Lithium-Excess Cathode Core-Shell Gradient for High-Rate Capability

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Solution Overview

Problem

Current non-aqueous electrolyte secondary batteries face limitations in high-rate capability, cycle performance, and energy density due to the poor lithium diffusion rates and structural incompatibilities in existing positive electrode active materials, particularly lithium-excess lithium-transition metal composite oxides.

Innovation Solution

A positive electrode active material with a layered structure inner portion and a surface adjacent portion having a gradually changing crystal structure from layered to spinel, maintaining identical Mn and M ratios, and a protective layer to prevent metal dissolution, is developed, along with a manufacturing method involving heat treatment with a reducing agent to enhance lithium diffusion and charge-discharge efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If the particle size of the positive electrode active material is reduced to decrease diffusion distance, then high-rate capability is improved, but packing density decreases and energy density decreases

Engineering Contradiction:
Improvelithium diffusion rateVSAvoidpacking density
Core Design Contradiction:
SpeedVSQuantity of substance

Solution Approach 1:

The patent applies local quality by creating a core-shell structure where the inner core region maintains a layered structure for high capacity while the outer shell region transforms to a spinel structure for improved kinetics. This spatial differentiation allows different regions of the particle to serve different functions: the core provides lithium storage capacity while the shell facilitates rapid lithium diffusion, thereby resolving the contradiction between particle size reduction and packing density maintenance.

Inventive Principle:
Principle #3Local quality

2Productivity

If the particle size is reduced to improve high-rate capability, then lithium diffusion rate increases, but the energy density decreases due to lower packing density

Engineering Contradiction:
Improvehigh-rate capabilityVSAvoidenergy density
Core Design Contradiction:
ProductivityVSUse of energy by moving object

Solution Approach 1:

The invention implements local quality by spatially differentiating the crystal structure within the particle: the inner core retains the layered structure optimized for capacity, while the outer shell transforms to spinel structure optimized for rate capability. This allows the particle to simultaneously achieve high energy density (from the core) and high power density (from the shell), resolving the contradiction between productivity and energy usage.

Inventive Principle:
Principle #3Local quality

3Stability of the object's composition

If a boundary forms between layered structure and spinel structure, then structural compatibility is achieved, but lithium diffusion is limited

Engineering Contradiction:
Improvestructural compatibilityVSAvoidlithium diffusion rate
Core Design Contradiction:
Stability of the object's compositionVSSpeed

Solution Approach 1:

The patent applies preliminary action by pre-forming a gradient transition layer during the heat treatment process, where the crystal structure gradually changes from layered in the core to spinel in the shell. This gradual transition, rather than an abrupt boundary, is prepared in advance to facilitate continuous lithium diffusion pathways, thereby maintaining both structural compatibility and high lithium diffusion rates.

Inventive Principle:
Principle #10Preliminary action

4Ease of operation

If acid treatment is used to modify the surface, then initial charge-discharge efficiency is improved, but cycle performance deteriorates due to surface damage

Engineering Contradiction:
Improveinitial charge-discharge efficiencyVSAvoidcycle performance
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The invention applies parameter changes by transforming the surface crystal structure from layered to spinel through controlled heat treatment with a reducing agent, rather than using acid treatment. This thermal-chemical transformation modifies surface properties to improve initial charge-discharge efficiency while maintaining structural integrity and stability, thereby avoiding the surface damage that would deteriorate cycle performance.

Inventive Principle:
Principle #35Parameter changes

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

This configuration significantly improves high-rate capability, charge-discharge efficiency, and discharge capacity while maintaining energy density, preventing the degradation issues associated with smaller particle sizes and high-temperature treatments.

Implementation Method 1

immersing particles of a lithium-excess lithium-transition metal composite oxide in an aqueous solution containing a first reducing agent... heat-treating the particles at a temperature within the range of from 200° C. to 500° C.

Methodology Applied
Scientific EffectReduction: Reduction

Implementation Method 2

the high-rate capability is affected by the lithium diffusion rate in the bulk and the smoothness of lithium insertion and deinsertion in the particle surface

Methodology Applied
Scientific EffectDiffusion: Diffusion

Data Source

PatentUS8557440B2Positive electrode active material including particle comprising crystal structure changing from a layered structure to a spinel structure, method of manufacturing the positive electrode active material, and non-aqueous electrolyte secondary battery using the positive electrode active material
Publication Date: 2013.10.15 PANASONIC ENERGY CO LTD
  • US8557440B2 patent drawing
  • US8557440B2 patent drawing
  • US8557440B2 patent drawing

AI summary

A positive electrode active material having a lithium-excess lithium-transition metal composite oxide particle represented by the chemical formula Li1.2Mn0.54Ni0.13Co0.13O2. The lithium-excess lithium-transition metal composite oxide particle has an inner portion (1) having a layered structure and a surface adjacent portion (2) having a crystal structure gradually changing from a layered structure to a spinel structure from the inner portion (1) toward the outermost surface portion (3). The layered structure and the spinel structure have an identical ratio of the amount of Mn and the total amount of Ni and Co.