanese Patent Application No. 2021-028807, filed Feb. 25, 2021, Japanese Patent Application No. 2021-101742, filed Jun. 18, 2021, and Japanese Patent Application No. 2022-007354, filed Jan. 20, 2022, all of which are hereby incorporated by reference herein in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2022/007439 | Feb 2022 | US |
| Child | 18450297 | US |
