Precursor materials for the synthesis of lithium-ion battery cathodes

Abstract

Provided are particles for use as a precursor material for synthesizing Li-ion cathode active materials for lithium-ion cells, the particles comprising: non-lithiated nickel oxide particles of the formula MOx, where M comprises 80 at. % or more Ni, x is 0.7 to 1.2, and M optionally excludes boron in the MOx crystal structure; and a modifying oxide mixed with, coated on, or present within the non-lithiated nickel oxide particles, or a combination thereof, wherein the modifying oxide is associated with the non-lithiated nickel oxide such that crystallite growth, as measured by XRD, is 2 nanometers or less upon calcination at 500°C for 2 hours. Also provided are methods for forming electrochemically active particles using the precursor nickel oxide.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application is dependent upon and claims priority from U.S. Patent Application No. 16 / 662,616, filed October 24, 2019, the entire contents of which are incorporated herein by reference.

[0002] Precursor materials for lithium nickel oxide based cathode materials are disclosed.

[0003] Background of the Invention Materials based on layered lithium nickelate (LiNiO2) have been developed for lithium-ion battery cathodes because they generally have lower cost, higher capacity, and higher rate capability than the historically dominant LiCoO2 cathode material. Unfortunately, the electrochemical performance of stoichiometric LiNiO2 is poor, exhibiting a rapid degradation with cycling. To address these shortcomings, the incorporation of elemental additives other than nickel (e.g., Co and Mn) into LiNiO2 has enabled reproducible synthesis and improved the cycling performance of Li-ion battery cathode materials. As energy density demands increase, current research is focused on reducing the amount of stabilizing elements, such as Co, to achieve the capacity of high-Ni materials while maintaining cycling performance. However, LiNiO2 materials with low levels of Co are difficult to synthesize. Furthermore, the quality of the resulting cathode materials is significantly dependent on the quality of the metal hydroxide precursor materials.

[0004] Therefore, new precursor materials are needed to address the demand for high capacity materials with long cycle life.

[0005] Summary of the Invention The following summary is provided to facilitate an understanding of some innovative features unique to the present disclosure and is not intended to be a complete description. The various aspects of the present disclosure can be fully understood by reading the entire specification, claims, drawings, and abstract as a whole.

[0006] Particles are provided that can be used in the synthesis of final electrochemically active materials for use in the cathode of a lithium-ion cell. The particles have the formula MO x [wherein M contains 80 at % or more of Ni, x is 0.7 to 1.2, and M optionally contains MO x and boron oxide mixed with, coated on, or present within, or a combination thereof, the non-lithiated nickel oxide particles, wherein the boron oxide is associated with the non-lithiated nickel oxide such that the crystallite growth is 2 nanometers or less upon calcination at 500°C for 2 hours as measured by XRD, and optionally the crystallite size is less than 20 nm. The particles provide a novel synthesis route for electrochemically active cathode materials that utilize the excellent capacity of these materials to facilitate the use of high Ni content while promoting long cycle life.

[0007] The embodiments set forth in the drawings are illustrative and exemplary in nature and are not intended to limit the subject matter defined by the claims. The following detailed description of illustrative embodiments can be understood when read in conjunction with the following drawings. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a titration curve showing that the boron species are water soluble and are not within the crystallites or crystalline structure of cathode materials synthesized from precursor particles provided herein. [Figure 2] 1 shows the cycle life of cathode materials made with particles according to some embodiments provided herein, measured at 45° C. in a coin-shaped full cell with a graphite anode. [Figure 3] The corresponding impedance increase is shown in Figure 2 for cycle life data. [Figure 4]Figure 1 shows the cycle life of cathode materials prepared using standard hydroxide precursors but with added boron oxide, measured at 45°C in a coin-type full cell with a graphite anode. [Figure 5] The corresponding impedance increase is shown in Figure 4 for cycle life data.

[0009] Detailed Description Disclosed herein are precursor materials for synthesizing electrochemically active cathode materials suitable for use in lithium-ion cells. The precursor materials include nickel-based oxide particles incorporating boron, optionally as boron oxide. Such precursor materials can be used in the synthesis of final lithiated cathode materials for Li-ion batteries. It has been found that cathode materials prepared from such nickel oxides containing the above elements exhibit significantly improved electrochemical performance.

[0010] The term "non-lithiated" as used herein is defined as the absence of Li in the particle and the absence of any previous lithium present in the particle, such that the resulting crystallinity of the particle is not dictated by the presence of Li in the structure or composition.

[0011] Metal oxides are not preferred precursors for the synthesis of high-nickel cathode materials for Li-ion batteries because the resulting cathode materials typically exhibit poor electrochemical performance. Reaction of a lithium source (e.g., LiOH) with a metal oxide can form layered metal oxides. However, the reaction rate between the lithium source and the metal oxide is typically slow. With increasing time and temperature, the primary crystallite size of the metal oxide increases rapidly. As the primary crystallite size of the metal oxide increases, the reaction rate with lithium further decreases. As a result, the layered lithium metal oxide formed by the metal oxide has poor crystalline quality (has numerous crystal defects).

[0012] The quality of layered lithium metal oxides can be improved by calcining at high temperatures for extended periods. However, as the nickel content of the precursor material (and therefore the cathode material) increases, the maximum time and temperature must be limited to reduce the tendency of the layered metal oxide to decompose. For these reasons, the synthesis of cathode materials typically begins with a precipitated metal hydroxide precursor, which is then mixed with a lithium source and calcined.

