LFMP and NMC cathode active materials mixtures for li-ion secondary batteries and preparation method therefor
A dual-fraction cathode active material composition of LFMP and NMC with specific morphologies addresses the need for improved cycle life and energy density in lithium-ion batteries, enhancing battery performance for electric vehicles.
Patent Information
- Application Number
- PCT/EP2025/072199
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-08-05
- Filing Date
- 2025-08-01
- Publication Date
- 2026-02-12
AI Technical Summary
There is a need to optimize the electrochemical performance of cathode active materials (CAMs) used in lithium-ion secondary batteries, particularly for applications in electric vehicles, by improving cycle life and volumetric energy density.
A cathode active material composition comprising two fractions: a first fraction of olivine-based LiFeMnP (LFMP) and a second fraction of nickel manganese cobalt-based NMC, with specific atomic ratios and morphologies, including semi-monolithic and polycrystalline particles, is developed to enhance battery performance.
The proposed CAM composition achieves improved cycle stability and volumetric energy density, as evidenced by lower QF01C and QF1C values, indicating enhanced battery lifespan and energy storage capabilities.
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Abstract
Description
LFMP and NMC cathode active materials mixtures for Li-ion secondary batteries and preparation method therefor TECHNICAL FIELD
[0001] The present disclosure concerns cathode active materials for rechargeable batteries, and processes for manufacturing therefor. In this disclosure, the term cathode active material (also referred to as positive electrode active material) is referred to as CAM or CAM powder.
[0002] In particular, the present disclosure relates to a cathode active material (hereafter referred to as CAM) powder comprising a CAM fraction lithium (Li), nickel (Ni), manganese (Mn) and cobalt (Co). Such a CAM fraction is also referred hereunder as NMC (NiMnCo) CAM.
[0003] For instance, a NMC CAM comprises a Ni / (Ni+Mn+Co) ratio of at least 0.50 at% / at% (e.g., NMC532), or of at least 0.80 at% / at% (e.g., NMC811), or even of at least 0.90 at% / at% (e.g. NMC90.50.5). In the present disclosure, “at%” or “at.%” signifies atomic percentage. The at% or “atomic percent” of a given element means a percentage of atoms of said element among all atoms in a claimed composition. at% can be measured by inductively coupled plasma - optical emission spectrometry (hereafter referred to as ICP-OES). Equivalently at% can be equal to mol% or mol.%.
[0004] In the present disclosure, the terms “CAM” and “CAM powder” can be used interchangeably.
[0005] The term “comprising”, as used herein and in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It needs to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression “a composition comprising components A and B” should not be limited to compositions consisting only of components A and B. It means that with respect to the present disclosure, the only relevant components of the composition are A and B. Accordingly, the terms “comprising” and “including” encompass the more restrictive terms “consisting essentially of” and “consisting of”.
[0006] The term “a cathode active material” as used herein and claimed is defined as a material which is electrochemically active in a positive electrode or cathode. By active material, it must be understood to be a material capable ofcapturing and releasing Li ions when subjected to a predetermined voltage change over a predetermined period of time. The NMC CAM according to the present disclosure is suitable to be used in Li-ions secondary batteries (hereafter referred to as LIBs). BACKGROUND
[0007] Along with the developments of (hybrid, in particular plug-in hybrid electric vehicles) electric vehicles (hereafter referred to as (H)EVs or PHEVs), it comes a demand for LIBs eligible for such applications and NMC CAMs are expected to be widely used materials as a component of CAM powder compositions, because of their high mass or volumetric energy density, and their higher (discharge) capacities at higher operating voltages when used in a battery.
[0008] In the framework of the disclosure, an electric vehicle may include any vehicle suitable for marine, air, aerospace and ground transportation.
[0009] Still, there is a need to further optimize electrochemical (hereafter referred to as EC) performances of CAMs.
[0010] Therefore, it is a first object of the present disclosure to provide a CAM powder composition including a NMC CAM and having improved cycle life as well as at least optimized or at best improved volumetric energy density (hereafter referred to as VED). SUMMARY OF THE DISCLOSURE CAM powders
[0011] The first object of the disclosure is achieved by providing a first cathode active material powder according to claim 1. FIRST ACTIVE MATERIAL
[0012] The first CAM of the disclosure comprises two fractions of CAM: - a first fraction of an olivine CAM that includes lithium (Li), iron (Fe), manganese (Mn), and phosphor (P). Such a CAM powder is also referred to as LFMP (LiFeMnP) CAM powder; and - a second fraction of NMC CAM that includes Li, Ni, Mn and cobalt (Co). The cobalt nickel manganese containing cathode active material of the 2ndfraction is a powder comprising particles that are standalone particles including at least one and at most twenty primary particles. This CAM powder is referred to as a semi monolithic powder or a powder having a semi monolithic morphology.
[0013] The term semi monolithic powder refer to a powder including single or secondary particles, each of the secondary particles consisting of no more than twenty primary particles. The number of primary particles constituting the secondary particles is determined based upon a scanning electron microscopy (hereafter referred to as SEM) image, for instance, in a field of view of at least 45 μm x at least 60 μm (i.e. of at least 2700 μm²), preferably of at least 30 μm x 100 μm (i.e. of at least 3000 μm²). The secondary particles in the image should be well distributed therefore avoiding overlap between secondary particles. This can be achieved by pouring a small amount of powder sample to the adhesive attached on the SEM sample holder and blowing air to remove the excess powder. In the context of the present invention primary particles are distinguished from each other in a SEM image by observing grain boundaries between the primary particles. A grain boundary is defined as the interface between two primary particles, for instance wherein the atomic planes of the two primary particles are aligned to different orientations and meet as a crystalline discontinuity.
[0014] Single particles are grain free and each of them consists of solely one standalone particle.
[0015] Both first and 2ndfractions are suitable to be used in Li-ions secondary batteries. Hence, the first CAM powder is suitable to be used in Li-ions secondary batteries.
[0016] More specifically, the first CAM of the disclosure has: a. a first fraction F1of a first olivine cathode active material powder comprising Li, M1, D1, and O, wherein M1 includes Fea1Mnx1Pz1, with: - 10.0 ≤ a1 ≤ 25.0, - 25.0 ≤ x1 ≤ 35.0, - 40.0 ≤ z1 ≤ 65.0, and with D1 including at least one element different than Li, P, Fe, Mn, and O, and b. a second fraction F2of a second nickel manganese containing cathode active material comprising Li, M4, D4, and O, wherein M4 has a formula Niy4Mnx4CoZ4, with - 0.50 ≤ x4 ≤ 29.5, - 50.0 ≤ y4 ≤ 95.0, - 4.5 ≤ z4 ≤ 20.5,or with : - 0.50 ≤ x4 ≤ 5.0, - 90.0 ≤ y4 ≤ 95.0, - 4.5 ≤ z4 ≤ 5.0, and with D4 including at least one element different than Li, Ni, Mn, and O, the second fraction having a D50 of at least 1.0 µm and at most 5.0 µm, and comprising standalone particles including at least one and at most twenty primary particles.
[0017] In the first CAM powder, F1and F2are present in the following contents: - 15.045.0 wt.%, and - 55.085.0 wt. %, or wherein : - 15.0 wt.% ≤ F1≤ 40.0 wt.%, and - 60.0 wt.% ≤ F2≤ 85.0 wt. %, - 20.0 wt.% ≤ F1≤ 40.0 wt.%, and - 60.0 wt.% ≤ F2≤ 80.0 wt. %, or: - 20.0 wt.% ≤ F1≤ 25.0 wt.%, and - 75.0 wt.% ≤ F2≤ 80.0 wt. %, or: - 15.0 wt.% ≤ F1≤ 25.0 wt.%, and - 75.0 wt.% ≤ F2≤ 85.0 wt. %, wherein: F1+F2= 100 wt.%, and wherein all of : a1, x1, z1, x4, y4, and z4 are expressed in at%.
[0018] Wt. % expresses a mass (or weight) fraction with a denominator of 100. Wt. % is a percentage by mass (or percentage by weight).
[0019] The first cathode active material may have a porosity of at least 20.0 % and at most 30.0 %, or of at least 25.0 % and at most 30.0 %, or of at least 28.0 % and at most 30.0 %.
[0020] The first cathode active material may have a PD of at least 2.5 or of at least 2.8 g / cm³, and optionally of at most 3.5 g / cm³.
[0021] In the first cathode active material of any of the preceding claims, the first fraction may have a D50 of at least 1.5 µm and at most 3.0 µm, or of at least 2.0 µm and at most 2.5 µm.
[0022] In the first cathode active material, the second fraction may have a D50 of at least 1.5 µm and at most 3.5 µm.
[0023] In the first cathode active material, the first fraction may have a span of at least 8.0 and at most 12.0, or of at least 9.0 and at most 11.0, or of at least 10.0 and at most 11.0.
[0024] In the first cathode active material, the second fraction may have a span of at least 1.00 and at most 1.50.
[0025] In the first cathode active material, the first fraction may have a PD of at least 2.0 g / cm³, and optionally of at most 2.5 g / cm³.
[0026] In the first cathode active material, the second fraction may have a PD of at least 2.0 g / cm³, or of at least 2.5 g / cm³, and optionally of at most 3.5 g / cm³.
[0027] In the first cathode active material, D1 may include at least one of or all of: Co, Al, Ca, Mg, Si, and Ti.
[0028] The first olivine cathode active material of the first cathode active material powder may have a Formula I: Lib1D1y1Fea1Mnx1Pz1O4, wherein : - 10.0 ≤ a1 ≤ 20.0, - 25.0 ≤ x1 ≤ 35.0, - 40.0 ≤ z1 ≤ 65.0, - 0.00 ≤ y1 ≤ 5.0, - 0.45 ≤ b1 ≤ 0.55, and wherein all of : a1, x1, z1, and y1 are expressed in at% and b1 is expressed in at% / at%, and wherein a1 + x1 + z1 + y1 = 100.0 at%.
[0029] D1 may include at least one or all of : Co, Al, Ca, Mg, Si, and Ti.
[0030] D4 of the first cathode active material may include at least one of or all of : Nb, B, Zr, Y, Al, Ca, Mg, Si, and Ti, optionally least one of or all of : Nb, B, Zr, and Y.
[0031] The second nickel manganese containing cathode active material of the 1stcathode active material may have a Formula II: Lib4Niy4Mnx4CoZ4D4a4O2, wherein all of : a1, x1, z1, and y1 are expressed in at% and b1 is expressed in at% / at%, with: - 0.50 ≤ x4 ≤ 25.5, - 50.0 ≤ y4 ≤ 95.0, - 4.5 ≤ z4 ≤ 19.5, - 0.00 ≤ a4 ≤ 5.00, and - 0.95 ≤ b4 ≤ 1.05, wherein all of : a4, x4, z4, and y4 are expressed in at% and b4 is expressed in at% / at%, and wherein a4 + x4 + z4 + y4 = 100.0 at%.
[0032] Optionally: - 0.50 ≤ x4 ≤ 2.5, - 90.0 ≤ y4 ≤ 95.0, and - 4.55.0, - 0.00 ≤ a4 ≤ 1.5, and - 0.95 ≤ b4 ≤ 1.05.
[0033] Optionally: - 0.50 ≤ x4 ≤ 1.00, - 92.5 ≤ y4 ≤ 95.0, and - 4.55.0, - 0.00 ≤ a4 ≤ 1.5, and - 0.95 ≤ b4 ≤ 1.05.
[0034] Optionally: - 0.50 ≤ x4 ≤ 1.00, - 92.0 ≤ y4 ≤ 95.0, and- 4.5 5.0, - 0.00 ≤ a4 ≤ 2.0, and 0.95 ≤ b4 ≤ 1.05.
[0035] D4 may include at least one of or all of: Nb, B, Zr, and Y. SECOND ACTIVE MATERIAL
[0036] The first object of the disclosure is also achieved by providing a second cathode active material powder according to claim 16, comprising at least two of following four fractions of CAM powder: - a first LFMP fraction; - a 2ndfraction of NMC having semi monolithic particles; - a 3rdfraction of NMC having secondary particles including a plurality of primary particles. This CAM powder is referred to as polycrystalline particles. A CAM powder having (standalone) particles including more than twenty primary particles can be referred to as a polycrystalline CAM or a CAM having a polycrystalline morphology; and - a 4thfraction of NMC having polycrystalline particles.
