Methods and compositions for high-energy battery cathodes

Patent metadata

Field	Value
Publication number	US-2022263086-A1
Application number	US-202017623578-A
Country	US
Kind code	A1
Filing date	Jun 28, 2020
Priority date	Jun 28, 2019
Publication date	Aug 18, 2022
Grant date	—

Abstract

In one aspect, the disclosure relates to electrochemically active materials for use in constructing cathodes in lithium ion batteries. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure. In accordance with the purpose(s) of the present disclosure, as embodied and broadly described herein, the disclosure, in one aspect, relates to electrochemically active materials for use as cathodes in lithium-ion batteries, methods of introducing dopants into the electrochemically active materials, and electrochemical cells and batteries comprising the same. Cathodes made using the electrochemically active materials disclosed herein exhibit smoother voltage profiles as well as enhanced specific energy, cycle life, rate capability, self-discharge resistance, and thermal stability compared to conventional cathodes.

First claim

1 . A cathode comprising an electrochemically active material having a crystalline structure characterized by the formula LiMO 2 , wherein M represents a metal ion and wherein the electrochemically active material comprises at least one dopant;
wherein the electrochemically active material is substantially free of Co.

2 . (canceled)

3 . The cathode of claim 1 , where M comprises Ni x Mn y where x+y is about 1.

4 . (canceled)

5 . The cathode of claim 1 , wherein the at least one dopant comprises Al, Na, Mg, Ti, Zr, Si, Nb, Ca, Sr, Ba, Zn, V, Fe, Cr, Cu, Nd, La, Mn, Ga, Sb, Ce, Mo, Tc, Ru, Rh, Ag, Cd, Ge, W, Ca, B, F or a combination thereof.

6 . The cathode of claim 1 , wherein the at least one dopant is Mn, Mg, Ti, and combinations thereof.

7 . The cathode of claim 1 , wherein the at least one dopant occupies M lattice sites in the crystalline structure.

8 . The cathode of claim 6 , wherein the at least one dopant is present in a concentration of from about 1 mol % to about 6 mol %.

9 . (canceled)

10 . (canceled)

11 . (canceled)

12 . The cathode according to claim 1 , wherein the battery is a cobalt-free battery and the electrochemically active material comprises LiNiO 2 .

13 . (canceled)

14 . (canceled)

15 . (canceled)

16 . (canceled)

17 . (canceled)

18 . The cathode of claim 3 , wherein the at least one dopant is Mg, Mn, Ti, or a combination thereof having a combined concentration of about 4 mol % or less.

19 . A process for preparing the cathode of claim 1 , the process comprising:
a. preparing a slurry containing a solvent, the electrochemically active material, a conductive additive, and a binder; b. casting the slurry on a substrate; and c. drying the cathode.

20 . The process of claim 19 , wherein the solvent comprises N-methyl-2-pyrrolidone or water.

21 . The process of claim 19 , wherein the conductive additive comprises acetylene carbon, carbon black, graphite, graphene, or a combination thereof.

22 . The process of claim 19 , wherein the binder comprises polyvinylidene fluoride (PVDF), polyvinylidene fluoride-co-hexafluoropropylene (PVDF-HFP), polytetrafluoroethylene, carboxymethyl cellulose, alginate, or a combination thereof.

23 . (canceled)

24 . (canceled)

25 . (canceled)

26 . (canceled)

27 . (canceled)

28 . (canceled)

29 . (canceled)

30 . An electrochemical cell comprising the cathode of claim 1 , an anode, and an electrolyte.

31 . The electrochemical cell of claim 30 , wherein the anode comprises graphite, activated carbon, carbon nanotubes, graphene, lithium foil, or a combination thereof.

32 . (canceled)

33 . The electrochemical cell of claim 30 , wherein mass loading of the cathode is from about 3 to about 75 mg/cm 2 .

34 . (canceled)

35 . The electrochemical cell of claim 30 , wherein the electrochemical cell has an initial capacity of from 150 to 200 mAh/g when discharged to the end-of-discharge voltage at a C-rate of C1.

36 . The electrochemical cell of claim 35 , wherein the electrochemical cell retains at least 85% capacity after 300 charge/discharge cycles at a C-rate of C1.

37 . (canceled)

38 . The electrochemical cell of claim 37 , wherein the electrochemical cell retains at least 90% capacity after 150 charge/discharge cycles at a C-rate of C/2.

39 . (canceled)

40 . The electrochemical cell of claim 39 , wherein the electrochemical cell retains at least 86% capacity after 150 charge/discharge cycles at a C-rate of C/5.

41 . The electrochemical cell of claim 30 , wherein the electrochemical cell has an initial capacity of from 180 to 230 mAh/g when discharged to the end-of-discharge voltage at a C-rate of C/10.

42 . (canceled)

43 . (canceled)

Assignees

• Virginia Tech Intellectual Properties Inc

Inventors

• Lin Feng
• Ma Linqin
• Steiner James D

Classifications

• H01M10/446

  Initial charging measures · CPC title

• H01M2004/027

  Negative electrodes · CPC title

• H01M4/0404

  by coating on electrode collectors · CPC title

• Y02P70/50

  Manufacturing or production processes characterised by the final manufactured product · CPC title

• H01M2004/028

  Positive electrodes · CPC title