[0013] Similar problems to those described above can occur during the calcination step in the synthesis of lithiated oxides from metal hydroxides. Essentially, two parallel reactions occur during the synthesis of cathode materials from metal hydroxide precursors. The first is the dehydration of the metal hydroxide to form the metal oxide, and the second is the lithiation of the metal hydroxide and / or oxide to form a layered lithiated metal oxide structure. Typically, the overall reaction rate between the lithium source and the metal oxide is slower than the reaction rate between lithium and the metal hydroxide. Initially, the metal oxide is formed with a specific primary crystallite size. However, with increasing time and temperature, the crystallite size of the metal oxide increases rapidly. As the primary crystallite size of the metal oxide increases, the reaction rate with lithium further decreases. As a result, the layered lithium metal oxide formed from the metal oxide has poorer quality (having numerous crystal defects) than the layered lithium metal oxide formed from the metal hydroxide. As mentioned above, it is difficult to synthesize good-quality cathode materials using metal oxides.

[0014] The present inventors have now produced metal oxide particles that can be lithiated to form electrochemically active particles for use in lithium-ion battery cathodes, without the drawbacks of conventional materials, without significant and undesirable crystal growth, and without crystalline defects. This allows for lithiation of metal oxides at lower temperatures, improving performance. The provided materials incorporate boron oxide into dehydrated metal oxide materials. It has been found that the incorporation of boron results in oxide particles that are more easily lithiated, are of more uniform quality, and are advantageous material precursors for synthesizing cathode materials for Li-ion batteries.

[0015] Formula MO x Non-lithiated nickel oxide particles are provided, where M comprises 80 at% or more Ni and x is 0.7 to 1.2. The particles further comprise a modifier that is an oxide of boron, and the modifier is coated on the particle, present within the particle, or a combination thereof. As used herein, the term "present within" excludes incorporation of the modifier into the crystalline structure of the particle. However, the modifier may be present in the intercrystalline space, coated thereon, or otherwise associated with the particle. The presence of the modifier results in the formation of particles that, after calcination at 500 degrees Celsius (°C) for 2 hours, optionally have crystallite growth characteristics of 2 nanometers (nm) or less as measured by XRD, and / or an overall crystallite size (average cross-sectional diameter) of 30 nm or less, optionally 20 nm or less. This lack of crystallite growth optionally exists throughout the particle or within a portion of the particle.

[0016] Formula MO xM in includes or is Ni. Ni is present at 80 atomic percent (at %) or more of the total M. Optionally, M is present at 85 atomic percent or more, optionally 90 atomic percent or more, optionally 91 atomic percent or more, optionally 92 atomic percent or more, optionally 93 atomic percent or more, optionally 94 atomic percent or more, optionally 95 atomic percent or more, optionally 96 atomic percent or more, optionally 97 atomic percent or more, optionally 98 atomic percent or more, optionally 99 atomic percent or more, optionally 99.5 atomic percent or more, optionally 99.6 atomic percent or more, optionally 99.7 atomic percent or more, optionally 99.8 atomic percent or more, optionally 99.9 atomic percent or more.

[0017] M optionally comprises one or more additional metals. The second metal is optionally Mg, Sr, Co, Al, Ca, Cu, Zn, Mn, V, Ba, Zr, Ti, Nb, Ta, Cr, Fe, Mo, W, Hf, B, or any combination thereof. The additional metal is optionally present in an amount of about 0.1 at% to about 20 at%. Optionally, M comprises an additional metal that is or comprises cobalt, with a cobalt concentration in the range of 0.1 at% to about 20 at%, optionally in the range of 1 at% to about 15 at%. In some embodiments, the additional metal is or comprises Mn present in an amount of about 0.1 at% to about 20 at%. Optionally, the additional metal is or comprises Al present in an amount of about 0.1 at% to about 20 at%.

[0018] In some embodiments, M includes 80 at% or more Ni, 0.1 at% to 20 at% Co, and 0.1 at% to 20 at% Mn. Optionally, M includes 80 at% or more Ni and 0.1 at% to 20 at% Co.

[0019] The particles provided herein include a modifier element that is an oxide of boron. In some embodiments, the modifier element is coated on the particle. By coated on, it is meant that the particle is optionally completely coated or partially coated. In some embodiments, the modifier element is present within the particle. By present internally, it is meant that the modifier element is optionally present throughout the particle in a substantially homogeneous substance, or distributed internally at varying concentrations over a portion of the total particle volume. Optionally, the modifier element is both coated on the particle and present within the particle.

[0020] The modifying element is optionally present in the oxide particles at a weight percent (wt%) of 1 wt% or less, hi some embodiments, the modifying element is present at a weight percent of 0.9 wt% or less, optionally 0.8 wt%, optionally 0.7 wt%, optionally 0.6 wt%, optionally 0.5 wt%, optionally 0.4 wt%, optionally 0.3 wt%, optionally 0.2 wt%, or optionally 0.1 wt%.

[0021] In some embodiments, the modifying elements present in the nickel-based oxide material are water-insoluble. Additionally, the particles provided herein preferably do not contain any components that are water soluble at 1 atmosphere and 25°C.

[0022] The particles provided herein can be produced by combining one or more hydroxide precursor materials in powder form with a modifier element oxide (optionally micronized) and mixing the materials. The hydroxide precursor materials can be formed by a precipitation or co-precipitation process, as recognized in the art. Optionally, the precursor material powder can be formed by ball milling or other grinding procedures, as recognized in the art. The mixed materials are then subjected to a first firing at a temperature of 600°C or less for a firing time of 6 hours or less. The resulting crystalline particles contain crystals of the metal oxide intermixed with the modifier element. Without being limited to one particular theory, it is believed that when produced as provided herein, the modifier element is present in the intercrystalline space. If so, the presence of this modifier element inhibits further or excessive rates of crystal growth with subsequent firing alone or in the presence of other desired elements, such as Li, specifically LiOH.