[0037] More specifically, the second cathode active material powder comprises at least two fractions of : a. a first fraction F1of a first olivine cathode active material powder comprising Li, M1, D1, and O, wherein M1 includes Fea1Mnx1Pz1, with: - 10.0 ≤ a1 ≤ 25.0, - 25.0 ≤ x1 ≤ 35.0, and - 40.0 ≤ z1 ≤ 65.0, with D1 being at least one element different than Li, P, Fe, Mn, and O, b. a second fraction F2of a first nickel manganese containing cathode active material comprising Li, M4, D4, and O, wherein M4 has a formula Niy4Mnx4CoZ4, with: - 0.50 ≤ x4 ≤ 29.5, - 50.0 ≤ y4 ≤ 95.0, - 4.5 ≤ z4 ≤ 20.5, or with : - 0.50 ≤ x4 ≤ 5.0, - 90.0 ≤ y4 ≤ 95.0, and- 4.5 ≤ z4 ≤ 5.0, and with D4 being at least one element different than Li, Ni, Mn, and O, the second fraction powder having a D50 of at least 1.5 µm and of at most 5.0 µm, and comprising standalone particles including at least one and at most twenty primary particles, c. a third fraction F3of a second nickel manganese containing cathode active material comprising Li, M4’, D4’, and O, wherein M4 has a formula Niy4’Mnx4’CoZ4’, with - 0.50 ≤ x4’ ≤ 29.5, - 50.0 ≤ y4’ ≤ 95.0, - 4.5 ≤ z4’ ≤ 20.5, or with: - 0.50 ≤ x4’ ≤ 7.0, - 85.0 ≤ y4’ ≤ 95.0, - 4.5 ≤ z4’ ≤ 8.0, and with D4’ being at least one element different than Li, Ni, Mn, and O, the third fraction powder having a D50 of at least 8.0 µm and at most 10.0 µm, and a span of at least 0.3 and optionally of at most 0.5, the third fraction powder having polycrystalline particles, and d. a fourth fraction F4of a third nickel manganese containing cathode active material comprising Li, M4”, D4”, and O, wherein M4 has a formula Niy4’’Mnx4’’CoZ4’’, with - 0.50 ≤ x4” ≤ 29.5, - 50.0 ≤ y4” ≤ 95.0, - 4.5 ≤ z4” ≤ 20.5, or with: - 0.50 ≤ x4” ≤ 7.0, - 85.0 ≤ y4” ≤ 95.0, and - 4.5 ≤ z4” ≤ 8.0 and with D4’’ being at least one element different than Li, Ni, Mn, and O, the third fraction powder having a D50 of more than 10.0 µm and at most 15.0 µm, and a span of at least 0.25 and optionally of at most 0.5, the fourth fraction powder having polycrystalline particles, wherein either : - 10.0 wt.% ≤ F1≤ 30.0 wt.%,- 15.0 wt.% ≤ F2≤ 25.0 wt.%, and - 45.0 wt. % ≤ F3 ≤ 75.0 wt. %, or: - 10.0 wt.% ≤ F1≤ 30.0 wt.%, - 15.0 wt.% ≤ F2≤ 25.0 wt.%, and - 45.0 wt.% ≤ F4≤ 75.0 wt.%, or: - 25.0 wt.% ≤ F3≤ 35.0 wt.%, and - 65.0 wt.% ≤ F1≤ 75.0 wt.%, or: - 25.0 wt.% ≤ F4≤ 35.0 wt.%, and - 65.0 wt.% ≤ F1≤ 75.0 wt.%. wherein: F1+F2+F3= 100 wt.%, or F1+F2+F4= 100 wt.%, or F1+F4= 100 wt.%, or F1+F3= 100 wt.% and wherein all of : a1, x1, z1, x4, y4, z4, x4’, y4’, z4’, x4”, y4”, and z4’’ are expressed in at%.
[0038] Subject-matter of claim 16) includes two alternatives wherein: - 1stLFMP-based alternative 25.0 wt.% ≤ F3≤ 35.0 wt.%, and 65.0 wt.% ≤ F1≤ 75.0 wt.%. - 2ndLFMP-based alternative 25.0 wt.% ≤ F4≤ 35.0 wt.%, and 65.0 wt.% ≤ F1≤ 75.0 wt.%.
[0039] These two LFMP-based alternatives correspond to a CAM powder wherein more than 50 wt% of NMC CAM material has been substituted by an olivine fraction.
[0040] The other alternatives in subject-matter of claim 16) are NMC-based alternatives.
[0041] As demonstrated in the Results section of the disclosure, all the above mentioned alternatives (NMC-based and LFMP-based) allows to resolve above- mentioned technical problem. Notably, a battery including the CAM powder of claim16) demonstrates: improved cycling stability (indicated by lowest QF01C and QF1C values) along with sufficiently high VED.
[0042] All of 1st, 2nd, 3rdand 4thfractions are suitable to be used in Li-ions secondary batteries. Hence, the 2ndCAM powder is suitable to be used in Li-ions secondary batteries.
[0043] Optionally, the second cathode active material powder has a porosity of at least 20.0 % and at most 30.0 %, or of at least 22.5 % and at most 28.5 %.
[0044] Optionally, the second cathode active material has a PD of at least 2.5 or of at least 3.0 g / cm³, and optionally of at most 3.5 g / cm³.
[0045] Optionally, the second cathode active material powder has a first fraction that has a D50 of at least 1.5 µm and at most 3.0 µm, or of at least 2.0 µm and at most 2.5 µm.
[0046] Optionally, the second cathode active material powder has a second fraction that has a D50 of at least 1.5 µm and at most 3.5 µm.
[0047] Optionally, the second cathode active material powder has a first fraction that has a span of at least 8.0 and at most 12.0, or of at least 9.0 and at most 11.0, or of at least 10.0 and at most 11.0.
[0048] Optionally, the second cathode active material powder has a second fraction that has a span of at least 1.00 and at most 1.50.
[0049] Optionally, the second cathode active material powder has a first fraction that has a PD of at least 2.0 g / cm³, and optionally of at most 2.5 g / cm³.
[0050] Optionally, the second cathode active material powder has a second fraction that has a PD of at least 2.0 g / cm³, or of at least 2.5 g / cm³, and optionally of at most 3.5 g / cm³.
[0051] In the second cathode active material powder, D1 may include at least one of or all of: Co, Al, Ca, Mg, Si, and Ti.
[0052] In the second cathode active material powder, the first olivine cathode active material powder has a Formula I: Lib1D1y1Fea1Mnx1Pz1O4, wherein : - 10.0 ≤ a1 ≤ 20.0,- 25.0 ≤ x1 ≤ 35.0, - 40.0 ≤ z1 ≤ 65.0, - 0.00 ≤ y1 ≤ 5.0, - 0.45 ≤ b1 ≤ 0.55, wherein all of : a1, x1, z1, and y1 are expressed in at%, and b1 is expressed in at% / at%, and wherein a1 + x1 + z1 + y1 = 100.0 at%.
[0053] In the second cathode active material powder, D1 may include at least one of, or all of: Co, Al, Ca, Mg, Si, and Ti.
[0054] In the second cathode active material powder, D4 may include at least one of or all of : Nb, B, Zr, Y, Al, Ca, Mg, Sr, Si, and Ti, optionally least one of or all of : Sr, Nb, B, Zr, and Y, or D4 may include at least one of, or all of : Al, Sr, Nb, B, Zr, and Y.
[0055] In the second cathode active material powder, D4’ may include at least one of or all of : Nb, B, Zr, Y, Al, Ca, Mg, Sr, Si, and Ti, optionally least one of or all of : Sr, Nb, B, Zr, and Y.
[0056] In the second cathode active material powder, D4” may include at least one of or all of : Nb, B, Zr, Y, Al, Ca, Mg, Sr, Si, and Ti, optionally least one of or all of : Sr, Nb, B, Zr, and Y.
[0057] In the second cathode active material powder, D4’ may include at least one of or all of: Al, Sr, Nb, B, Zr, and Y.
[0058] In the second cathode active material powder, D4” may include at least one of or all of: Al, Sr, Nb, B, Zr, and Y.
[0059] In the second cathode active material powder, the first nickel manganese containing cathode active material has a Formula II: Lib4Niy4Mnx4CoZ4D4a4O2, , with: - 0.50 ≤ x4 ≤ 25.5, - 50.0 ≤ y4 ≤ 95.0, - 4.0 ≤ z4 ≤ 19.5, - 0.50 ≤ a4 ≤ 5.00, and - 0.95 ≤ b4 ≤ 1.05,wherein all of : a4, x4, z4, and y4 are expressed in at%, and b4 is expressed in at% / at%, and wherein a4 + x4 + z4 + y4 = 100.0 at%. D4 may include at least one of or all of: B, Zr, Nb, and Y.
[0060] Optionally: - 0.50 ≤ x4 ≤ 2.5, - 90.0 ≤ y4 ≤ 95.0, and - 4.55.0, - 0.00 ≤ a4 ≤ 1.5, and - 0.95 ≤ b4 ≤ 1.05.
[0061] Optionally: - 0.50 ≤ x4 ≤ 1.00, - 92.5 ≤ y4 ≤ 95.0, and - 4.5 ≤ z4 ≤ 5.0, - 0.00 ≤ a4 ≤ 1.5, and - 0.95 ≤ b4 ≤ 1.05.
[0062] Optionally: - 0.50 ≤ x4 ≤ 1.00, - 92.0 ≤ y4 ≤ 95.0, and - 4.5 ≤ z4 ≤ 5.0, - 0.00 ≤ a4 ≤ 2.0, and 0.95 ≤ b4 ≤ 1.05.
[0063] Optionally: - 0.50 ≤ x4 ≤ 1.00, - 92.5 ≤ y4 ≤ 95.0, and - 4.5 ≤ z4 ≤ 5.0, - 0.00 ≤ a4 ≤ 1.5, and - 0.95 ≤ b4 ≤ 1.05, and D4 may include at least one of or all of: Nb, B, Zr, and Y.
[0064] In the second cathode active material powder, the second nickel manganese containing cathode active material has a Formula III: Lib4’Niy4’Mnx4’CoZ4’D4’a4’O2, with:- 0.50 ≤ x4’ ≤ 25.5, - 50.0 ≤ y4’ ≤ 95.0, - 4.0 ≤ z4’ ≤ 19.5, - 0.50 ≤ a4’ ≤ 5.00, and - 0.95 ≤ b4’ ≤ 1.05, wherein all of : a4’, x4’, z4’, and y4’ are expressed in at%, and b4’ is expressed in at% / at%, and wherein a4’ + x4’ + z4’ + y4’ = 100.0 at%. D4’ may include at least one of, or all of: Nb, B, Zr, and Y.
[0065] Optionally, in the second cathode active material powder : - 0.50 ≤ x4’ ≤ 6.0, - 86.0 ≤ y4’ ≤ 95.0, - 4.5 ≤ z4’ ≤ 8.0
[0066] Optionally, - 0.50 ≤ x4’ ≤ 5.5, - 85.0 ≤ y4’ ≤ 95.0, - 4.5 ≤ z4’ ≤ 8.0 - 0.00 ≤ a4’ ≤ 1.5, and - 0.95 ≤ b4’ ≤ 1.05.
[0067] In the second cathode active material powder, the third nickel manganese containing cathode active material has a Formula III: Lib4”Niy4”Mnx4”CoZ4”D4”a4”O2, with: - 0.50 ≤ x4” ≤ 25.5, - 50.0 ≤ y4” ≤ 95.0, - 4.0 ≤ z4” ≤ 19.5, - 0.50 ≤ a4” ≤ 5.00, and - 0.95 ≤ b4” ≤ 1.05, wherein all of : a4”, x4”, z4”, and y4” are expressed in at%, and b4” is expressed in at% / at%, and wherein a4” + x4” + z4” + y4” = 100.0 at%. D4” may include at least one of, or all of: Nb, B, Zr, Sr, and Y.
[0068] Optionally, in the second cathode active material powder :- 0.50 ≤ x4’’ ≤ 6.0, - 86.0 ≤ y4’’ ≤ 95.0, - 4.5 ≤ z4’’ ≤ 8.0
[0069] Optionally, - 0.50 ≤ x4’’ ≤ 5.5, - 85.0 ≤ y4’’ ≤ 95.0, - 4.5 ≤ z4’’ ≤ 8.0, - 0.00 ≤ a4” ≤ 1.5, and - 0.95 ≤ b4” ≤ 1.05.
[0070] Optionally, - 2.5 ≤ x4’’ ≤ 3.0, - 85.0 ≤ y4’’ ≤ 93.0, - 4.5 ≤ z4’’ ≤ 7.0, - 0.00 ≤ a4” ≤ 5.00, and - 0.95 ≤ b4” ≤ 1.05.
[0071] In the second cathode active material of the disclosure, the third fraction may have a PD of at least 2.0 g / cm³, or of at least 2.5 g / cm³, and optionally of at most 3.5 g / cm³.
[0072] In the second cathode active material powder, the fourth fraction may have a PD of at least 2.0 g / cm³, or of at least 2.5 g / cm³, and optionally of at most 3.5 g / cm³.
[0073] In the second cathode active material powder, the span of the third fraction can be inferior to the span of the second fraction.
[0074] The span of the fourth fraction can be inferior to the span of the second fraction.
[0075] The span of the fourth fraction can be inferior or equal to the span of the third fraction.
[0076] The fourth fraction may have a PD of at least 2.00 g / cm³ and of at most 4.0 g / cm³, or of at most 3.5 g / cm³, or of at most 3.0 g / cm³.
[0077] Considering that the olivine (LFMP) cathode active material fraction is present in each of the first positive electrode active material and the second positiveelectrode active material in a content F1of at least 10 wt%, this compound is not considered as an additive. Indeed, olivine is not present in aforementioned CAMs in a small quantity, i.e. in a quantity much inferior to 10 wt%. Generally speaking, an additive is present in a composition in a relative content of no more than 1.0 wt%.
[0078] In the framework of the present invention, it is indeed observed that a CAM powder according to claim 1 or 16 allows to improve cycle stability and therefore lifespan of a Li-ion secondary battery using aforementioned CAM powder, as indicated by relatively lower QF01C and QF1C values compared to a LiB which electrode includes a CAM powder consisting of a single NMC compound.
[0079] The present disclosure also includes a process for manufacturing each of the above-mentioned CAM powder fractions. In particular, the present disclosure includes a process for manufacturing each of the semi monolithic CAM powder and a polycrystalline NMC CAM powder from a precursor of the CAM (hereafter referred to as pCAM). The term “precursor (of a CAM) or (CAM) precursor” as used herein and claimed is defined as a material suitable for manufacturing of a cathode material. By precursor, it must be understood a material that requires to be reacted with a Li ions source to make the cathode active material.
[0080] Furthermore, the present disclosure relates to a battery comprising the first and / or the second cathode active material powder(s) according to the disclosure; and to (H)EVs or PHEVs including the battery, and including therefore the use of the lithium ion battery including the CAM of the disclosure in an electric vehicle ((H)EV or PHEV).
[0081] Eventually, the present disclosure relates to an electrode (of the battery, for instance, of a coin cell type of battery) including the first or the second CAM powder of the disclosure.
[0082] Alternatively, the present disclosure may concern the use of a battery according to the present disclosure in a portable electronic device, such as portable computer, tablet, or mobile phone, in a power tool, in an energy storage system. CAM fractions
[0083] The disclosure includes several different CAM fractions : LFMP fraction
[0084] A first olivine cathode active material comprising Li, M1, D1, and O, wherein M1 includes Fea1Mnx1Pz1, with :- 10.0 ≤ a1 ≤ 25.0, - 25.0 ≤ x1 ≤ 35.0, and - 40.0 ≤ z1 ≤ 65.0, wherein all of : a1, x1, z1 are measured by ICP-OES and expressed in at% with regard to (wrt) the total content of M1 and D1, with D1 being at least one element different than Li, P, Fe, Mn, and O. This first olivine cathode active material is referred to as OLIV.
