Disordered Rock-Salt Cathode Composition for Fast-Charging Stability

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Solution Overview

Problem

The development of new cathode materials for batteries is time and cost intensive, and existing materials often face challenges such as high volume change during charging and discharging, which affects battery performance.

Innovation Solution

The introduction of cathode materials with a disordered-rock-salt (DRX) crystal structure and/or a combined DRX+layered crystal structure, which are synthesized using methods that estimate synthesizability, metal-ion diffusion, voltage discharge, charge capacity, and oxygen stability to select optimal compositions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If new cathode materials are developed through traditional methods, then material performance can be improved, but development time and cost increase significantly

Engineering Contradiction:
Improvecathode material performanceVSAvoiddevelopment time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The patent applies preliminary action by performing computational screening and estimation of synthesizability, metal-ion diffusion, voltage discharge, charge capacity, and oxygen stability for multiple cathode material compositions before actual synthesis. This pre-screening approach identifies promising candidates (Li4+δMx1M′y1M′′z1O8 and Li2+δMx2M′y2M′′z2O4) in advance, reducing the need for extensive trial-and-error experimentation and significantly cutting development time while maintaining performance improvement goals

Inventive Principle:
Principle #10Preliminary action

2Quantity of substance

If cathode materials with high charge capacity are designed, then battery energy density improves, but volume change during charging and discharging increases

Engineering Contradiction:
Improvecharge capacityVSAvoidvolume stability
Core Design Contradiction:
Quantity of substanceVSStability of the object's composition

Solution Approach 1:

The patent applies parameter changes by systematically varying the stoichiometric parameters (δ, x1, y1, z1, x2, y2, z2) and elemental composition (M, M′, M′′ selected from 18 different elements) of the cathode material formulas Li4+δMx1M′y1M′′z1O8 and Li2+δMx2M′y2M′′z2O4. This computational exploration of parameter space identifies compositions that achieve high charge capacity while maintaining reduced volume change during electrochemical cycling, resolving the contradiction between capacity and stability

Inventive Principle:
Principle #35Parameter changes

3Power

If expensive elements like cobalt are used in cathode materials, then charge capacity and voltage discharge improve, but manufacturing cost increases

Engineering Contradiction:
Improvevoltage dischargeVSAvoidmanufacturing cost
Core Design Contradiction:
PowerVSEase of manufacture

Solution Approach 1:

The patent applies this principle by replacing expensive long-lived strategic elements (like cobalt) with cheaper alternative elements (M, M′, M′′ selected from Al, Ga, Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Ge, Ag, In, Sn, Sb, Te, Hf, Ta, W, Re, Os, Ir, Pt, Au, and their combinations). The computational screening identifies compositions that achieve desirable voltage discharge and charge capacity using these more abundant, cost-effective elements, making the cathode materials easier and cheaper to manufacture

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

These new cathode materials exhibit reduced volume change, enhanced ion diffusion, and potentially shorter charging times, while also avoiding the use of costly elements like cobalt, thus reducing development costs and time.

Implementation Method 1

cations migrating from an anode and through an electrolyte electrochemically react with electrons arriving at the cathode via an external circuit

Methodology Applied
Scientific EffectCation migration: Ion Exchange

Implementation Method 2

cations migrating from an anode and through an electrolyte electrochemically react with electrons arriving at the cathode via an external circuit

Methodology Applied
Scientific EffectElectrochemical reaction: Redox Reactions

Implementation Method 3

enhanced ion diffusion

Methodology Applied
Scientific EffectIon diffusion: Diffusion

Data Source

PatentUS20250174649A1Disordered rock-salt battery cathode composition and syntheses thereof
Publication Date: 2025.05.29 TOYOTA RESEARCH INSTITUTE INC
  • US20250174649A1 patent drawing
  • US20250174649A1 patent drawing
  • US20250174649A1 patent drawing

AI summary

A cathode material has the chemical formula Li4+δMx1M′y1M″z1O8 or Li2+δMx2M′y2M″z2O4 where 0≤δ≤1, x1, y1, z1 are integers (+/−0.5) and x1+y1+z1=4, and x2, y2, z2 are integers (+/−0.05) and x2+y2+z2=2. A method for discovering a cathode material includes estimating synthesizability for a plurality of cathode material compositions, selecting a first subset of cathode material compositions from the plurality of cathode material compositions as a function of the estimated synthesizability and metal-ion diffusion availability, estimating voltage discharge, charge capacity, and oxygen stability for the first subset of cathode material compositions, and selecting a second subset of cathode material compositions from the first subset plurality of cathode material compositions as a function of the estimated voltage discharge, charge capacity, and oxygen stability.