[0023] For the formation of the particles provided herein, the mixed particles are subjected to a first firing at a firing temperature of 600°C or less. For the formation of the precursor materials provided herein, a second firing or other additional processing is not required unless or until electrochemically active particles are formed, such as by subsequent firing with Li. Thus, the term "first firing" is provided herein for illustrative purposes only. Optionally, the first firing temperature is less than 550°C; optionally less than 500°C; and optionally less than 400°C. The first firing time is optionally 6 hours or less, optionally 3 hours or less, optionally 2 hours or less, optionally 1 hour or less, and optionally 0.5 hours or less.

[0024] The resulting precursor particles are characterized by having modifying elements disposed within or on the particles such that a second calcination at 500°C for 2 hours results in additional crystallite growth of 2 nanometers or less as measured by XRD, and / or results in a crystallite size of less than 40 nm, optionally less than 35 nm, optionally less than 30 nm, optionally less than 25 nm, and optionally less than 20 nm. Because of this slowed crystal growth that occurs during subsequent calcination, it is believed that the particles can be successfully used as precursor materials for forming electrochemically active lithium metal oxides in the cathodes of lithium-ion cells. Because of the slowed crystal growth, materials can be formed that are free or substantially free of crystalline defects.

[0025] In some embodiments, the particles are nickel oxides further comprising a modifying element B. The boron-containing nickel oxide precursor can be synthesized by mixing boron oxide with a nickel-containing hydroxide and calcining the resulting mixture at a specified temperature for a specified time. The weight ratio of boron oxide to nickel hydroxide can be <1%, <0.75%, <0.5%, <0.25%, or <0.1%. The specified temperature for the first calcination can be less than 600°C; optionally less than 550°C; optionally less than 500°C; or optionally less than 400°C. The specified time can be less than 6 hours, optionally less than 3 hours, optionally less than 2 hours, optionally less than 1 hour, or optionally less than 0.5 hours.

[0026] In some embodiments, the precursor material is a Ni-Co mixed oxide incorporating a modifier element that is boron. Optionally, the amount of Ni (relative to the sum of Ni and Co) is less than 99 at%, optionally less than 95 at%, and optionally less than 90 at%. Optionally, the amount of Ni (relative to the sum of Ni and Co) is 70 at% or more, optionally 75 at% or more, optionally 80 at% or more, optionally 85 at% or more, optionally 90 at% or more, optionally 91 at% or more, optionally 92 at% or more, optionally 93 at% or more, optionally 94 at% or more, optionally 95 at% or more, optionally 96 at% or more, optionally 97 at% or more, optionally 98 at% or more, and optionally 99 at% or more.

[0027] In some embodiments, the precursor material is a Ni-Co-Mn mixed oxide incorporating elemental boron. The amount of Ni relative to the sum of Ni, Co, and Mn is 99 at% or less, optionally 98 at% or less, optionally 95 at% or less, and optionally 85 at% or less. Optionally, the amount of Ni (relative to the sum of Ni, Co, and Mn) is 70 at% or more, optionally 75 at% or more, optionally 80 at% or more, optionally 85 at% or more, optionally 90 at% or more, optionally 91 at% or more, optionally 92 at% or more, optionally 93 at% or more, optionally 94 at% or more, optionally 95 at% or more, optionally 96 at% or more, optionally 97 at% or more, optionally 98 at% or more, and optionally 99 at% or more.

[0028] The resulting non-lithiated oxide particles are a population of crystallites throughout some or all of the particles. The average crystallite size, as measured by X-ray diffraction, is optionally 40 nm or less, optionally 30 nm or less, optionally 25 nm or less, and optionally 20 nm or less. Optionally, when a second calcination is performed, optionally without added elements or optionally in the presence of Li, a second calcination at 500°C for 2 hours results in crystallite growth of 2 nanometers or less, as measured by XRD, and / or a crystallite size of less than 40 nm, optionally less than 35 nm, optionally less than 30 nm, optionally less than 25 nm, and optionally less than 20 nm.

[0029] Thus, according to some embodiments, the formula MO x [wherein M contains 80 at % or more of Ni, x is 0.7 to 1.2, and M optionally contains MO xProvided herein are non-lithiated nickel oxide particles having an average crystallite size of less than 40 nm, optionally less than 30 nm, optionally less than 25 nm, and optionally less than 20 nm, as measured by X-ray diffraction, wherein boron in the crystal structure is excluded. Such non-lithiated nickel oxide particles optionally contain up to 99 at% Ni, optionally up to 98 at% Ni, optionally up to 95 at% Ni, and optionally up to 85 at% Ni, based on total metals. Optionally, the amount of Ni (based on total metals) is 70 at% or more, optionally 75 at% or more, optionally 80 at% or more, optionally 85 at% or more, optionally 90 at% or more, optionally 91 at% or more, optionally 92 at% or more, optionally 93 at% or more, optionally 94 at% or more, optionally 95 at% or more, optionally 96 at% or more, optionally 97 at% or more, optionally 98 at% or more, optionally 99 at% or more. The particles optionally include Ni and one or more additional metals. The additional metals are optionally Mg, Sr, Co, Al, Ca, Cu, Zn, Mn, V, Ba, Zr, Ti, Nb, Ta, Cr, Fe, Mo, W, Hf, B, or any combination thereof. The additional metals are optionally present in an amount of about 0.1 at% to about 20 at%. Optionally, the additional metal is or includes cobalt, and the concentration of cobalt ranges from 0.1 at% to about 20 at% and optionally from 1 at% to about 15 at%. In some embodiments, the additional metal is or includes Mn present in an amount of from about 0.1 at% to about 20 at%. Optionally, the additional metal is or includes Al present in an amount of from about 0.1 at% to about 20 at%. Optionally, such particles are Ni-Co mixed oxides incorporating a modifying element that is boron, or Ni-Co-Mn mixed oxides optionally incorporating a modifying element that is boron, where Ni-Co oxide or Ni-Co-Mn oxide are as described elsewhere herein.