[0085] This first olivine cathode active material is a powder and the first fraction is a powder.
[0086] Alternatively : - 15.0 ≤ a1 ≤ 22.0, - 25.0 ≤ x1 ≤ 30.0, and - 48.0 ≤ z1 ≤ 60.0. NMC fractions
[0087] A nickel manganese containing cathode active material comprising Li, Mi, D4, or D4’, or D4”, and O, wherein Mihas a formula NiyMnxCoZ, with - 0.50 ≤ x ≤ 29.5, - 50.0 ≤ y ≤ 95.0, - 4.5 ≤ z ≤ 20.5, with D4, or D4’, or D4” being at least one element different than Li, Ni, Mn, and O, with i being labelled as 2, or as 3, or as 4, wherein x, y, and z are measured by ICP-OES and expressed in at% wrt the total content of Mi and of D4, or D4’, or D4”. Optionally : - 0.50 ≤ x ≤ 5.0, - 85.0 ≤ y ≤ 100.0, - 4.5 ≤ z ≤ 5.0. Optionally : - 0.50 ≤ x ≤ 7.0, - 85.0 ≤ y ≤ 95.0, - 4.5 ≤ z ≤ 8.0 In particular, x can be equal to x4, or to x4’ or to x4”.In particular, x can be equal to y4, or to y4’ or to y4”. In particular, x can be equal to z4, or to z4’ or to z4”. This nickel manganese containing cathode active material is referred to as NMC CAM. The nickel manganese containing cathode active material is a powder comprising particles. The particles are either: i) polycrystalline particles, or ii) as semi monolithic particles. Each of the polycrystalline (standalone) particles has more than twenty primary particles. Process for manufacturing the LFMP CAM fraction
[0088] The disclosure also includes a first process PROC1 for manufacturing LFMP CAM, also referred to as OLIV.
[0089] The first process comprises the steps of: a) Blending of Li, Fe, P, Mn precursors and optionally C, and D1 precursors, for example using a ball mill process. The precursors are put in a vial with zirconia balls and acetone. For instance, lithium carbonate, iron oxalate dihydrate, manganese oxalate, and ammonium phosphate are used as the lithium, iron, manganese, and phosphate precursor. D1 (with D1 = at least one of Ca, Mg, Si, and Ti) hydroxide can be used as at least one precursor. Polyethylene-block-polyethylene glycol may be used as a carbon precursor for improving electric conductivity of the LFMP. The precursors are milled and blended in the vial by a ball mill process. The wet-type blend is dried at 120 °C in an oven to remove acetone. Finally, the dried blend is milled by a grinding machine. b) Sintering in a reducing atmosphere. The LFMP material is synthesized by using the blend from step a) in a tube furnace in a reducing atmosphere. The sintering temperature can be 650 °C and the dwell time can be 2 hours. A mixture of nitrogen (N2, 99%) and hydrogen (H2, 1%) gas may be used as a reducing gas. c) Milling. After sintering, finally, the sample is milled by a grinding machine.Process for manufacturing the semi monolithic NMC CAM fraction
[0090] The disclosure also includes a second process PROC2 for manufacturing the semi monolithic NMC CAM having standalone particles including at least one and at most twenty primary particles.
[0091] The 2ndprocess comprises the steps of: a) First mixing: a precursor of the CAM having a formula : NiaMnbCoc(OH)(2-z), with 0 ≤ a ≤ 1.0, 0.0 ≤ b < 1.0, 0.0 ≤ c < 1.0, -0.5 ≤ z ≤ 0.5, wherein a, c, and b are at% / at% or mol% / mol% and are measured by ICP-OES, wherein z is a partial oxidation degree, a first source of Li, and optionally: at least one 1stsource of at least one element of D4, or D4’, or D4”, were mixed to prepare a first mixture including a Li over (Ni+Mn+Co) atomic ratio of at least 0.90 and at most 1.10; b) First heating: the first mixture was heated at a temperature of at least 750 °C and at most 850 °C for a duration of at least 15hours (or 15h) and at most 35 hours under oxygen atmosphere, followed by jaw crushing and milling (see next step); c) Milling: the heated material from step b) was air classified milled and sieved. The crushed material was bead milled with a water-based solution followed by filtering and drying. The sieving was followed by 200 mesh and drying at a temperature of at least 100 °C for a duration of at least 10 hours, or of at least 15 hours under inert (for instance : nitrogen) atmosphere to obtain a dried material; d) Second mixing: the dried material was mixed with a second source of Li and, optionally, with at least one 1stsource of at least one element of D’, thereby obtaining a 2ndmixture; and of: e) Second heating: the second mixture from step d) was heated at a temperature of at least 700 °C and at most 800 °C for a duration of at least 15 hours and at most 30 hours under an oxidizing (e.g., O2) atmosphere followed by grinding and sieving, thereby obtaining a NMC positive electrode active material having semi monolithic particles (flagged as NMCSM). Process for manufacturing the NMC CAM fractions
[0092] The disclosure also includes a third process PROC3 for manufacturing the polycrystalline NMC CAM fraction having polycrystalline particles.
[0093] The 3rdprocess comprises the steps of: a) First mixing: a precursor of the CAM having a formula : NiaMnbCoc(OH)(2-z), with 0.0 ≤ a ≤ 1.0, 0.0 ≤ b < 1.0, 0.0 ≤ c < 1.0, -0.5 ≤ z ≤ 0.5, wherein a, c, and b are at. or mole measured by ICP-OES, wherein z is a partial oxidation degree, a first source of Li, and optionally: at least one 1stsource of at least one element of D4, or D4’, or D4”, were mixed to prepare a first mixture including a Li over (Ni+Mn+Co) atomic ratio of at least 0.90 and at most 1.10; and of : b) First heating: the first mixture was heated at a temperature of at least 750 °C and at most 850 °C for a duration of at least 15 hours and at most 35 hours under oxygen atmosphere, thereby obtaining a heated material that is then crushed, thereby obtaining a NMC positive electrode active material having polycrystalline particles (flagged as NMCPOL).
[0094] Compared to PROC2, PROC3 is a milling-free process wherein no milling step is performed. In particular, in PROC3, the heated (intermediate) material is not milled to achieve a final material having polycrystalline (standalone) particles. Electrodes
[0095] The disclosure also includes a first electrode including the first cathode active material powder according to any of the claims 1 to 15.
[0096] The disclosure also includes a second electrode including the first cathode active material powder according to any of the claims 16 to 43.
[0097] Each of the 1stand second electrode includes a binder and a conductor agent. FIRST ELECTRODE
[0098] More specifically, the first electrode comprises the first CAM of the disclosure, the 1stCAM having: a. a first fraction F1of a first olivine cathode active material powder comprising Li, M1, D1, and O, wherein M1 includes Fea1Mnx1Pz1, with: - 10.0 ≤ a1 ≤ 25.0, - 25.0 ≤ x1 ≤ 35.0,- 40.0 ≤ z1 ≤ 65.0, and with D1 including at least one element different than Li, P, Fe, Mn, and O, and b. a second fraction F2of a second nickel manganese containing cathode active material comprising Li, M4, D4, and O, wherein M4 has a formula Niy4Mnx4CoZ4, with - 0.50 ≤ x4 ≤ 29.5, - 50.0 ≤ y4 ≤ 95.0, - 4.5 ≤ z4 ≤ 20.5, or with : - 0.50 ≤ x4 ≤ 5.0, - 90.0 ≤ y4 ≤ 95.0, - 4.5 ≤ z4 ≤ 5.0, and with D4 including at least one element different than Li, Ni, Mn, and O, the second fraction having a D50 of at least 1.0 µm and at most 5.0 µm, and comprising standalone particles including at least one and at most twenty primary particles.
[0099] In the first CAM powder, F1and F2are present in the following contents: - 15.0 wt.% ≤ F1≤ 45.0 wt.%, and - 55.0 wt. % ≤ F2≤ 85.0 wt. %, or with : - 15.0 wt.% ≤ F1≤ 40.0 wt.%, and - 60.0 wt. % ≤ F2≤ 85.0 wt. %, or: - 20.0 wt.% ≤ F1≤ 40.0 wt.%, and - 60.0 wt. % ≤ F2≤ 80.0 wt. %, or: - 20.0 wt.% ≤ F1≤ 25.0 wt.%, and - 75.0 wt. % ≤ F2≤ 80.0 wt. %, or: - 15.0 wt.% ≤ F1≤ 25.0 wt.%, and - 75.0 wt. % ≤ F2≤ 85.0 wt. %,wherein: F1+F2= 100 wt.%, and wherein all of : a1, x1, z1, x4, y4, and z4 are expressed in at%.
[0100] The first cathode active material may have a porosity of at least 20.0 % and at most 30.0 %, or of at least 25.0 % and at most 30.0 %, or of at least 28.0 % and at most 30.0 %.
[0101] The first cathode active material may have a PD of at least 2.5 or of at least 2.8 g / cm³, and optionally of at most 3.5 g / cm³.
[0102] In the first cathode active material of any of the preceding claims, the first fraction may have a D50 of at least 1.5 µm and at most 3.0 µm, or of at least 2.0 µm and at most 2.5 µm.
[0103] In the first cathode active material, the second fraction may have a D50 of at least 1.5 µm and at most 3.5 µm.
[0104] In the first cathode active material, the first fraction may have a span of at least 8.0 and at most 12.0, or of at least 9.0 and at most 11.0, or of at least 10.0 and at most 11.0.
[0105] In the first cathode active material, the second fraction may have a span of at least 1.00 and at most 1.50.
[0106] In the first cathode active material, the first fraction may have a PD of at least 2.0 g / cm³, and optionally of at most 2.5 g / cm³.
[0107] In the first cathode active material, the second fraction may have a PD of at least 2.0 g / cm³, or of at least 2.5 g / cm³, and optionally of at most 3.5 g / cm³.
[0108] In the first cathode active material, D1 may include at least one of or all of: Co, Al, Ca, Mg, Si, and Ti.
[0109] The first olivine cathode active material of the first cathode active material powder may have a Formula I: Lib1D1y1Fea1Mnx1Pz1O4, wherein : - 10.0 ≤ a1 ≤ 20.0, - 25.0 ≤ x1 ≤ 35.0, - 40.0 ≤ z1 ≤ 65.0, - 0.00 ≤ y1 ≤ 5.0, - 0.45 ≤ b1 ≤ 0.55, andwherein all of : a1, x1, z1, and y1 are expressed in at% and b1 is expressed in at% / at%, and wherein a1 + x1 + z1 + y1 = 100.0 at%.
[0110] D1 may include at least one or all of : Co, Al, Ca, Mg, Si, and Ti.
[0111] D4 of the first cathode active material may include at least one of or all of : Nb, B, Zr, Y, Al, Ca, Mg, Si, and Ti, optionally least one of or all of : Nb, B, Zr, and Y.
[0112] The second nickel manganese containing cathode active material of the 1stcathode active material may have a Formula II: Lib4Niy4Mnx4CoZ4D4a4O2, wherein all of : a1, x1, z1, and y1 are expressed in at% and b1 is expressed in at% / at%, with: - 0.50 ≤ x4 ≤ 25.5, - 50.0 ≤ y4 ≤ 95.0, - 4.5 ≤ z4 ≤ 19.5, - 0.00 ≤ a4 ≤ 5.00, and - 0.95 ≤ b4 ≤ 1.05, wherein all of : a4, x4, z4, and y4 are expressed in at% and b4 is expressed in at% / at%, and wherein a4 + x4 + z4 + y4 = 100.0 at%. Optionally: - 0.50 ≤ x4 ≤ 2.5, - 90.0 ≤ y4 ≤ 95.0, and - 4.55.0, - 0.00 ≤ a4 ≤ 1.5, and - 0.95 ≤ b4 ≤ 1.05. Optionally: - 0.50 ≤ x4 ≤ 1.00, - 92.5 ≤ y4 ≤ 95.0, and - 4.55.0, - 0.00 ≤ a4 ≤ 1.5, and - 0.95 ≤ b4 ≤ 1.05. Optionally: - 0.50 ≤ x4 ≤ 1.00,- 92.0 ≤ y4 ≤ 95.0, and - 4.55.0, - 0.00 ≤ a4 ≤ 2.0, and 0.95 ≤ b4 ≤ 1.05.
