Cathode Active Materials Void Elimination
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Solution Overview
Problem
Conventional cathode active materials for lithium batteries have low volumetric energy density due to voids and pores in secondary particles, which also lead to poor resistance to fracture and increased risk of electrolyte decomposition, resulting in unstable battery performance.
Innovation Solution
Development of cathode active materials with improved particle morphologies that are substantially free of voids and pores, comprising high proportions of primary particles with densities approaching ideal crystalline densities, achieved through wet solution processing and specific compositions like mixed-metal oxides and lithiated mixed-metal oxides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional cathode active materials are used, then manufacturing process is simple, but volumetric energy density is low due to voids and pores in secondary particles
Solution Approach 1:
The patent changes the physical and chemical parameters of the cathode active material particles by controlling synthesis conditions to achieve high density (≥90% of ideal crystalline density) and specific morphology characteristics, eliminating voids and pores while maintaining electrochemical performance
Solution Approach 2:
The patent employs composite particle structures combining primary particles with specific crystallographic orientations and controlled secondary particle formations, creating a composite morphology that achieves both high density and good electrochemical performance
2Strength
If secondary particles with voids and pores are used, then particle formation is easier, but resistance to fracture is poor
Solution Approach 1:
The patent modifies synthesis parameters including temperature, time, and chemical composition to produce particles with enhanced mechanical strength and fracture resistance, achieving densities ≥90% of ideal crystalline density through controlled crystallization processes
3Quantity of substance
If particles with voids and pores are used, then volumetric energy density is low, but manufacturing process is simpler
Solution Approach 1:
The patent implements precise control of synthesis parameters including temperature profiles, reaction times, and chemical compositions to achieve consistent high particle density (≥90% of ideal crystalline density), requiring advanced manufacturing precision
Solution Approach 2:
The patent employs feedback control mechanisms during synthesis to monitor and adjust process parameters, ensuring consistent production of high-density particles with controlled morphology and minimal voids
4Object-affected harmful factors
If conventional particle morphologies are used, then processing is easier, but gassing propensity is increased
Solution Approach 1:
The patent modifies particle morphology parameters including density, surface area, and internal structure to reduce gassing propensity, achieving compact particles with minimized void spaces that prevent electrolyte decomposition and gas formation
Data Source
AI summary
Mixed-metal oxides and lithiated mixed-metal oxides are disclosed that involve compounds according to, respectively, NixMnyCozMeαOβ and Li1+γNixMnyCozMeαOβ. In these compounds, Me is selected from B, Na, Mg, Al, Si, K, Ca, Sc, Ti, V, Cr, Fe, Cu, Zn, Ga, Ge, Zr, Nb, Mo, Ru, Ag, In, and combinations thereof; 0≤x≤1; 0≤y≤1; 0≤z<1; x+y+z>0; 0≤α≤0.5; and x+y+α>0. For the mixed-metal oxides, 1≤β≤5. For the lithiated mixed-metal oxides, −0.1≤γ≤1.0 and 1.9≤β≤3. The mixed-metal oxides and the lithiated mixed-metal oxides include particles having an average density greater than or equal to 90% of an ideal crystalline density.