[0030] Also provided herein are hydroxide precursors of lithiated nickel oxides, whereby the hydroxide precursor contains boron within the particles, thereby also reducing oxide crystal growth during the formation of the final lithiated nickel oxide particles. As discussed above, during a typical metal hydroxide lithiation process, two competing reactions occur: one is the dehydration of the metal hydroxide to the metal oxide; and the other is the simultaneous lithiation of the metal hydroxide / oxide to form a layered lithiated metal oxide structure. Because the reaction rate between the lithium source and the metal oxide is slower than the reaction rate between lithium and the metal hydroxide, metal oxide crystal growth occurs during the sintering reaction, resulting in crystals that react less quickly with lithium compared to hydroxide-based materials. This results in a non-uniform lithiated product with crystalline defects. The present disclosure addresses this issue through a second method, the formation of co-precipitated boron-containing nickel hydroxides, where boron reduces the rate of oxide crystal growth during lithiation, resulting in the formation of more uniform lithiated particles with fewer crystalline defects.

[0031] Thus, there is provided a non-lithiated nickel hydroxide that includes boron within the particle arranged to function as an oxide crystal growth inhibitor during subsequent high temperature reactions in the presence or absence of lithium. The non-lithiated nickel hydroxide particles have the formula M(OH) x wherein M contains 80 at% or more of Ni and x is 0.7 to 1.2. The particles further contain a modifier that is boron or contains boron, and the modifier is coprecipitated so as to be present in the particles after precipitation.

[0032] Formula M(OH) xM in comprises or is Ni. Ni is present in at least 80 atomic percent (at %) of the total M. Optionally, Ni is present in at least 85 atomic percent, optionally at least 90 atomic percent, optionally at least 91 atomic percent, optionally at least 92 atomic percent, optionally at least 93 atomic percent, optionally at least 94 atomic percent, optionally at least 95 atomic percent, optionally at least 96 atomic percent, optionally at least 97 atomic percent, optionally at least 98 atomic percent, optionally at least 99 atomic percent, optionally at least 99.5 atomic percent, optionally at least 99.6 atomic percent, optionally at least 99.7 atomic percent, optionally at least 99.8 atomic percent, optionally at least 99.9 atomic percent of the total M.

[0033] Formula M(OH) x wherein M optionally comprises one or more additional metals. The second metal is optionally Mg, Sr, Co, Al, Ca, Cu, Zn, Mn, V, Ba, Zr, Ti, Nb, Ta, Cr, Fe, Mo, W, Hf, B, or any combination thereof. The additional metal is optionally present in an amount of about 0.1 at% to about 20 at%. Optionally, M comprises an additional metal that is or comprises cobalt, with a cobalt concentration in the range of 0.1 at% to about 20 at%, optionally in the range of 1 at% to about 15 at%. In some embodiments, the additional metal is or comprises Mn present in an amount of about 0.1 at% to about 20 at%. Optionally, the additional metal is or comprises Al present in an amount of about 0.1 at% to about 20 at%. In some embodiments, the additional metal has the formula M(OH) x M therein includes 80 at% or more Ni, 0.1 at% to 20 at% Co, and 0.1 at% to 20 at% Mn. Optionally, M includes 80 at% or more Ni and 0.1 at% to 20 at% Co.

[0034] The modifying element in the metal hydroxide particle is present within the particle and distributed as a result of co-precipitation with the metal in forming the metal hydroxide particle. The modifying boron is optionally present throughout the particle in a substantially uniform form or distributed at varying concentrations over a portion of the overall particle volume.

[0035] The modifying element is optionally present in the hydroxide particles at a weight percent (wt%) of 1 wt% or less, hi some embodiments, the modifying element is present at 0.9 wt% or less, optionally 0.8 wt% or less, optionally 0.7 wt% or less, optionally 0.6 wt% or less, optionally 0.5 wt% or less, optionally 0.4 wt% or less, optionally 0.3 wt% or less, optionally 0.2 wt% or less, and optionally 0.1 wt% or less.

[0036] Non-lithiated metal hydroxide particles can be produced by a coprecipitation method in which the metal and boron are simultaneously precipitated from one or more components in an aqueous solution or suspension. For example, a nickel salt is mixed with the modified boron described herein and optionally one or more other metal salts (e.g., cobalt salt, manganese salt, magnesium salt), any of which may be the sulfate, nitrate, acetate, halide, hydroxide, or oxyhydroxide of the metal, respectively. To precipitate the boron and metal into particles, a base material can be added to the solution or suspension, designed to distribute the metal substantially uniformly throughout the particles, or in other forms, such as gradients or other configurations, such that boron is included in the resulting hydroxide particles and is therefore available to retard crystal growth of the metal oxide during the subsequent lithiation reaction.

[0037] Optionally, a non-lithiated metal oxide precursor material can be produced from the non-lithiated metal hydroxide precursor co-precipitated with modified boron by calcination at a specified temperature for a specified time. The specified temperature can be less than 600°C; optionally less than 550°C; optionally less than 500°C; or optionally less than 400°C. The specified time can be less than 3 hours; optionally less than 2 hours; optionally less than 1 hour; or optionally less than 0.5 hours. This precursor can then be used to produce a lithiated metal oxide cathode material as described elsewhere herein.

[0038] Also provided is a method for forming electrochemically active particles suitable for use in primary or secondary batteries, illustratively lithium ion batteries, comprising: a modifying element oxide; a compound having the formula M(OH) x

[0023] The method includes forming precursor particles provided herein by mixing particles of a non-lithiated nickel hydroxide of formula (I), where M comprises 80 at% or more of Ni and x is 1.7 to 2.3, to form a precursor mixture; and calcining the precursor mixture at a calcination temperature of about 600°C or less for a calcination time of about 6 hours or less to form a first calcined product that is a boron-containing metal oxide. Alternatively, the boron-containing metal hydroxide precursor is formed by mixing or co-precipitation to form a boron-containing metal hydroxide precursor. In doing so, the oxide precursor, the hydroxide precursor, or both can be subsequently mixed with a lithium source, and the method further includes calcining the precursor oxide or hydroxide with the lithium source to form electrochemically active particles.