[0113] D4 may include at least one of or all of: Nb, B, Zr, and Y. SECOND ELECTRODE
[0114] More specifically, the second electrode comprises the second CAM of the disclosure, the 2ndCAM having at least two fractions of: a. a first fraction F1 of a first olivine cathode active material powder comprising Li, M1, D1, and O, wherein M1 includes Fea1Mnx1Pz1, with: - 10.0 ≤ a1 ≤ 25.0, - 25.0 ≤ x1 ≤ 35.0, and - 40.0 ≤ z1 ≤ 65.0, with D1 being at least one element different than Li, P, Fe, Mn, and O, b. a second fraction F2of a first nickel manganese containing cathode active material comprising Li, M4, D4, and O, wherein M4 has a formula Niy4Mnx4CoZ4, with: - 0.50 ≤ x4 ≤ 29.5, - 50.0 ≤ y4 ≤ 95.0, - 4.0 ≤ z4 ≤ 20.5, or with : - 0.50 ≤ x4 ≤ 5.0, - 90.0 ≤ y4 ≤ 95.0, and - 4.5 ≤ z4 ≤ 5.0, and with D4 being at least one element different than Li, Ni, Mn, and O, the second fraction powder having a D50 of at least 1.5 µm and of at most 5.0 µm, and comprising standalone particles including at least one and at most twenty primary particles, c. a third fraction F3of a second nickel manganese containing cathode active material comprising Li, M4’, D4’, and O, wherein M4 has a formula Niy4’Mnx4’CoZ4’, with - 0.50 ≤ x4’ ≤ 29.5, - 50.0 ≤ y4’ ≤ 95.0, - 4.5 ≤ z4’ ≤ 20.5,or with: - 0.50 ≤ x4’ ≤ 7.0, - 85.0 ≤ y4’ ≤ 95.0, - 4.5 ≤ z4’ ≤ 8.0, and with D4’ being at least one element different than Li, Ni, Mn, and O, the third fraction powder having a D50 of at least 8.0 µm and at most 10.0 µm, and a span of at least 0.3 and optionally of at most 0.5, the third fraction powder having polycrystalline particles, and d. a fourth fraction F4of a third nickel manganese containing cathode active material comprising Li, M4”, D4”, and O, wherein M4 has a formula Niy4’’Mnx4’’CoZ4’’, with - 0.50 ≤ x4” ≤ 29.5, - 50.0 ≤ y4” ≤ 95.0, - 4.5 ≤ z4” ≤ 20.5, or with: - 0.50 ≤ x4” ≤ 7.0, - 85.0 ≤ y4” ≤ 95.0, and - 4.5 ≤ z4” ≤ 8.0 and with D4’’ being at least one element different than Li, Ni, Mn, and O, the third fraction powder having a D50 of more than 10.0 µm and at most 15.0 µm, and a span of at least 0.25 and optionally of at most 0.5, the fourth fraction powder having polycrystalline particles, wherein either : - 10.0 wt.% ≤ F1≤ 30.0 wt.%, - 15.0 wt.% ≤ F2≤ 25.0 wt.%, and - 45.0 wt. % ≤ F3≤ 75.0 wt. %, or: - 10.0 wt.% ≤ F1≤ 30.0 wt.%, - 15.0 wt.% ≤ F2≤ 25.0 wt.%, and - 45.0 wt.% ≤ F4≤ 75.0 wt.%, or: - 25.0 wt.% ≤ F3≤ 35.0 wt.%, and - 65.0 wt.% ≤ F1≤ 75.0 wt.%, or:- 25.0 wt.% ≤ F3≤ 35.0 wt.%, and - 65.0 wt.% ≤ F1≤ 75.0 wt.%. wherein: F1+F2+F3= 100 wt.%, or F1+F2+F4= 100 wt.%, or F1+F4= 100 wt.%, or F1+F3= 100 wt.% and wherein all of : a1, x1, z1, x4, y4, z4, x4’, y4’, z4’, x4”, y4”, and z4’’ are expressed in at%.
[0115] Optionally, the second cathode active material powder has a porosity of at least 20.0 % and at most 30.0 %, or of at least 22.5 % and at most 28.5 %.
[0116] Optionally, the second cathode active material has a PD of at least 2.5 or of at least 3.0 g / cm³, and optionally of at most 3.5 g / cm³.
[0117] Optionally, the second cathode active material powder has a first fraction that has a D50 of at least 1.5 µm and at most 3.0 µm, or of at least 2.0 µm and at most 2.5 µm.
[0118] Optionally, the second cathode active material powder has a second fraction that has a D50 of at least 1.5 µm and at most 3.5 µm.
[0119] Optionally, the second cathode active material powder has a first fraction that has a span of at least 8.0 and at most 12.0, or of at least 9.0 and at most 11.0, or of at least 10.0 and at most 11.0.
[0120] Optionally, the second cathode active material powder has a second fraction that has a span of at least 1.00 and at most 1.50.
[0121] Optionally, the second cathode active material powder has a first fraction that has a PD of at least 2.0 g / cm³, and optionally of at most 2.5 g / cm³.
[0122] Optionally, the second cathode active material powder has a second fraction that has a PD of at least 2.0 g / cm³, or of at least 2.5 g / cm³, and optionally of at most 3.5 g / cm³.
[0123] In the second cathode active material powder, D1 may include at least one of or all of: Co, Al, Ca, Mg, Si, and Ti.
[0124] In the second cathode active material powder, the first olivine cathode active material powder has a Formula I: Lib1D1y1Fea1Mnx1Pz1O4, wherein : - 10.0 ≤ a1 ≤ 20.0, - 25.0 ≤ x1 ≤ 35.0,- 40.0 ≤ z1 ≤ 65.0, - 0.00 ≤ y1 ≤ 5.0, - 0.45 ≤ b1 ≤ 0.55, wherein all of : a1, x1, z1, and y1 are expressed in at%, and b1 is expressed in at% / at%, and wherein a1 + x1 + z1 + y1 = 100.0 at%.
[0125] In the second cathode active material powder, D1 may include at least one of, or all of: Co, Al, Ca, Mg, Si, and Ti.
[0126] In the second cathode active material powder, D4 may include at least one of or all of : Nb, B, Zr, Y, Al, Ca, Mg, Sr, Si, and Ti, optionally least one of or all of : Sr, Nb, B, Zr, and Y, or D4 may include at least one of, or all of : Al, Sr, Nb, B, Zr, and Y.
[0127] In the second cathode active material powder, D4’ may include at least one of or all of : Nb, B, Zr, Y, Al, Ca, Mg, Sr, Si, and Ti, optionally least one of or all of : Sr, Nb, B, Zr, and Y.
[0128] In the second cathode active material powder, D4” may include at least one of or all of : Nb, B, Zr, Y, Al, Ca, Mg, Sr, Si, and Ti, optionally least one of or all of : Sr, Nb, B, Zr, and Y.
[0129] In the second cathode active material powder, D4’ may include at least one of or all of: Al, Sr, Nb, B, Zr, and Y.
[0130] In the second cathode active material powder, D4” may include at least one of or all of: Al, Sr, Nb, B, Zr, and Y.
[0131] In the second cathode active material powder, the first nickel manganese containing cathode active material has a Formula II: Lib4Niy4Mnx4CoZ4D4a4O2, , with: - 0.50 ≤ x4 ≤ 25.5, - 50.0 ≤ y4 ≤ 95.0, - 4.0 ≤ z4 ≤ 19.5, - 0.50 ≤ a4 ≤ 5.00, and - 0.95 ≤ b4 ≤ 1.05,wherein all of : a4, x4, z4, and y4 are expressed in at%, and b4 is expressed in at% / at%, and wherein a4 + x4 + z4 + y4 = 100.0 at%. D4 may include at least one of or all of: B, Zr, Nb, and Y.
[0132] Optionally: - 0.50 ≤ x4 ≤ 2.5, - 90.0 ≤ y4 ≤ 95.0, and - 4.55.0, - 0.00 ≤ a4 ≤ 1.5, and - 0.95 ≤ b4 ≤ 1.05.
[0133] Optionally: - 0.50 ≤ x4 ≤ 1.00, - 92.5 ≤ y4 ≤ 95.0, and - 4.5 ≤ z4 ≤ 5.0, - 0.00 ≤ a4 ≤ 1.5, and - 0.95 ≤ b4 ≤ 1.05.
[0134] Optionally: - 0.50 ≤ x4 ≤ 1.00, - 92.0 ≤ y4 ≤ 95.0, and - 4.5 ≤ z4 ≤ 5.0, - 0.00 ≤ a4 ≤ 2.0, and 0.95 ≤ b4 ≤ 1.05.
[0135] Optionally: - 0.50 ≤ x4 ≤ 1.00, - 92.5 ≤ y4 ≤ 95.0, and - 4.5 ≤ z4 ≤ 5.0, - 0.00 ≤ a4 ≤ 1.5, and - 0.95 ≤ b4 ≤ 1.05, and D4 may include at least one of or all of: Nb, B, Zr, and Y.
[0136] In the second cathode active material powder, the second nickel manganese containing cathode active material has a Formula III: Lib4’Niy4’Mnx4’CoZ4’D4’a4’O2, with: - 0.50 ≤ x4’ ≤ 25.5, - 50.0 ≤ y4’ ≤ 95.0, - 4.0 ≤ z4’ ≤ 19.5, - 0.50 ≤ a4’ ≤ 5.00, and - 0.95 ≤ b4’ ≤ 1.05, wherein all of : a4’, x4’, z4’, and y4’ are expressed in at%, and b4’ is expressed in at% / at%, and wherein a4’ + x4’ + z4’ + y4’ = 100.0 at%. D4’ may include at least one of, or all of: Nb, B, Zr, and Y.
[0137] Optionally, in the second cathode active material powder : - 0.50 ≤ x4’ ≤ 6.0, - 86.0 ≤ y4’ ≤ 95.0, - 4.5 ≤ z4’ ≤ 8.0
[0138] Optionally, - 0.50 ≤ x4’ ≤ 5.5, - 85.0 ≤ y4’ ≤ 95.0, - 4.5 ≤ z4’ ≤ 8.0 - 0.00 ≤ a4’ ≤ 1.5, and - 0.95 ≤ b4’ ≤ 1.05.
[0139] In the second cathode active material powder, the third nickel manganese containing cathode active material has a Formula III: Lib4”Niy4”Mnx4”CoZ4”D4”a4”O2, with: - 0.50 ≤ x4” ≤ 25.5, - 50.0 ≤ y4” ≤ 95.0, - 4.0 ≤ z4” ≤ 19.5, - 0.50 ≤ a4” ≤ 5.00, and - 0.95 ≤ b4” ≤ 1.05, wherein all of : a4”, x4”, z4”, and y4” are expressed in at%, and b4” is expressed in at% / at%, and wherein a4” + x4” + z4” + y4” = 100.0 at%. D4” may include at least one of, or all of: Nb, B, Zr, Sr, and Y.
[0140] Optionally, in the second cathode active material powder : - 0.50 ≤ x4’’ ≤ 6.0, - 86.0 ≤ y4’’ ≤ 95.0, - 4.5 ≤ z4’’ ≤ 8.0
[0141] Optionally, - 0.50 ≤ x4’’ ≤ 5.5, - 85.0 ≤ y4’’ ≤ 95.0, - 4.5 ≤ z4’’ ≤ 8.0, - 0.00 ≤ a4” ≤ 1.5, and - 0.95 ≤ b4” ≤ 1.05.
[0142] Optionally, - 2.5 ≤ x4’’ ≤ 3.0, - 85.0 ≤ y4’’ ≤ 93.0, - 4.5 ≤ z4’’ ≤ 7.0, - 0.00 ≤ a4” ≤ 5.00, and - 0.95 ≤ b4” ≤ 1.05.
[0143] In the second cathode active material of the disclosure, the third fraction may have a PD of at least 2.0 g / cm³, or of at least 2.5 g / cm³, and optionally of at most 3.5 g / cm³.
[0144] In the second cathode active material powder, the fourth fraction may have a PD of at least 2.0 g / cm³, or of at least 2.5 g / cm³, and optionally of at most 3.5 g / cm³.
[0145] In the second cathode active material powder, the span of the third fraction can be inferior to the span of the second fraction.
[0146] The span of the fourth fraction can be inferior to the span of the second fraction.
[0147] The span of the fourth fraction can be inferior or equal to the span of the third fraction.
[0148] The fourth fraction may have a PD of at least 2.00 g / cm³ and of at most 4.0 g / cm³, or of at most 3.5 g / cm³, or of at most 3.0 g / cm³.
[0149] Optionally, the first electrode or second electrode includes:- the first or second cathode active material powder according to the disclosure, - a conductor, and - a binder.
[0150] Optionally, the binder is a polyvinylidene fluoride or PVDF (like KUREHA KF Polymer).
[0151] Optionally, the conductor is a carbon black powder, like Super P.
[0152] For each of the 1stand 2ndcathode active material powder of the disclosure, and the 1stand 2ndelectrode including the 1stand 2ndCAM, respectively, all of the following contents: a1, x1, y1, z1, a4, x4, y4, z4, a4’, x4’, y4’, z4’, and a4”, x4”, y4”, z4” (are expressed in at% and) are measured by ICP-OES. b1, b4”, b4’, and b4 are expressed in at% / at% and are measured by ICP-OES.
[0153] In each of the 1stand 2ndcathode active material powder of the disclosure, and the 1stand 2ndelectrode including the 1stand 2ndCAM, respectively, D1 may include at least one of, or all of: Ni, Co, Al, B, W, Zr, Y, Nb, Sr, Ca, Mg, Si, Ti.
[0154] In each of the 1stand 2ndcathode active material powder of the disclosure, and the 1stand 2ndelectrode including the 1stand 2ndCAM, respectively, D4 may include at least one of, or all of: Co, Al, B, W, Zr, Y, Nb, Sr, Ca, Mg, Si, Ti.
[0155] In each of the 1stand 2ndcathode active material powder of the disclosure, and the 1stand 2ndelectrode including the 1stand 2ndCAM, respectively, D4’ may include at least one of, or all of: Co, Al, B, W, Zr, Y, Nb, Sr, Ca, Mg, Si, Ti.
[0156] In each of the 1stand 2ndcathode active material powder of the disclosure, and the 1stand 2ndelectrode including the 1stand 2ndCAM, respectively, D4” may include at least one of, or all of: Co, Al, B, W, Zr, Y, Nb, Sr, Ca, Mg, Si, Ti.
[0157] For the 1stcathode active material powder of the disclosure, and the 1stand electrode including the 1stCAM: - D1 may include at least one of, or all of: Ni, Co, Al, B, W, Zr, Y, Nb, Sr, Ca, Mg, Si, Ti, and - D4 may include at least one of, or all of: Co, Al, B, W, Zr, Y, Nb, Sr, Ca, Mg, Si, Ti, and- D4’ may include at least one of, or all of: Co, Al, B, W, Zr, Y, Nb, Sr, Ca, Mg, Si, Ti, and - D4” may include at least one of, or all of: Co, Al, B, W, Zr, Y, Nb, Sr, Ca, Mg, Si, Ti. DETAILED DESCRIPTION OF THE DISCLOSURE EXPERIMENTAL ANALYSIS USED IN THE EXAMPLES
[0158] The following analysis methods are used in the Examples: A) Inductively Coupled Plasma Optical Emission Spectrometry (ICP- OES) measurements
[0159] The amount of Li, Ni, Co, Mn, Fe, P, D1, D4, D4’, and D4”, or for instance of: Li, Ni, Co, Mn, Al, Zr, B, Fe, P, Y, Nb, Sr, Ca, Mg, Si, and Ti in the positive electrode active material powder is measured with the ICP-OES method by using an Agilent ICP 720-ES (Agilent Technologies).
