Electrodes comprising blended active materials

Patent metadata

Field	Value
Publication number	US-12388085-B2
Application number	US-202217950032-A
Country	US
Kind code	B2
Filing date	Sep 21, 2022
Priority date	Sep 21, 2022
Publication date	Aug 12, 2025
Grant date	Aug 12, 2025

Abstract

Provided are electrodes for lithium-ion batteries comprising: a first lithium metal phosphate material comprising a first plurality of active material particles; and a second lithium metal phosphate material comprising a second plurality of active material particles, wherein both the first lithium metal phosphate material and the second lithium metal phosphate material are LiMPO 4 , wherein M is one or more of iron (Fe) or manganese (Mn), and wherein the first lithium metal phosphate material is blended with the second lithium metal phosphate material at a weight ratio of greater than 1:1.

First claim

The invention claimed is:

1. An electrode for a lithium-ion battery comprising a blend of:
a first lithium metal phosphate material comprising a first plurality of primary active material particles having a D50 of from 150 nanometers to 2 microns; and
a second lithium metal phosphate material comprising a second plurality of primary active material particles having a D50 of from 5 to 300 times larger than the first plurality of primary active material particles,
wherein the first lithium metal phosphate material and the second lithium metal phosphate material are independently represented by formula LiMPO 4 , wherein M is one or more of iron (Fe) or manganese (Mn), and
wherein the first lithium metal phosphate material is blended with the second lithium metal phosphate material at a weight ratio of greater than 1:1.

2. The electrode of claim 1 , wherein the second plurality of primary active material particles have a D50 of from 5 to 50 times larger than the first plurality of primary active material particles.

3. The electrode of claim 1 , wherein the D50 of the first plurality of primary active material particles is from 150 nm to 1 microns.

4. The electrode of claim 1 , wherein the D50 of the first plurality of primary active material particles is from 150 nm to 500 nm.

5. The electrode of claim 1 , wherein M for the first lithium metal phosphate material and the second lithium metal phosphate material is iron (Fe).

6. The electrode of claim 1 , wherein the first and second lithium metal phosphate materials are the same LiMPO 4 .

7. The electrode of claim 2 , wherein the D50 of the first plurality of primary active material particles is from 300 nanometers to 2 microns.

8. The electrode of claim 1 , wherein the second plurality of primary active material particles have a D50 of from 5 to 25 times larger than the first plurality of primary active material particles.

9. The electrode of claim 1 , wherein the blend comprises from 0.5 to 3 wt. % carbon.

10. The electrode of claim 1 , wherein the blend has a resistivity of less than or equal to 600 ohm-cm.

11. The electrode of claim 1 , wherein the blend has a tap density of greater than or equal to 0.8 g/cc.

12. The electrode of claim 1 , wherein the first lithium metal phosphate material is blended with the second lithium metal phosphate material at a weight ratio of greater than 3:2.

13. The electrode of claim 1 , wherein the first lithium metal phosphate material is blended with the second lithium metal phosphate material at a weight ratio of greater than 3:1.

14. The electrode of claim 1 , wherein the electrode has an electrode press density from 1.8 to 2.8 g/cc.

15. The electrode of claim 2 , wherein a surface area of the first plurality of primary active material particles is less than or equal to 15 m 2 /g.

16. The electrode of claim 2 , wherein the D50 of the first plurality of primary active material particles is from 150 nm to 500 nm.

17. The electrode of claim 2 , wherein the D50 of the first plurality of primary active material particles is from 150 nm to 1 microns.

18. A rechargeable lithium-ion battery comprising:
an electrode comprising a blend of:
a first lithium metal phosphate material comprising a first plurality of primary active material particles having a D50 of from 150 nanometers to 2 microns; and
a second lithium metal phosphate material comprising a second plurality of primary active material particles having a D50 of from 5 to 300 times larger than the first plurality of primary active material particles,
wherein the first lithium metal phosphate material and the second lithium metal phosphate material are independently represented by formula LiMPO 4 , wherein M is one or more of iron (Fe) or manganese (Mn), and
wherein the first lithium metal phosphate material is blended with the second lithium metal phosphate material at a weight ratio of greater than 1:1.

19. An electric vehicle system comprising the rechargeable lithium-ion battery of claim 18 .

20. The rechargeable lithium-ion battery claim 18 , wherein the second plurality of primary active material particles have a D50 of from 5 to 50 times larger than the first plurality of primary active material particles.

Assignees

• Rivian Ip Holdings Llc

Inventors

• Talebiesfandarani Majid
• Kim Yumi
• Sun Liyuan
• Jeong Sookyung
• Kim Soo
• Kim Tae Kyoung
• Park Ki Tae

Classifications

• H01M4/364

  as mixtures · CPC title

• H01M2004/021

  Physical characteristics, e.g. porosity, surface area · CPC title

• H01M2220/20

  Batteries in motive systems, e.g. vehicle, ship, plane · CPC title

• H01M10/0525 Primary

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title