[0039] The lithium source can include lithium salts such as lithium nitrate, lithium carbonate, lithium hydroxide, or combinations thereof.

[0040] The lithium source and precursor particles provided herein are sintered. Sintering can be accomplished by heating at a rate of about 5°C per minute to about 450°C and holding at about 450°C for about 2 hours. The temperature can then be increased at about 2°C per minute to about 680°C and held for about 6 hours. The sample can then be allowed to cool naturally to room temperature. The resulting electrochemically active material is used as the active material in the cathode of a lithium-ion cell.

[0041] The method for forming an electrochemically active material optionally further includes enriching one or more of Co and Al at the grain boundaries of the resulting electrochemically active particles. An exemplary process for enriching Co at the grain boundaries is described in U.S. Patent No. 9,391,317. A process for enriching Co, Al, or Co and Al at the grain boundaries is described in U.S. Patent Application Publication No. 16 / 250,615. Such Co, Al, or Co and Al grain boundary enriched materials can be readily produced by firing a green body composition containing LiOH and particles of the precursor material provided herein to form electrochemically active particles with defined grain boundaries, and then enriching Co, Al, or a combination of Co and Al at the grain boundaries, such that the resulting particles have grain boundaries in which the concentrations of Co, Al, or Co and Al are higher than before enrichment, optionally higher than in the primary crystallites, and whose outer surfaces define the edges of the grain boundaries in the secondary particles.

[0042] Illustratively, a method of forming electrochemically active particles suitable for use in a cathode of a secondary battery further includes immersing the electrochemically active particles in a treatment solution containing Co alone or Co and Al; drying the electrochemically active particles after immersion; and heat-treating the electrochemically active particles after drying to form particles having a concentration of Co, Al, or both in the grain boundaries that is greater than the concentration of Al, Co, or both in the crystallites.

[0043] The grain boundary enriched particles can be formed by a multi-step process whereby a precursor particle material is formed as an oxide or hydroxide mixed and calcined with a modifying element provided herein, optionally in the presence of Li, to form defined grain boundaries, optionally with primary particles having an α-NaFeO structure with few, if any, crystalline defects. The particles are then subjected to a liquid process that applies desired concentration levels of Co, Al, or Co and Al, followed by drying and then a heat treatment, which results in selective migration of surface Co or Al precipitate species to the grain boundaries, thereby forming secondary particles with higher concentrations of Co and Al at the grain boundaries than the crystallites.

[0044] According to a method for producing secondary particles having a nickel oxide base as provided herein, for example, the formation may include mixing a lithium compound with one or more metal or metalloid nickel oxide or hydroxide precursors (e.g., a combination of Ni, Co, and Mg) provided herein to form a mixture; heat-treating the mixture by a second calcination at about 30 to about 200°C to form a dried mixture; heat-treating the dried mixture at about 200°C to about 500°C for about 0.1 to about 5 hours; and then heat-treating the dried mixture at 600°C to less than about 800°C for about 0.1 to about 10 hours to produce lithiated secondary particles. The maximum temperature of the second calcination is relative and specific to the material used for the oxide precursor. Optionally, the maximum temperature in the second calcination may be 850°C or less, optionally 720°C or less, optionally 715°C or less, optionally 710°C or less, 705°C or less, or optionally 700°C or less. Optionally, the maximum temperature of the second firing may be about 680°C or less. Optionally, the maximum temperature may be about 660°C or less. Optionally, the maximum temperature may be about 640°C or less. In yet another embodiment, the maximum temperature may be less than about 700°C, less than about 695°C, less than about 690°C, less than about 685°C, less than about 680°C, less than about 675°C, less than about 670°C, less than about 665°C, less than about 660°C, less than about 655°C, less than about 650°C, less than about 645°C, or less than about 640°C. The hold time at the maximum temperature is optionally less than 10 hours. Optionally, the hold time at the maximum temperature is 8 hours or less; optionally 7 hours or less; optionally 6 hours or less; optionally 5 hours or less; optionally 4 hours or less; optionally 3 hours or less; or optionally 2 hours or less.

[0045] After firing, subsequent processing may include grinding the electrochemically active material with a mortar and pestle so that the resulting powder passes through a desired sieve, optionally a #35 sieve. The powder is then optionally ball milled in a 1 gallon jar containing a 2 cm drum of YSZ media, optionally for 5 minutes or a suitable time, so that the material optionally passes through a #270 sieve.

[0046] The electrochemically active product of the second calcination (or the first calcination if metal hydroxide precursor particles are used) can then optionally be treated in a manner that results in enriched grain boundaries after a third calcination. Co or Al to be enriched in the grain boundaries can optionally be applied by suspending the ground product in an aqueous slurry containing Co, Al, or Co / Al and a lithium compound, optionally at a temperature of about 60°C, so that the Co and Al are present in the aqueous solution (treatment solution) at the desired concentration. The slurry can then be spray-dried to form a free-flowing powder, which then undergoes a third calcination, optionally using a heating curve that follows a two-step ramp / hold process. The first of the two ramp / hold temperature profiles can be from ambient temperature (about 25°C) to 450°C, optionally at a rate of 5°C per minute, and held at 450°C for one hour. The second ramp / hold may then be from 450°C to the maximum temperature at a rate of 2°C per minute, and held at the maximum temperature for 2 hours. In some embodiments, the maximum temperature is less than about 725°C, and optionally about 700°C.