[0160] For the ICP analysis of bimodal and trimodal mixtures comprising CAM F1, CAM F2, CAM F3, and CAM F4, 0.5 grams of powder sample is dissolved in a mixture of 15 mL of high purity ammonium hydroxide solution (NH4OH ; at least 20 wt.% of NH4OH with respect to the total weight of solution) + 15 mL of high purity hydrochloric acid solution (at least 35 wt.% of HCl with respect to the total weight of solution) in an Erlenmeyer flask.
[0161] For the ICP analysis of CAM A (CAM F1, CAM F2, CAM F3, and CAM F4as well as CEX1.3, CEX1.4, CEX2.1, CEX2.2, CEX2.3 and CEX2.4), 2 grams of powder sample is dissolved into 10 mL of high purity hydrochloric acid solution (at least 35 wt.% of HCl with respect to the total weight of solution) in an Erlenmeyer flask.
[0162] The flask is covered by a glass and heated on a hot plate at 380 °C until complete dissolution of the precursor. After being cooled to room temperature, the solution of the Erlenmeyer flask is poured into a 250 mL volumetric flask. Optionally, the solution is filtered to remove residues and afterwards, the volumetric flask is filled with deionized water up to the 250 mL mark, followed by complete homogenization.
[0163] ICP-OES provides wt.% (or % w / w, or even wt%) of each element included in a material whose composition is determined by this technique.
[0164] Conversion from wt.% to at% or mol% is as follows: at% of a first element E1(Eat1) in a material can be converted from a given wt.% of said first element E1(Ewt1) in said material by applying the following formula,wherein Eaw1is a standard atomic weight (or molecular weight) of the first element E1, Ewtiis wt% of an ithelement Ei, Eawiis a standard atomic weight (molecular weight) of said ithelement Ei, and n is an integer which represents the number of types of all elements included in the material. B) Particle Size Distribution (PSD)
[0165] The particle size distribution (PSD) of a powder is measured by laser diffraction particle size analysis using a Malvern Mastersizer 3000 with a Hydro SV (for CAM F1as well as CEX1.3 and CEX2.1) or MV (for the other CAMs or mixtures) wet dispersion accessory after having dispersed each of the powder samples in a solvent. In order to improve the dispersion of the powder, sufficient ultrasonic irradiation and stirring is applied (unless explicitly indicated otherwise), and a surfactant is introduced. The sodium hexametaphosphate (10 %, 3 ml) solution was used as the surfactant. The solvent used to disperse each powder sample are: - isopropyl alcohol (99.5 % purity) for CAM F1(as well as CEX1.3 and CEX2.1) without ultrasonic irradiation; - deionized water for CAMs F2, F3, and F4(CEX2.1, 2.2, 2.3, 2.4) with ultrasonic irradiation; and - deionized water for EX1.1, 1.2, and 1.3, as well as EX2.1, 2.2, 2.3, 2.4, and 2.5, with ultrasonic irradiation and without using the surfactant.
[0166] D50 is defined as the particle size at 50 % of the cumulative volume% distributions, and a span (or SPAN) may be represented by D99 / D50 or span=(D90- D10) / D50, where D10, D50, D90 and D99 are defined as the particle size at 10 %, 50 %, 90 % and 99 % of the cumulative volume% distributions, respectively, obtained from the Malvern Mastersizer 3000 with Hydro SV or MV measurements. C) Pellet Density (PD)
[0167] The pressed density is measured as follows: 1.0~3.0 grams of powder is filled into a pellet die having an inner diameter "d" of 1.30 cm. A uniaxial load pressure of 207 MPa is applied to the powder in pellet die during 3 minutes and 30 seconds. After relaxing the load, the thickness "t (cm)" of the pressed powder is measured.
[0168] The pellet density (PD expressed in g / cm³) is then calculated as follows:D) Porosity
[0169] The porosity of a mixture of three CAMs, A, B, and C, are calculated by using the below equation: 100
[0170] The porosity is calculated with the above equation and by following the below steps: 1. A 1ststep of defining Ad(g / cc), Bd(g / cc), and Cd(g / cc), each representing a theoretical density of CAM A, B, and C, respectively, where each of the CAMs may be one of CAMs F1to F4. The theoretical densities were obtained from Published Crystal Structure Data (ICSD), for example, the theoretical density of CAM F1is 3.47 g / cc and of CAM F2, F3, and F4is 4.67 g / cc. 2. A 2ndstep of defining Aw(wt%) , Bw(wt%), and Cw(wt%), each representing a mass or weight fraction of each of CAM A, B, and C, respectively relative to the total amount of mixture. 3. In a 3rdstep, a specific volume of each CAM (in cc / g) is calculated by using the below equation:^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^ ^^^^^^^^^^^^ ^^^^ =^^^^^^^^(^^^^^^^^%) ^^^^^^^^ (^^^^⁄ ^^^^^^^^ )4. In a 4st step, by summing these specific volumes, a total specific volume (cc / g) of the mixture is obtained. The reciprocal of the total specific volume (cc / g) gives the theoretical density (g / cc) of the CAM mixture. 5. In a 5thstep, the porosity is then calculated by using the below equation: wherein
[0171] The porosity value indicates how densely the CAM is packed. Pellet density measurement are provided in Section C) above.
[0172] For the porosity of a mixture of CAMs A and B, the theoretical density of the mixture is calculated with an equation:
[0173] For the porosity of a (standalone) of CAM A, the theoretical density of the material is calculated with an equation:, wherein, Aw= 100 wt%. E) Coin cell testing E-1) Coin cell preparation
[0174] For the preparation of a positive electrode, a homogeneous slurry that contains a mixture of : i) a positive electrode active material powder, ii) a conductive material such as carbon black (Li-435, Denka), iii) a binder (S5140, Solvay) – with a formulation of 92.7:3.3:4.0 by weight, and iv) with C5H9NO (N-Methyl-2-pyrrolidone) as solvent (NMP, Ashland) is prepared by mixing the above-mentioned i) to iv) components in a high-speed Thinky mixer. An electrode composite is prepared by spreading on one side of an aluminum foil or carbon-coated aluminum foil using a doctor blade coater followed by drying at 120˚C for 1 hour.
[0175] The loading level of the electrode is determined based on the electrode composite. For example, the loading level of the electrode composite comprising CAM A is calculated by using the below equation on a target areal capacity of 3 mAh / cm2:1000WA: weight fraction of CAM A which is 1 X (mAh / g) : 1C based theoretical discharge capacity in 4.3-2.5 V
[0176] For example of bimodal mixture, the loading level of the electrode composite comprising two CAMs, A, and B, is calculated by using the below equation on a target areal capacity of 3 mAh / cm2: 1000WA: weight fraction of CAM A in the total cathode active material in the mixture WB: weight fraction of CAM B in the total cathode active material in the mixture X (mAh / g): 1C based theoretical discharge capacity in 4.3-2.5 V Y (mAh / g): 1C based theoretical discharge capacity in 4.3-2.5 V
[0177] For example of trimodal mixture, the loading level of the electrode composite comprising three CAMs, A, B, and C, is calculated by using the below equation on a target areal capacity of 3 mAh / cm2: 1000WA: weight fraction of CAM A in the total cathode active material in the mixture WB: weight fraction of CAM B in the total cathode active material in the mixture WC: weight fraction of CAM C in the total cathode active material in the mixture X (mAh / g): 1C based theoretical discharge capacity in 4.3-2.5 V Y (mAh / g): 1C based theoretical discharge capacity in 4.3-2.5 V Z (mAh / g): 1C based theoretical discharge capacity in 4.3-2.5 V
[0178] For the theoretical capacity of CAM F1is 148 mAh / g, CAM F2is 220 mAh / g, and CAM F3and F4is 230 mAh / g.
[0179] After the loading level of the electrode is determined, the electrode composite is dried in an oven at 80~90 °C overnight. The dried electrode composite is then pressed using a calendaring tool to obtain a pressed electrode followed by punching using a 14 pi puncher, thereby obtaining a coin cell electrode. Then, the coin cell electrode is dried in a vacuum oven in order to completely remove the remaining solvent present in the positive electrode film.
[0180] A coin cell is assembled in an argon-filled glovebox. A 20 μm tri-layer Microporous Membrane (PP / PE / PP, polypropylene / Polyethylene / polypropylene) with pore size of 0.027 μm, 39 % porosity separator (Celgard 2320) is located between the positive electrode film and a piece of lithium foil used as a negative electrode. A mixture of LiPF6in EC / EMC (ethylene carbonate / ethyl methyl carbonate) 3:7 + 2 % LiBF4+ 5 % FEC (fluoroethylene carbonate) is used as electrolyte and is dropped between the separator and the electrodes. Then, the coin cell is completely sealed to prevent leakage of the electrolyte. Herein, the coin cell electrode is a foil coated with the slurry (i.e. a mixture constituted of the CAM powder, the conductive material, the binder, and the solvent) whereas the coin cell is constituted of the coated foil as positive electrode, the separator, and the lithium foil (anode). E-2) Coin cell testing Method
[0181] The testing method is a conventional “constant cut-off voltage” test. The conventional coin cell test in the present disclosure follows the schedule shown in Table 1. Each cell is cycled at 25 °C using a Toscat-3100 computer-controlled galvanostatic cycling station (from Toyo).
[0182] The prepared coin cell is charged with the current of 0.1C until 100 % of its theoretical capacity to measure the initial capacity. The coin cell is charged with a current of 0.1C up to 4.3 V and CC / CV mode (constant current-constant voltage) until a cut-off current of 0.05C is reached. The coin cell is discharged with a current of 0.1C in CC mode (constant current) down to 2.5 V. This step is done in 25 °C.
[0183] The discharge capacity after the 9th cycle (DQ9), and discharge capacity after the 36th cycle (DQ36) are measured in constant current mode (CC) at C rate of 0.1C in voltage range from 4.3 V to 2.5 V. The schedule uses a 1C current definition of 148 mAh / g in the 4.3 V to 2.5 V vs. Li / Li+ range. The first cycle is evaluated at 0.1C.
[0184] The capacity fading rate (QF01C) is obtained according to the following equation below:^^^^^^^^01^^^^(% / ^^^^^^^^^^^^^^^^^^^^) = 100100 27
[0185] The discharge capacity after the 10th cycle (DQ10), and discharge capacity after the 37th cycle (DQ37) are measured in constant current mode (CC) at C rate of 0.1C in voltage range from 4.3 V to 2.5 V. The schedule uses a 1C current definition of 148 mA / g in the 4.3 V to 2.5 V vs. Li / Li+ range. The first cycle is evaluated at 0.1C.
[0186] The capacity fading rate (QF1C) is obtained according to the following equation below: ^^^^^^^^1^^^^(%) = 100 ×�1 −^^^^^^^^37100 ^^^^^^^^� ×10Table 1. Cycle schedule for coin cell testing method Charge Discharge Cycle Rest End C Rest time number C Rate (C) time V vs. Li i+ / Li (V) current Rate V vs. Li i+ / Li (V) (min.) (min.) (C) (C) 1 0.10 10 4.3 0.05 0.10 10 2.5 2 0.33 10 4.3 0.05 0.33 10 2.5 3 0.25 10 4.3 0.05 0.20 10 2.5 4 0.25 10 4.3 0.05 0.33 10 2.5 5 0.25 10 4.3 0.05 0.50 10 2.5 6 0.25 10 4.3 0.05 1.00 10 2.5 7 0.25 10 4.3 0.05 2.00 10 2.5 8 0.25 10 4.3 0.05 3.00 10 2.5 9 0.25 10 4.3 0.05 0.10 10 2.5 10 0.25 10 4.3 0.05 1.00 10 2.5 11~35 0.50 10 4.3 0.05 1.00 10 2.5 36 0.25 10 4.3 0.05 0.10 10 2.5 37 0.25 10 4.3 0.05 1.00 10 2.5F) Volumetric Energy Density
[0187] Volumetric Energy Density is calculated by using the below equation, wherein DQ1 is discharge capacity of the 1st cycle and DV1 is averaged voltage of the 1st cycle from the coin cell testing: ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^^^^^^^^^^^^^^^^^ (^^^^ℎ⁄ ^^^^ )= ^^^^^^^^1 (^^^^^^^^^^^^^^^^ℎ^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^ 1^^^^^^^^ ^^^^^^^^^^^^^^^^^^^^,^^^^^^^^ℎ⁄ ^^^^ )× ^^^^^^^^1 ( ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^ 1^^^^^^^^ ^^^^^^^^^^^^^^^^^^^^,^^^^)× ^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^^^^^^^^^^^^^^^^^ (^^^^⁄ ^^^^^^^^ )RESULTS The present disclosure is further illustrated in the following examples and comparative examples. First CAM powder of the disclosure (embodiment 1) NMC semi monolithic Synthesis
[0188] CAM F2, was prepared by a process described in CAM F2example as detailed in the DETAILED EXAMPLES section. This NMC CAM is flagged as NMCSM. LFMP Synthesis
[0189] CAM F1is manufactured according to PROC1.