[0047] The amounts of Co, Al, or Co and Al present in the treatment solutions described below are relative to the total amount of M in the precursor particles.

[0048] The amount of Co in the treatment solution is optionally between 0.01 at% and 10 at%, optionally 9 at% or less, optionally 8 at% or less, optionally 7 at% or less, optionally 6 at% or less, optionally 5 at% or less, optionally 4 at% or less, optionally 3 at% or less, optionally 2 at% or less, optionally 1 at% or less, optionally between 0.1 at% and 1 at%, and optionally between 0.5 at% and 1 at%.

[0049] The amount of Al in the treatment solution is optionally between 0.01 at% and 10 at%, optionally 9 at% or less, optionally 8% or less, optionally 7% or less, optionally 6% or less, optionally 5% or less, optionally 4% or less, optionally 3% or less, optionally 2% or less, optionally 1% or less, optionally 0.1 at% to 1 at%, optionally 0.5 at% to 1 at%. Optionally, the amount of Al in the treatment solution is 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, or 1.5 atomic percent or less.

[0050] In some embodiments, the amount of Co in the treatment solution is optionally 0.01 at% to 10 at%, optionally 9 at% or less, optionally 8% or less, optionally 7% or less, optionally 6% or less, optionally 5% or less, optionally 4% or less, optionally 3% or less, optionally 2% or less, optionally 1% or less, optionally 0.1 at% to 1 at%, optionally 0.5 at% to 1 at%; and the amount of Al in the treatment solution is optionally 0.01 at% to 10 at%, optionally 9 at% or less, optionally 8% or less, optionally 7% or less, optionally 6% or less, optionally 5% or less, optionally 4% or less, optionally 3% or less, optionally 2% or less, optionally 1% or less, optionally 0.1 at% to 1 at%, optionally 0.5 at% to 1 at%. Optionally, the amount of Al in the treatment solution is less than or equal to 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, or 1.5 atomic percent.

[0051] Various aspects of the present disclosure will be illustrated by the following non-limiting examples. The examples are for illustrative purposes and are not intended to limit the practice of the invention. It will be understood that changes and modifications can be made without departing from the spirit and scope of the invention.

[0052] Example Example 1: Synthesis of boron-containing transition metal oxide precursors Three transition metal hydroxide precursor materials, each containing 8 at% cobalt and 92% nickel, with a D50 size of 5 micrometers, were mixed with 0.25 wt% boron oxide and calcined at 500 °C for 5 hours in air. The three materials were from different lots or different manufacturers. As a control, the three metal hydroxide precursors were calcined at 500 °C for 5 hours without the addition of boron oxide. Powder XRD analysis of the six resulting dark gray powders showed that the crystallite size of the 0.25% boron oxide sample was significantly smaller than that formed without boron oxide (Table 1).

[0053] [Table 1]

[0054] Subsequently, 1 gram (g) of each calcined sample was mixed with 10 g of water and stirred at room temperature for 20 minutes. All samples formed without boron oxide had a pH greater than 7. Samples formed with boron oxide mixed with water exhibited a pH less than 6, consistent with the expected acidity of boron oxide in water. Thus, calcining metal hydroxides with boron oxide yielded materials in which the boron oxide remained available for aqueous extraction.

[0055] Example 2: Preparation of cathode material using boron-containing nickel oxide Nickel oxides containing various levels of boron (0.66 wt%, 1.66 wt%, or 2.62 wt%) were prepared by the method described in Example 1. These nickel oxides were then mixed with LiOH and calcined to form electrochemically active cathode materials. The cathode samples were then washed with water (1 gram (g) of sample was shaken with 10 g of water for 5 minutes), centrifuged, and the supernatant was filtered through a 0.45 μm syringe filter. The supernatant was then titrated with 0.1 N HCl. The titration curve is shown in Figure 1. With increasing boron doping, more buffering was observed, consistent with the presence of soluble borate species on the outside of the particles.

[0056] In analyzing the titration curves, the range of lithiated borate species was set to 7–12.3. To eliminate the titration of LiOH external to the particles or extracted from the particles by water washing, the equivalents titrated at 12.3–11.0 were subtracted from the other materials. To eliminate any carbonate present, the equivalents titrated below 7 were subtracted from the equivalents of 7–12.3. In this way, the titration of bicarbonate ion was used to subtract the contribution of carbonate to the 7–12.3 range.

[0057] The calculated boron extracted from the samples is consistent with the amount that would be incorporated into the product if a lithium-to-boron ratio (LiB) of 4 were assumed. Such a species would be the uncommon Li8B2O7. However, if we assume the more common lithium orthoborate species Li3BO3, with a Li:B ratio of 3, we see significantly more boron than incorporated. Highly lithiated borate species are present at the very high pH of the first buffer range, essentially 12. In both cases, it is clear that most of the boron is observed on the outside of the particles, with borate buffering observed near pH 9.5. Elemental analysis of the wash water and unwashed material also supports the conclusion that the borate species are easily washed out of the finished cathode product as lithiated borate species. Therefore, boron doping of the final product is unlikely.

[0058] [Table 2]

[0059] [Table 3]

[0060] Example 3: Synthesis of cathode materials for Li-ion batteries Two electrochemically active materials suitable for use in lithium-ion battery cathodes were prepared from a single transition metal precursor containing 8% cobalt and 92% nickel, based on the total metal content. One sample served as a control, while the other was mixed with 0.25 wt. % finely divided boron oxide. Both samples were calcined at 500°C for 5 hours. After calcination, each sample was converted to a cathode material by first blending it in stoichiometric amounts with finely divided lithium hydroxide to produce a lithium transition metal oxide, or Li3BO3 for the boron-containing sample. Both mixtures were then calcined at 700°C for 6 hours in CO2-free air. The electrochemically active cathode materials were then crushed and sieved through a 325-mesh sieve.

[0061] The cathode product was enriched with Co and Al at the grain boundaries. Therefore, the powder was blended with an equal mass of water containing cobalt nitrate such that the cobalt was 4 at% of the total metals in the cathode material, the final lithium-to-transition ratio was 1.01, and the final Al content was 0.064% of the final transition metal content of the cathode material. The slurry was spray dried and heat-treated at 700 °C for 2 hours to form the final cathode material.

[0062] The cathode powder was blended with NMP, conductive carbon, and a PVDF binder and coated onto aluminum foil. Coin cells were assembled with MCMB anodes and cycled at 45°C for 200 cycles. The results are shown in Figures 2 and 3.

[0063] Example 4: Extraction of boron from formed precursor particles Using the process described in Example 1, two nickel oxide materials were formed using a 100% nickel hydroxide material. One contained 0.25 wt. % BO in the initial hydroxide formulation, and the other contained no BO. One gram of each was then added to 10 milliliters (mL) of nitric acid containing 10 millimolar (mM) sodium dodecyl sulfate (SDS), stirred for 5 hours, and then allowed to sit overnight. The supernatant was then removed, filtered through a 0.45 μm syringe filter, and tested for nickel and boron using ICP-OES. The results are shown in Table 4.

[0064] [Table 4]

[0065] The amount of boron incorporated into the oxide was 1.2 mg per gram of NiO. This process extracted approximately 50% of the boron while removing only 0.05% of the nickel. This supports the conclusion that the boron resides outside the nickel crystallites and does not dope them. Not all of the boron was extracted because the porous nickel oxide particles have very small pores that are inaccessible to the aqueous extractant.

[0066] Previous results from the same experiment for boron extraction, but with only a 20-minute exposure, have shown that access to all porous oxide particles is a critical point. In this case, one sample was formulated as above with 10 mM SDS added, and the other without. The SDS sample extracted 0.3 mg of boron, while the sample without surfactant extracted only 0.2 mg. Therefore, limited access of the nitric acid extractant to the entire porous matrix is ​​expected to be an issue, and this can be mitigated to some extent by the use of a surface tension-reducing agent such as SDS.

[0067] Comparative Example 1: Boron oxide as a cathode additive The transition metal hydroxide powder was blended with sufficient lithium hydroxide to effect the synthesis of a lithium transition metal oxide cathode material and calcined at 700 °C for 6 hours in CO2-free air. After heat treatment, the product was crushed and sieved through a 325 mesh sieve.

[0068] The product was then divided into three portions, and cobalt was enriched at the grain boundaries of each (as described in U.S. Patent No. 9,391,317). To this end, the cathode material was suspended in equal masses of water containing cobalt and lithium nitrates. Cobalt was 4 at% of the material, resulting in a final lithium to transition metal ratio of 1.01. Boron oxide was added to two slurries to mimic the boron oxide formulations blended as in Example 2, at either 0.1 wt. % or 0.25 wt. %. Additional lithium was added to these solutions to form Li3BO3. Each slurry was spray-dried and then heat-treated at 700°C for 2 hours in CO2-free air.

[0069] The final product was then made into an electrode by slurrying it with NMP, conductive carbon, and a PVDF binder and coating it on aluminum foil. The final electrode was 94% active, with the remainder split evenly between the binder and conductive additive. Coin cells were then assembled with an MCMB anode and cycled at 45°C.

[0070] The capacity fade of the above materials is shown in Figure 4. The fade for all materials is similar, although the boron-containing material is slightly worse than the control. The impedance increase as a function of time at constant voltage during charging is shown in Figure 5. Here, more differences can be seen between the materials. A larger impedance increase is observed for the comparative material made with boron additive, with more boron showing a larger rate of impedance increase.

[0071] These results demonstrate that simply adding boron oxide to the cathode material at the cobalt coating stage results in poorer electrochemical performance. Because the oxide treatment process releases all of the boron initially incorporated as lithiated oxide during cathode synthesis, the boron oxide added at the time of cobalt coating must be chemically equivalent. Nevertheless, poorer, less desirable electrochemical performance is observed. This indicates that the modified boron oxide is actually present during the initial heat treatment and subsequent synthesis, and is not merely present as a cathode surface additive in the final product. Indeed, the benefits of the modified boron process are observed despite the negative impact of the lithiated borate by-product remaining in the final product.

[0072] The foregoing description of specific embodiments is merely exemplary in nature and is in no way intended to limit the scope of the disclosure or its application or uses, which may, of course, vary. Materials and processes are described in conjunction with non-limiting definitions and terms contained herein. These definitions and terms are not intended to serve as limitations on the scope or practice of the disclosure, but are presented for illustrative and descriptive purposes only. While a process or composition is described as a sequence of individual steps or using specific materials, it is understood that the steps or materials may be interchangeable such that the description of the present invention may include multiple parts or steps arranged in numerous ways so that it can be readily understood by one of ordinary skill in the art.

[0073] Terms such as "first," "second," and "third" may be used herein to describe various elements, components, regions, layers, and / or sections, but it will be understood that these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms are used only to distinguish one element, component, region, layer, or section from another element, component, region, layer, or section. Thus, unless otherwise specified, a "first element," "component," "region," "layer," or "section" described below could be referred to as a second (or another) element, component, region, layer, or section without departing from the teachings herein.

[0074] The terms used herein are for the purpose of describing particular aspects only and are not intended to be limiting. As used herein, the singular forms "a," "an," and "the" are intended to include the plural, including "at least one," unless the context clearly dictates otherwise. "Or" means "and / or." As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. As used herein, the terms "comprises" and / or "comprising," or "includes" and / or "including" specify the presence of stated features, regions, integers, steps, operations, elements, and / or components, but it will be further understood that they do not exclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and / or groups thereof. The term "or combinations thereof" means combinations including at least one of the aforementioned elements.