[0190] Chemical composition measured by ICP, PSD and PD data of CAM F1 and CAM F2are provided in Table 2.1.a)gi)1 )1 CMSi(T 5(0 9 4 )47. 82 4A / 0 .0. 0.N (00()6 )34 )8 Br)ZY bA(N / 0044(N0. 10. 00. 0.( 00(l 2 9A404.50.01P2.A9 / N ) M4%ta( 7PeCF6.AI9 / 1N o5 1C0.80.40n8 4M.99.20iA9N / 4.N39 / M) 674 / %t%48iLa(ta.90.0bN +)³ YD m1 3 iT+rPc2.1. +iZ / 2 3S + g+b(N B g M+ +Ynn+ +M r+a5p.8aZis00C N 1.1+l+ A B +i+ +l TPA+i)+S 0 5 m40+ µ.22eo+.FCgD( 3+ +M o Cn+a+ M +iC P MSnN +lCM. .A M Fs s+L Mv voC D N % %t +: I_ta P1Xa P+.1 22 EF FPCC eIFelM MI1F2+nbA AFMMaC C MTA A = C C M 5
[0191] Embodiment 1 includes manufacturing CAMs by mixing fractions of CAM F1and CAM F2according to weight percentage (wt. %) provided into Table 2.2. Table 2.2: Fractions Volumetric LFMP NMCSM PD Porosity energy QF1C EX_ID CAM F1 CAM F2 (g / cm³) (%) density (% / cycle) wt. % (Wh / L) EX1.1 40.0 60.0 2.94 28.3 2202.3 11.2 EX1.2 30.0 70.0 3.10 26.9 2426.2 18.7 EX1.3 20.0 80.0 3.24 25.9 2627.2 9.5 CEX1.3 100.0 0.0 2.21 36.4 1230.0 0.0 CEX1.4 0.0 100.0 3.13 33.3 2678.5 35.5
[0192] In EXs 1.1 to 1.3, and CEX1.1, and CEX1.2, the mixing of the fractions is performed by mixing different fractions F1and F2(in wt%) in a turbular mixer under 45 rpm during 3.0 hours.
[0193] As data in Table 2.2 show, optimal VED and QF1C is achieved for a coin cell (battery) having an electrode including CAM powder according to EX1.3, whereas both EXs 1.1 & 1.2 allow to achieve improved QF1C when used in a coin cell. Second CAM powder of the disclosure (embodiment 2) NMC polycrystalline Synthesis
[0194] A CAM F3was prepared by a process described in CAM F3example as detailed in the DETAILED EXAMPLES section.
[0195] A CAM F4, was prepared by a process described in CAM F4example as detailed in the DETAILED EXAMPLES section.
[0196] CAM F3and CAM F4NMC CAM fractions are flagged as NMCPOL.
[0197] In addition to of CAM F1and CAM F2data, chemical composition measured by ICP, PSD and PD data of CAM F3and CAM F4are provided in Table 2.3.a)g i )i1 )519 4 )474A A / A) )AA 99CM(ST 0. 820 / / / / 00.0..N N NN(00( (N.0() ) )))6348737 ) 1 )84 ) 5BrZ( Y bNrA / 0( S N0 044A. 1 / 298 A / A / 800 A / 00. 00. 0.N9. 2. 0.9. 2. 1.1.(00( 00( 0N(N00 N(0 ( 0l 2 9 3 0A404 1 7.5.9.50 0 0.01P2.A9 / A / A4 N N / N ) M %ta7(eF6.A9 / A AN / N / P 1N CIo5018983C.0.4.35.6n8.4 4M99 7782.0.3.2iA9N / 45 4.1.7.N398888M / ) 6i748209 / %Lt% a4 97(ta.0.0 90.1.0)³D m1231195Pc / . . .9.g2 3 2 2(na5p.8 0 7001.3 21.0.S0D SP05 4. 00D2 20.23. 2.931PMLSOM C CPFLM D N M N: I3 _. X1 EF1F2F3F4elM M M MbA A A AaC C C CTiT+iSr+ iSg T+Mb+b+rNaN SC+ + +Y+Y Y YlA+r+ +r+r rZ+Z Z Zo+ + + + B BC B B+P+l+Al+l+n+ A Ae +MF o+o+o+i+C C C No+n+ ++iCn n T+M M M+n+ + +ii i iSM N N N += = = =g1 2MM M3 4+M Ma= =C == +M Ml. . M MAs s.s.s+v v v voC %t% % %+atatPata +PCP P PeFICIC C +F1F2 IF3 IF4 nMM M M MA A A A=C C C C M 5
[0198] Embodiment 2 includes manufacturing CAMs by mixing fractions of CAM F1to CAM F4according to weight percentage (wt.%) provided into Tables 2.4 – 2.6. Table 2.4: Fractions LFMP NMCSM NMCPOL PD Porosity EX_ID CAM F1 CAM F2 CAM F3 CAM F4 (g / cm³) (%) wt. % EX2.1 10.0 22.5 0.0 67.5 N / A N / A EX2.2 10.0 22.5 67.5 0.0 3.32 26.5 EX2.3 30.0 17.5 0.0 52.5 N / A N / A EX2.4 30.0 17.5 52.5 0.0 3.15 25.5 EX2.5 70.0 0.0 30.0 0.0 3.09 27.0 CEX2.1 100.0 0.0 0.0 0.0 2.21 36.4 CEX2.2 0.0 100.0 0.0 0.0 2.91 37.7 CEX2.3 0.0 0.0 100.0 0.0 2.95 36.8 CEX2.4 0.0 0.0 0.0 100.0 3.13 33.3 Table 2.5: FractionsVolumetricLFMP NMCSM NMCPOL EX_ID energy density CAM F1 CAM F2 * CAM F3 ** CAM F4 (Wh / L) wt. % EX2.1 10.0 22.5 0.0 67.5 N / A EX2.2 10.0 22.5 67.5 0.0 2816.7 EX2.3 30.0 17.5 0.0 52.5 2628.7 EX2.4 30.0 17.5 52.5 0.0 2458.4 EX2.5 70.0 0.0 30.0 0.0 2445.3 CEX2.1 100.0 0.0 0.0 0.0 1230.0 CEX2.2 0.0 100.0 0.0 0.0 2678.5 CEX2.3 0.0 0.0 100.0 0.0 2600.3 CEX2.4 0.0 0.0 0.0 100.0 2662.6 *CAM F3 has D50 of 9.2 µm **CAM F4 has D50 of 13.2 µmTable 2.6: Fractions Coin Cell LFMP NMCSM NMCPOL EX_ID QF01C QF1C CAM F1 CAM F2 * CAM F3 ** CAM F4 (% / cycle) (% / cycle) EX2.1 10.0 22.5 0.0 67.5 N / A N / A EX2.2 10.0 22.5 67.5 0.0 12.4 15.9 EX2.3 30.0 17.5 0.0 52.5 N / A N / A EX2.4 30.0 17.5 52.5 0.0 9.8 12.4 EX2.5 70.0 0.0 30.0 0.0 8.5 11.9 CEX2.1 100.0 0.0 0.0 0.0 -0.2 0.0 CEX2.2 0.0 100.0 0.0 0.0 10.1 35.5 CEX2.3 0.0 0.0 100.0 0.0 15.8 24.5 CEX2.4 0.0 0.0 0.0 100.0 17.2 28.6 *CAM F3 has D50 of 9.2 µm * CAM F4has D50 of 13.2 µm
[0199] In EX2.2 to 2.5, the mixing of the fractions of CAMs CAM F1to CAM F3(or CAM F4) is performed in a turbular mixer at 45 rpm mixing speed during 3.0 hours.
[0200] As above data show, improved cycling stability (indicated by lowest QF01C and QF1C values) is met for a coin cell (battery) having an electrode including CAM powder according to EXs 2.4 & 2.5 with sufficiently high VED whereas optimal VED is achieved for a coin cell (battery) having an electrode including CAM powder according to EX 2.2, with decent cycling stability (i.e., relatively low QF1C or QF01C values). Process to make CAM fractions CAM F2
[0201] The positive electrode active material CAM F2was obtained through following steps: a) First mixing: a precursor Ni0.96Mn0.01Co0.03(OH)2, LiOH, 1100 ppm Zr from ZrO2, 400 ppm of Y from Y2O3, and 700 ppm Al from Al2O3with respect to weight of the precursor were mixed homogeneously to prepare a first mixture including a Li over (Ni+Mn+Co) atomic ratio of 1.01;b) First heating: the first mixture was heated at 805 °C for 29 hours under oxygen atmosphere followed by jaw crushing, thereby obtaining a heated material. c) Milling: the heated material from step b) was air classified milled and sieved. The crushed material was bead milled with 0.5 mol% of Co from an aqueous solution of CoSO4followed by filtering and drying, followed by sieving was with a 200 mesh sieve and drying at 150 °C for 15 hours under nitrogen atmosphere thereby obtaining a dried material; d) Second mixing: the dried material was mixed with LiOH, 1.5 mol% of Co (Co to (Ni+Mn+Co)) from Co3O4, 500 ppm of Al (Al to (Ni+Mn+Co)) from Al2O3, and 500 ppm of Nb (Nb to (Ni+Mn+Co)) from NbO2, thereby obtaining a second mixture having a Li over (Ni+Mn+Co) atomic ratio of 0.995; and of : e) Second heating: the second mixture from step d) was heated at 730 °C for 24 hours under oxygen atmosphere followed by grinding and sieving with 500 ppm of Al from Al2O3.The sieving was followed by 325 mesh. CAM F3
[0202] The positive electrode active material CAM F3was obtained through following steps: a) First mixing: a precursor Ni0.9Mn0.04Co0.06(OH)2, LiOH, 1500 ppm of Al from Al2O3powder, 3000 ppm of Zr from ZrO2, and 1000 ppm of Y from Y2O3with respect to weight of the precursor were mixed homogeneously to prepare a first mixture including a Li over (Ni+Mn+Co) atomic ratio of 1.05; b) First heating: the first mixture was heated at 758 °C for 12 hours under oxygen atmosphere, thereby obtaining a first heated material; c) Washing: the first heated material obtained from step b) was washed with water with powder to water ratio of 2.0:5.0 at 15 °C for 1 minute followed by filtering and drying. The drying was progressed at 150 °C for 14 hours to obtain a dried material; d) Second mixing: the dried material was mixed with 1100 ppm of Al from Al2O3powder, and 1000 ppm of B from H3BO3powder with respect to weight of the dried material; thereby obtaining a 2ndmixture; and of:e) Second heating: the 2ndmixture from step d) was heated at 300 °C for 8 hours under oxygen atmosphere followed by grinding and sieving. The sieving was done with a 270 mesh sieve. CAM F4
[0203] A positive electrode active material CAM F4was obtained through following steps: a) First Mixing: a precursor Ni0.92Mn0.03Co0.05(OH)2, LiOH (Li over (Ni+Mn+Co) atomic ratio of 1.05), 2000 ppm of Zr from ZrO2, 1000 ppm Y from Y2O3, 1500 ppm Sb from Sb2O3, and 1000 ppm of Sr from SrO2with respect to weight of the precursor were mixed homogeneously to prepare a first mixture; b) First heating: the first mixture was heated at 750 °C for 12 hours under oxygen atmosphere, thereby obtaining a first heated material; c) Second mixing and second heating: the first heated material was mixed with 1.5 mol% of Co from CoOOH with respect to total among of Ni, Mn, and Co in the first heated material, and 500 ppm of Al from Al2O3with respect to weight of the first heated material. The mixture was then heated at 690 °C for 8 hours under oxygen atmosphere to obtain a 2ndheated material; d) Washing: the second heated material was washed with water with powder to water ratio of 1:1.5 at 15 °C for 1 minute followed by filtering and drying. The drying was progressed at 140 °C for 14 hours, thereby achieving a dried material; e) Third mixing: the dried material from step d) was mixed with 500 ppm Ti from TiO2, 1100 ppm of Al from Al2O3, and 1000 ppm of B from H3BO3with respect to weight of the dried material to obtain a 3rdmixture; and of: f) Third heating: the 3rdmixture was heated at 300 °C for 8 hours under oxygen atmosphere followed by grinding and sieving. The sieving was done by using a 270 mesh sieve. CLAUSES The present disclosure is inclusive of the following clauses: 1) A first cathode active material powder comprising : a. a first fraction F1of a first olivine cathode active material powder comprising Li, M1, D1, and O, wherein M1 includes Fea1Mnx1Pz1, with:- 10.0 ≤ a1 ≤ 25.0, - 25.0 ≤ x1 ≤ 35.0, - 40.0 ≤ z1 ≤ 65.0, wherein a1, x1, and z1 are expressed in at% and measured by ICP-OES, and with D1 including at least one element different than Li, P, Fe, Mn, and O, and b. a second fraction F2of a second nickel manganese containing cathode active material comprising Li, M4, D4, and O, wherein M4 has a formula Niy4Mnx4CoZ4, with - 0.50 ≤ x4 ≤ 29.5, - 50.0 ≤ y4 ≤ 95.0, - 4.5 ≤ z4 ≤ 20.5, wherein x4, y4, and z4 are are measured by ICP-OES and expressed in at%, and with D4 including at least one element different than Li, Ni, Mn, and O, the second fraction having a D50 of at least 1.0 µm and at most 5.0 µm, and comprising standalone particles including at least one and at most twenty primary particles, wherein : - 15.0 wt.% ≤ F1≤ 45.0 wt.%, and - 55.0 wt. % ≤ F2≤ 85.0 wt. %, or: - 15.0 wt.% ≤ F1≤ 40.0 wt.%, and - 60.0 wt. % ≤ F2≤ 85.0 wt. %, or: - 20.0 wt.% ≤ F1≤ 40.0 wt.%, and - 60.0 wt. % ≤ F2≤ 80.0 wt. %, or: - 20.0 wt.% ≤ F1≤ 25.0 wt.%, and - 75.0 wt. % ≤ F2≤ 80.0 wt. %, or: - 15.0 wt.% ≤ F1≤ 25.0 wt.%, and - 75.0 wt. % ≤ F2≤ 85.0 wt. %,wherein: F1+F2= 100 wt.%, and wherein all of : a1, x1, z1, x4, y4, and z4 are expressed in at%. 2) The first cathode active material powder of clause 1, having a porosity of at least 20.0% and at most 30.0%, or of at least 25.0% and at most 30.0%, or of at least 28.0% and at most 30.0%. 3) The first cathode active material powder of clause 1 or 2, having a PD of at least 2.5 or of at least 2.8 g / cm³, and optionally of at most 3.5 g / cm³. 4) The first cathode active material powder of any of the preceding clauses, wherein the first fraction has a D50 of at least 1.5 µm and at most 3.0 µm, or of at least 2.0 µm and at most 2.5 µm. 5) The first cathode active material powder of any of the preceding clauses, wherein the second fraction has a D50 of at least 1.5 µm and at most 3.5 µm. 6) The first cathode active material powder of any of the preceding clauses, wherein the first fraction has a span of at least 8.0 and at most 12.0, or of at least 9.0 and at most 11.0, or of at least 10.0 and at most 11.0. 7) The first cathode active material powder of any of the preceding clauses, wherein the second fraction has a span of at least 1.00 and at most 1.50. 8) The first cathode active material powder of any of the preceding clauses, wherein the first fraction has a PD of at least 2.0 g / cm³, and optionally of at most 2.5 g / cm³. 9) The first cathode active material powder of any of the preceding clauses, wherein the second fraction has a PD of at least 2.0 g / cm³, or of at least 2.5 g / cm³, and optionally of at most 3.5 g / cm³. 10) The first cathode active material powder of any of the preceding clauses, wherein D1 includes at least one of or all of: Co, Al, Ca, Mg, Si, and Ti.11) The first cathode active material powder of any of the preceding clauses, wherein the first olivine cathode active material powder has a Formula I: Lib1D1y1Fea1Mnx1Pz1O4, wherein : - 10.0 ≤ a1 ≤ 20.0, - 25.0 ≤ x1 ≤ 35.0, - 40.0 ≤ z1 ≤ 65.0, - 0.00 ≤ y1 ≤ 5.0, - 0.45 ≤ b1 ≤ 0.55, wherein all of : a1, x1, z1, and y1 are expressed in at%, and b1 is expressed in at% / at%, and are all measured by ICP-OES, and wherein a1 + x1 + z1 + y1 = 100.0 at%. 12) The first cathode active material powder of clause 11, wherein D1 includes Co, Al, Ca, Mg, Si, and Ti. 13) The first cathode active material powder of any of the preceding clauses, wherein D4 includes at least one of or all of : B, Zr, Y, Al, Ca, Mg, Si, Nb, and Ti, optionally least one of or all of : B, Zr, Nb, and Y. 14) The first cathode active material powder of any of the preceding clauses, wherein the second nickel manganese containing cathode active material has a Formula II: Lib4Niy4Mnx4CoZ4D4a4O2,wherein all of : a1, x1, z1, y1, and b1 are expressed in at%, with: - 0.50 ≤ x4 ≤ 25.5, - 50.0 ≤ y4 ≤ 95.0, - 4.5 ≤ z4 ≤ 19.5, - 0.00 ≤ a4 ≤ 5.00, and - 0.95 ≤ b4 ≤ 1.05 , wherein all of : a4, x4, z4, and y4 are expressed in at% and b4 is expressed in at% / at%, and are all measured by ICP-OES, and wherein a4 + x4 + z4 + y4 = 100.0 at%.15) The first cathode active material powder of clause 14, wherein D4 includes at least one of B, Zr, Nb, and Y. 16) A second cathode active material powder comprising at least two of: a. a first fraction F1of a first olivine cathode active material powder comprising Li, M1, D1, and O, wherein M1 includes Fea1Mnx1Pz1, with: - 10.0 ≤ a1 ≤ 25.0, - 25.0 ≤ x1 ≤ 35.0, and - 40.0 ≤ z1 ≤ 65.0, with D1 being at least one element different than Li, P, Fe, Mn, and O, and b. a second fraction F2of a first nickel manganese containing cathode active material comprising Li, M4, D4, and O, wherein M4 has a formula Niy4Mnx4CoZ4, with: - 0.50 ≤ x4 ≤ 29.5, - 50.0 ≤ y4 ≤ 95.0, - 4.5 ≤ z4 ≤ 20.5, and with D4 being at least one element different than Li, Ni, Mn, and O, the second fraction powder having a D50 of at least 1.5 µm and of at most 5.0 µm, and comprising standalone particles including at least one and at most twenty primary particles, c. a third fraction F3of a second nickel manganese containing cathode active material comprising Li, M4’, D4’, and O, wherein M4 has a formula Niy4’Mnx4’CoZ4’, with - 0.50 ≤ x4’ ≤ 29.5, - 50.0 ≤ y4’ ≤ 95.0, - 4.5 ≤ z4’ ≤ 20.5, and with D4’ being at least one element different than Li, Ni, Mn, and O, the third fraction powder having a D50 of at least 8.0 µm and at most 10.0 µm, and a span of at least 0.3 and optionally of at most 0.5, the third fraction powder having polycrystalline particles, and d. a fourth fraction F4of a third nickel manganese containing cathode active material comprising Li, M4”, D4”, and O, wherein M4 has a formula Niy4’’Mnx4’’CoZ4’’, with- 0.50 ≤ x4” ≤ 29.5, - 50.0 ≤ y4” ≤ 95.0, - 4.5 ≤ z4” ≤ 20.5, and with D4’’ being at least one element different than Li, Ni, Mn, and O, the third fraction powder having a D50 of more than 10.0 µm and at most 15.0 µm, and a span of at least 0.25 and optionally of at most 0.5, the fourth fraction powder having polycrystalline particles, and wherein either : - 10.0 wt.% ≤ F1≤ 30.0 wt.%, - 15.0 wt.% ≤ F2≤ 25.0 wt.%, and - 45.0 wt. % ≤ F3≤ 75.0 wt. %, or: - 10.0 wt.% ≤ F1≤ 30.0 wt.%, - 15.0 wt.% ≤ F2≤ 25.0 wt.%, and - 45.0 wt.% ≤ F4≤ 75.0 wt.%, or: - 25.0 wt.% ≤ F3≤ 35.0 wt.%, and - 65.0 wt.% ≤ F1≤ 75.0 wt.%, or: - 25.0 wt.% ≤ F4≤ 35.0 wt.%, and - 65.0 wt.% ≤ F1≤ 75.0 wt.%. wherein: F1+F2+F3= 100 wt.%, or F1+F2+F4= 100 wt.%, or F1+F4= 100 wt.%, or F1+F3= 100 wt.% and wherein all of : a1, x1, z1, x4, y4, z4, x4’, y4’, z4’, x4”, y4”, and z4’’ are expressed in at% and measured by ICP-OES. 17) The second cathode active material powder of clause 16, having a porosity of at least 20.0 % and at most 30.0 %, or of at least 22.5 % and at most 28.5 %. 18) The second cathode active material powder of clause 16 or 17, having a PD of at least 2.5 or of at least 3.0 g / cm³, and optionally of at most 3.5 g / cm³.19) The second cathode active material powder of any of the clauses 16 to 18, wherein the first fraction has a D50 of at least 1.5 µm and at most 3.0 µm, or of at least 2.0 µm and at most 2.5 µm. 20) The second cathode active material powder of any of the clauses 16 to 19, wherein the second fraction has a D50 of at least 1.5 µm and at most 3.5 µm. 21) The second cathode active material powder of any of the clauses 16 to 20, wherein the first fraction has a span of at least 8.0 and at most 12.0, or of at least 9.0 and at most 11.0, or of at least 10.0 and at most 11.0. 22) The second cathode active material powder of any of the clauses 16 to 21, wherein the second fraction has a span of at least 1.00 and at most 1.50. 23) The second cathode active material powder of any of the clauses 16 to 22, wherein the first fraction has a PD of at least 2.0 g / cm³, and optionally of at most 2.5 g / cm³. 24) The second cathode active material powder of any of the clauses 16 to 23, wherein the second fraction has a PD of at least 2.0 g / cm³, and optionally of at most 3.5 g / cm³. 25) The second cathode active material powder of any of the clauses 16 to 24, wherein the second fraction has a PD of at least 2.5 g / cm³. 26) The second cathode active material powder of any of the clauses 16 to 25, wherein the first olivine cathode active material powder has a Formula I: Lib1D1y1Fea1Mnx1Pz1O4, wherein : - 10.0 ≤ a1 ≤ 20.0, - 25.0 ≤ x1 ≤ 35.0, - 40.0 ≤ z1 ≤ 65.0, - 0.00 ≤ y1 ≤ 5.0, - 0.95 ≤ b1 ≤ 1.05,wherein all of : a1, x1, z1, and y1 are expressed in at%, and b1 is expressed in at% / at%, and are all measured by ICP-OES, and wherein a1 + x1 + z1 + y1 = 100.0 at%. 27) The second cathode active material powder of clause 26, wherein D1 includes Co, Al, Ca, Mg, Si, and Ti. 28) The second cathode active material powder of any of the clauses 16 to 27, wherein D4 includes at least one of or all of : Nb, B, Zr, Y, Al, Ca, Mg, Sr, Si, and Ti, optionally least one of or all of : Sr, Nb, B, Zr, and Y. 29) The second cathode active material powder of any of the clauses 16 to 28, wherein D4 includes Al, Sr, Nb, B, Zr, and Y. 30) The second cathode active material powder of any of the clauses 16 to 29, wherein D4’ and / or D4” includes at least one of or all of : Nb, B, Zr, Y, Al, Ca, Mg, Sr, Si, and Ti, optionally least one of or all of : Sr, Nb, B, Zr, and Y. 31) The second cathode active material powder of any of the clauses 16 to 30, wherein D4’ and / or D4” includes Al, Sr, Nb, B, Zr, and Y. 32) The second cathode active material of any of the clauses 16 to 31, wherein the first nickel manganese containing cathode active material has a Formula II: Lib4Niy4Mnx4CoZ4D4a4O2, , with: - 0.50 ≤ x4 ≤ 25.5, - 50.0 ≤ y4 ≤ 95.0, - 4.0 ≤ z4 ≤ 19.5, - 0.50 ≤ a4 ≤ 5.00, and - 0.95 ≤ b4 ≤ 1.05, wherein all of : a4, x4, z4, and y4 are expressed in at%, and b4 is expressed in at% / at%, and are all measured by ICP-OES, and wherein a4 + x4 + z4 + y4 = 100.0 at%.33) The second cathode active material powder of clause 32, wherein D4 includes B, Zr, Nb, and Y. 34) The second cathode active material powder of any of the clauses 16 to 33, wherein the second nickel manganese containing cathode active material has a Formula III: Lib4’Niy4’Mnx4’CoZ4’D4’a4’O2, with: - 0.50 ≤ x4’ ≤ 25.5, - 50.0 ≤ y4’ ≤ 95.0, - 4.0 ≤ z4’ ≤ 19.5, - 0.50 ≤ a4’ ≤ 5.00, and - 0.95 ≤ b4’ ≤ 1.05, wherein all of : a4’, x4’, z4’, and y4’ are expressed in at% and b4’ is expressed in at% / at%, and are all measured by ICP-OES, and wherein a4’ + x4’ + z4’ + y4’ = 100.0 at%. 35) The second cathode active material powder of clause 34, wherein D4’ includes B, Zr, and Y. 36) The second cathode active material powder of any of the clauses 16 to 35, wherein the third nickel manganese containing cathode active material has a Formula III: Lib4”Niy4”Mnx4”CoZ4”D4”a4”O2, with: - 0.50 ≤ x4” ≤ 25.5, - 50.0 ≤ y4” ≤ 95.0, - 4.0 ≤ z4” ≤ 19.5, - 0.50 ≤ a4” ≤ 5.00, and - 0.95 ≤ b4” ≤ 1.05, wherein all of : a4”, x4”, z4”, and y4” are expressed in at% and b4” is expressed in at% / at%, and are all measured by ICP-OES, and wherein a4” + x4” + z4” + y4” = 100.0 at%.37) The second cathode active material powder of clause 36, wherein D4” includes B, Zr, Sr, and Y. 38) The second cathode active material powder of any of the clauses 16 to 37, wherein the third fraction has a PD of at least 2.0 g / cm³, or of at least 2.5 g / cm³, and optionally of at most 3.5 g / cm³. 39) The second cathode active material powder of any of the clauses 16 to 38, wherein the fourth fraction has a PD of at least 2.0 g / cm³, or of at least 2.5 g / cm³, and optionally of at most 3.5 g / cm³. 40) The second cathode active material powder of any of the clauses 16 to 39, wherein the span of the third fraction is inferior to the span of the second fraction. 41) The second cathode active material powder of any of the clauses 16 to 40, wherein the span of the fourth fraction is inferior to the span of the second fraction. 42) The second cathode active material powder of any of the clauses 16 to 41, wherein the span of the fourth fraction is inferior or equal to the span of the third fraction. 43) The second cathode active material powder of any of the clauses 16 to 42, wherein the fourth fraction has a PD of at least 2.00 g / cm³ and of at most 4.0 g / cm³, or of at most 3.5 g / cm³, or of at most 3.0 g / cm³. 44) A battery comprising the first cathode active material powder according to any of the clauses 1 to 15 or the second active cathode active material powder according to any of the clauses 16 to 43. 45) An electric vehicle comprising the battery of clause 44. 46) A first electrode including: - the first cathode active material powder according to any of the clauses 1 to 15, - a conductor, and - a binder.) A second electrode including: - the first cathode active material powder according to any of the clauses 16 to 43, - a conductor, and - a binder.