[0075] Unless otherwise specified, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. Furthermore, terms defined in commonly used dictionaries should be interpreted to have a meaning consistent with their meaning in the context of the relevant art and this disclosure, and should not be interpreted in an idealized or overly formal sense unless explicitly defined in this specification.

[0076] Various modifications will be apparent to those skilled in the art from the foregoing description, in addition to those shown and described herein, and such modifications are intended to be included within the scope of the present disclosure.

[0077] Unless otherwise specified, it is understood that all reagents are available from suppliers known in the art.

[0078] The patents, publications, and applications mentioned in this specification are indicative of the level of skill of those skilled in the art to which the disclosure pertains, and are herein incorporated by reference to the same extent as if each individual patent, publication, or application was specifically and individually indicated to be incorporated by reference.

[0079] The foregoing description illustrates certain embodiments of the present invention but is not intended to limit its practice.

Claims

1. 1. Particles for use as precursor materials for synthesizing a Li-ion cathode active material in a lithium-ion cell, comprising: Non-lithiated nickel oxide particles of the formula MOx, where M comprises 80 at% or more of Ni and x is 0.7 to 1.2; and boron oxide mixed with, coated on, or present within non-lithiated nickel oxide particles, or a combination thereof, wherein the boron oxide is associated with the non-lithiated nickel oxide such that the crystallite growth of the non-lithiated nickel oxide particles is 2 nanometers or less upon calcination at 500° C. for 2 hours, as measured by XRD; Particles containing

2. 2. The particle of claim 1, wherein said nickel is present at 92 atomic percent or greater of the total M.

3. 2. The particle of claim 1, wherein said nickel is present at 99 atomic percent or greater of the total M.

4. 10. The particles of claim 1, wherein the boron oxide is present at less than 1% by weight relative to the non-lithiated nickel oxide particles.

5. 5. The particle of claim 4, wherein the boron oxide is present at 0.25% by weight or less.

6. 2. The particle of claim 1, wherein M comprises Ni and one or more elements selected from the group consisting of Mg, Sr, Co, Al, Ca, Cu, Zn, Mn, V, Ba, Zr, Ti, Nb, Ta, Cr, Fe, Mo, W, Hf, and B.

7. 10. The particle of claim 1, wherein M excludes boron in the MOx crystal structure.

8. The particle of claim 1 , wherein M comprises Ni and Co.

9. 10. The particles of claim 1, wherein the non-lithiated nickel oxide particles have an average crystallite size as measured by X-ray diffraction of less than 30 nm.

10. 10. The particle of claim 9, wherein Ni is present at 92 atomic percent or greater.

11. 11. The particle of claim 10, wherein M comprises Ni and one or more elements selected from the group consisting of Mg, Sr, Co, Al, Ca, Cu, Zn, Mn, V, Ba, Zr, Ti, Nb, Ta, Cr, Fe, Mo, W, Hf, and B.

12. 12. The particles of claim 11, wherein the boron oxide is present at less than 1% by weight relative to the non-lithiated nickel oxide particles.

13. 2. The particles of claim 1, which are free of any component that is water-soluble at 1 atmosphere and 25°C.

14. 1. A method of forming electrochemically active particles suitable for use in a cathode of a secondary battery, comprising: mixing boron oxide with particles of non-lithiated nickel hydroxide of formula M(OH)x, where M comprises 80 at% or more of Ni and x is between 1.7 and 2.3, to form a precursor mixture; calcining the precursor mixture at a calcination temperature of 600°C or less for a calcination time of 6 hours or less to form a first calcined product; combining the first calcined product with a lithium source and calcining the first calcined product and the lithium source to form electrochemically active particles; A method comprising:

15. immersing the electrochemically active particles in a treatment solution containing Co alone or Co and Al; drying the electrochemically active particles after said immersion; heat treating the electrochemically active particles after said drying to form particles having a higher concentration of Co, Al, or both in the grain boundaries than the concentration of Al, Co, or both in the crystallites; 15. The method of claim 14, further comprising:

16. 16. The method of claim 14 or 15, wherein the nickel is present in greater than or equal to 92 atomic percent of the total of M.

17. The method of claim 16 , wherein the nickel is present in greater than or equal to 99 atomic percent of the total of M.

18. 16. The method of claim 14 or 15, wherein the boron oxide is present at less than 1% by weight relative to the particles of the non-lithiated nickel hydroxide.

19. 16. The method of claim 14 or 15, wherein M comprises Ni and one or more elements selected from the group consisting of Mg, Sr, Co, Al, Ca, Cu, Zn, Mn, V, Ba, Zr, Ti, Nb, Ta, Cr, Fe, Mo, W, Hf, and B.

20. 16. The method of claim 14 or 15, wherein M comprises Ni and Co.

21. 16. The method of claim 14 or 15, wherein the first calcined product has an average crystallite size as measured by X-ray diffraction of less than 30 nm.

22. 22. The method of claim 21, wherein Ni is present at 92 atomic percent or greater.

23. 23. The method of claim 22, wherein M comprises Ni and one or more elements selected from the group consisting of Mg, Sr, Co, Al, Ca, Cu, Zn, Mn, V, Ba, Zr, Ti, Nb, Ta, Cr, Fe, Mo, W, Hf, and B.

24. 24. The method of claim 23, wherein the boron oxide is present at less than 1% by weight relative to the particles of the non-lithiated nickel hydroxide.

25. 15. The method of claim 14, wherein the firing temperature is 500°C or less.

26. 15. The method of claim 14, wherein the baking time is 5 hours or less.

27. 15. The method of claim 14, wherein the boron oxide is present at 0.25 wt% or less.

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