Claims
CLAIMS 1) A first cathode active material powder comprising : a. a first fraction F1of a first olivine cathode active material powder comprising Li, M1, D1, and O, wherein M1 includes Fea1Mnx1Pz1, with: - 10.0 ≤ a1 ≤ 25.0, - 25.0 ≤ x1 ≤ 35.0, - 40.0 ≤ z1 ≤ 65.0, wherein a1, x1, and z1 are expressed in at% and measured by ICP-OES, and with D1 including at least one element different than Li, P, Fe, Mn, and O, and b. a second fraction F2of a second nickel manganese containing cathode active material comprising Li, M4, D4, and O, wherein M4 has a formula Niy4Mnx4CoZ4, with - 0.50 ≤ x4 ≤ 29.5, - 50.0 ≤ y4 ≤ 95.0, - 4.5 ≤ z4 ≤ 20.5, wherein x4, y4, and Z4 are are measured by ICP-OES and expressed in at%, and with D4 including at least one element different than Li, Ni, Mn, and O, the second fraction having a D50 of at least 1.0 µm and at most 5.0 µm, and comprising standalone particles including at least one and at most twenty primary particles, wherein : - 15.0 wt.% ≤ F1≤ 45.0 wt.%, and - 55.0 wt. % ≤ F2≤ 85.0 wt. %, or: - 15.0 wt.% ≤ F1≤ 40.0 wt.%, and - 60.0 wt. % ≤ F2≤ 85.0 wt. %, or: - 20.0 wt.% ≤ F1≤ 40.0 wt.%, and - 60.0 wt. % ≤ F2≤ 80.0 wt. %, or: - 20.0 wt.% ≤ F1≤ 25.0 wt.%, and- 75.0 wt. % ≤ F2≤ 80.0 wt. %, or: - 15.0 wt.% ≤ F1 ≤ 25.0 wt.%, and - 75.0 wt. % ≤ F2≤ 85.0 wt. %, wherein: F1+F2= 100 wt.%, and wherein all of : a1, x1, z1, x4, y4, and z4 are expressed in at%. 2) The first cathode active material powder of claim 1, having a porosity of at least 20.0% and at most 30.0%, or of at least 25.0% and at most 30.0%, or of at least 28.0% and at most 30.0%. 3) The first cathode active material powder of claim 1 or 2, having a PD of at least 2.5 or of at least 2.8 g / cm³, and optionally of at most 3.5 g / cm³. 4) The first cathode active material powder of any of the preceding claims, wherein the first fraction has a D50 of at least 1.5 µm and at most 3.0 µm, or of at least 2.0 µm and at most 2.5 µm. 5) The first cathode active material powder of any of the preceding claims, wherein the second fraction has a D50 of at least 1.5 µm and at most 3.5 µm. 6) The first cathode active material powder of any of the preceding claims, wherein the first fraction has a span of at least 8.0 and at most 12.0, or of at least 9.0 and at most 11.0, or of at least 10.0 and at most 11.
0. 7) The first cathode active material powder of any of the preceding claims, wherein the second fraction has a span of at least 1.00 and at most 1.
50. 8) The first cathode active material powder of any of the preceding claims, wherein the first fraction has a PD of at least 2.0 g / cm³, and optionally of at most 2.5 g / cm³. 9) The first cathode active material powder of any of the preceding claims, wherein the second fraction has a PD of at least 2.0 g / cm³, or of at least 2.5 g / cm³, and optionally of at most 3.5 g / cm³.10) The first cathode active material powder of any of the preceding claims, wherein D1 includes at least one of or all of: Co, Al, Ca, Mg, Si, and Ti. 11) The first cathode active material powder of any of the preceding claims, wherein the first olivine cathode active material powder has a Formula I: Lib1D1y1Fea1Mnx1Pz1O4, wherein : - 10.0 ≤ a1 ≤ 20.0, - 25.0 ≤ x1 ≤ 35.0, - 40.0 ≤ z1 ≤ 65.0, - 0.00 ≤ y1 ≤ 5.0, - 0.45 ≤ b1 ≤ 0.55, wherein all of : a1, x1, z1, and y1 are expressed in at%, and b1 is expressed in at% / at%, and are all measured by ICP-OES, and wherein a1 + x1 + z1 + y1 = 100.0 at%. 12) The first cathode active material powder of claim 11, wherein D1 includes Co, Al, Ca, Mg, Si, and Ti. 13) The first cathode active material powder of any of the preceding claims, wherein D4 includes at least one of or all of : B, Zr, Y, Al, Ca, Mg, Si, Nb, and Ti, optionally least one of or all of : B, Zr, Nb, and Y. 14) The first cathode active material powder of any of the preceding claims, wherein the second nickel manganese containing cathode active material has a Formula II: Lib4Niy4Mnx4CoZ4D4a4O2, wherein all of : a1, x1, z1, y1, and b1 are expressed in at%, with: - 0.50 ≤ x4 ≤ 25.5, - 50.0 ≤ y4 ≤ 95.0, - 4.5 ≤ z4 ≤ 19.5, - 0.00 ≤ a4 ≤ 5.00, and- 0.95 ≤ b4 ≤ 1.05 , wherein all of : a4, x4, z4, and y4 are expressed in at% and b4 is expressed in at% / at%, and are all measured by ICP-OES, and wherein a4 + x4 + z4 + y4 = 100.0 at%. 15) The first cathode active material powder of claim 14, wherein D4 includes at least one of B, Zr, Nb, and Y. 16) A second cathode active material powder comprising at least two of: a. a first fraction F1of a first olivine cathode active material powder comprising Li, M1, D1, and O, wherein M1 includes Fea1Mnx1Pz1, with: - 10.0 ≤ a1 ≤ 25.0, - 25.0 ≤ x1 ≤ 35.0, and - 40.0 ≤ z1 ≤ 65.0, with D1 being at least one element different than Li, P, Fe, Mn, and O, and b. a second fraction F2of a first nickel manganese containing cathode active material comprising Li, M4, D4, and O, wherein M4 has a formula Niy4Mnx4CoZ4, with: - 0.50 ≤ x4 ≤ 29.5, - 50.0 ≤ y4 ≤ 95.0, - 4.0 ≤ z4 ≤ 20.5, and with D4 being at least one element different than Li, Ni, Mn, and O, the second fraction powder having a D50 of at least 1.5 µm and of at most 5.0 µm, and comprising standalone particles including at least one and at most twenty primary particles, c. a third fraction F3of a second nickel manganese containing cathode active material comprising Li, M4’, D4’, and O, wherein M4 has a formula Niy4’Mnx4’CoZ4’, with - 0.50 ≤ x4’ ≤ 29.5, - 50.0 ≤ y4’ ≤ 95.0, - 4.5 ≤ z4’ ≤ 20.5,and with D4’ being at least one element different than Li, Ni, Mn, and O, the third fraction powder having a D50 of at least 8.0 µm and at most 10.0 µm, and a span of at least 0.3 and optionally of at most 0.5, the third fraction powder having polycrystalline particles, and d. a fourth fraction F4of a third nickel manganese containing cathode active material comprising Li, M4”, D4”, and O, wherein M4 has a formula Niy4’’Mnx4’’CoZ4’’, with - 0.50 ≤ x4” ≤ 29.5, - 50.0 ≤ y4” ≤ 95.0, - 4.5 ≤ z4” ≤ 20.5, and with D4’’ being at least one element different than Li, Ni, Mn, and O, the third fraction powder having a D50 of more than 10.0 µm and at most 15.0 µm, and a span of at least 0.25 and optionally of at most 0.5, the fourth fraction powder having polycrystalline particles, and wherein either : - 10.0 wt.% ≤ F1≤ 30.0 wt.%, - 15.0 wt.% ≤ F2≤ 25.0 wt.%, and - 45.0 wt. % ≤ F3≤ 75.0 wt. %, or: - 10.0 wt.% ≤ F1≤ 30.0 wt.%, - 15.0 wt.% ≤ F2≤ 25.0 wt.%, and - 45.0 wt.% ≤ F4≤ 75.0 wt.%, or: - 25.0 wt.% ≤ F3≤ 35.0 wt.%, and - 65.0 wt.% ≤ F1≤ 75.0 wt.%, - 25.0 wt.% ≤ F4≤ 35.0 wt.%, and - 65.0 wt.% ≤ F1≤ 75.0 wt.%. wherein: F1+F2+F3= 100 wt.%, or F1+F2+F4= 100 wt.%, or F1+F4= 100 wt.%, or F1+F3= 100 wt.% and wherein all of : a1, x1, z1, x4, y4, z4, x4’, y4’, z4’, x4”, y4”, and z4’’ are expressed in at% and measured by ICP-OES.17) The second cathode active material powder of claim 16, having a porosity of at least 20.0 % and at most 30.0 %, or of at least 22.5 % and at most 28.5 %. 18) The second cathode active material powder of claim 16 or 17, having a PD of at least 2.5 or of at least 3.0 g / cm³, and optionally of at most 3.5 g / cm³. 19) The second cathode active material powder of any of the claims 16 to 18, wherein the first fraction has a D50 of at least 1.5 µm and at most 3.0 µm, or of at least 2.0 µm and at most 2.5 µm. 20) The second cathode active material powder of any of the claims 16 to 19, wherein the second fraction has a D50 of at least 1.5 µm and at most 3.5 µm. 21) The second cathode active material powder of any of the claims 16 to 20, wherein the first fraction has a span of at least 8.0 and at most 12.0, or of at least 9.0 and at most 11.0, or of at least 10.0 and at most 11.
0. 22) The second cathode active material powder of any of the claims 16 to 21, wherein the second fraction has a span of at least 1.00 and at most 1.
50. 23) The second cathode active material powder of any of the claims 16 to 22, wherein the first fraction has a PD of at least 2.0 g / cm³, and optionally of at most 2.5 g / cm³. 24) The second cathode active material powder of any of the claims 16 to 23, wherein the second fraction has a PD of at least 2.0 g / cm³, and optionally of at most 3.5 g / cm³. 25) The second cathode active material powder of any of the claims 16 to 24, wherein the second fraction has a PD of at least 2.5 g / cm³. 26) The second cathode active material powder of any of the claims 16 to 25, wherein the first olivine cathode active material powder has a Formula I: Lib1D1y1Fea1Mnx1Pz1O4, wherein : - 10.0 ≤ a1 ≤ 20.0,- 25.0 ≤ x1 ≤ 35.0, - 40.0 ≤ z1 ≤ 65.0, - 0.00 ≤ y1 ≤ 5.0, - 0.95 ≤ b1 ≤ 1.05, wherein all of : a1, x1, z1, and y1 are expressed in at%, and b1 is expressed in at% / at%, and are all measured by ICP-OES, and wherein a1 + x1 + z1 + y1 = 100.0 at%. 27) The second cathode active material powder of claim 26, wherein D1 includes Co, Al, Ca, Mg, Si, and Ti. 28) The second cathode active material powder of any of the claims 16 to 27, wherein D4 includes at least one of or all of : Nb, B, Zr, Y, Al, Ca, Mg, Sr, Si, and Ti, optionally least one of or all of : Sr, Nb, B, Zr, and Y. 29) The second cathode active material powder of any of the claims 16 to 28, wherein D4 includes Al, Sr, Nb, B, Zr, and Y. 30) The second cathode active material powder of any of the claims 16 to 29, wherein D4’ and / or D4” includes at least one of or all of : Nb, B, Zr, Y, Al, Ca, Mg, Sr, Si, and Ti, optionally least one of or all of : Sr, Nb, B, Zr, and Y. 31) The second cathode active material powder of any of the claims 16 to 30, wherein D4’ and / or D4” includes Al, Sr, Nb, B, Zr, and Y. 32) The second cathode active material of any of the claims 16 to 31, wherein the first nickel manganese containing cathode active material has a Formula II: Lib4Niy4Mnx4CoZ4D4a4O2, , with: - 0.50 ≤ x4 ≤ 25.5, - 50.0 ≤ y4 ≤ 95.0, - 4.0 ≤ z4 ≤ 19.5, - 0.50 ≤ a4 ≤ 5.00, and - 0.95 ≤ b4 ≤ 1.05,wherein all of : a4, x4, z4, and y4 are expressed in at%, and b4 is expressed in at% / at%, and are all measured by ICP-OES, and wherein a4 + x4 + z4 + y4 = 100.0 at%. 33) The second cathode active material powder of claim 32, wherein D4 includes B, Zr, Nb, and Y. 34) The second cathode active material powder of any of the claims 16 to 33, wherein the second nickel manganese containing cathode active material has a Formula III: Lib4’Niy4’Mnx4’CoZ4’D4’a4’O2, with: - 0.50 ≤ x4’ ≤ 25.5, - 50.0 ≤ y4’ ≤ 95.0, - 4.0 ≤ z4’ ≤ 19.5, - 0.50 ≤ a4’ ≤ 5.00, and - 0.95 ≤ b4’ ≤ 1.05, wherein all of : a4’, x4’, z4’, and y4’ are expressed in at% and b4’ is expressed in at% / at%, and are all measured by ICP-OES, and wherein a4’ + x4’ + z4’ + y4’ = 100.0 at%. 35) The second cathode active material powder of claim 34, wherein D4’ includes B, Zr, and Y. 36) The second cathode active material powder of any of the claims 16 to 35, wherein the third nickel manganese containing cathode active material has a Formula III: Lib4”Niy4”Mnx4”CoZ4”D4”a4”O2, with: - 0.50 ≤ x4” ≤ 25.5, - 50.0 ≤ y4” ≤ 95.0, - 4.0 ≤ z4” ≤ 19.5, - 0.50 ≤ a4” ≤ 5.00, and- 0.95 ≤ b4” ≤ 1.05, wherein all of : a4”, x4”, z4”, and y4” are expressed in at% and b4” is expressed in at% / at%, and are all measured by ICP-OES, and wherein a4” + x4” + z4” + y4” = 100.0 at%. 37) The second cathode active material powder of claim 36, wherein D4” includes B, Zr, Sr, and Y. 38) The second cathode active material powder of any of the claims 16 to 37, wherein the third fraction has a PD of at least 2.0 g / cm³, or of at least 2.5 g / cm³, and optionally of at most 3.5 g / cm³. 39) The second cathode active material powder of any of the claims 16 to 38, wherein the fourth fraction has a PD of at least 2.0 g / cm³, or of at least 2.5 g / cm³, and optionally of at most 3.5 g / cm³. 40) The second cathode active material powder of any of the claims 16 to 39, wherein the span of the third fraction is inferior to the span of the second fraction. 41) The second cathode active material powder of any of the claims 16 to 40, wherein the span of the fourth fraction is inferior to the span of the second fraction. 42) The second cathode active material powder of any of the claims 16 to 40, wherein the span of the fourth fraction is inferior or equal to the span of the third fraction. 43) The second cathode active material powder of any of the claims 16 to 42, wherein the fourth fraction has a PD of at least 2.00 g / cm³ and of at most 4.0 g / cm³, or of at most 3.5 g / cm³, or of at most 3.0 g / cm³. 44) A battery comprising the first cathode active material powder according to any of the claims 1 to 15 or the second active cathode active material powder according to any of the claims 16 to 43. 45) An electric vehicle comprising the battery of claim 44. 46) A first electrode including:- the first cathode active material powder according to any of the claims 1 to 15, - a conductor, and - a binder. 47) A second electrode including: - the first cathode active material powder according to any of the claims 16 to 43, - a conductor, and - a binder.
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