Lithium Nickel Composite Oxide Cathode with Aluminum Gradient

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Solution Overview

Problem

Lithium nickel composite oxide cathode materials for lithium ion secondary batteries face challenges with low crystal stability, cycling characteristics, and thermal stability, which affect the durability and safety of batteries, especially for large-scale applications like hybrid and electric automobiles.

Innovation Solution

A cathode active material is developed using lithium nickel composite oxide with a specific composition and particle size distribution, where fine secondary particles with higher aluminum content are mixed with rough secondary particles, enhancing both safety and durability by stabilizing the crystal structure and maintaining high discharge capacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If lithium nickel composite oxide is used as cathode material to achieve high capacity and lower cost, then battery capacity and cost-effectiveness are improved, but crystal stability, cycling characteristics, and thermal stability deteriorate

Engineering Contradiction:
Improvebattery capacityVSAvoidcrystal stability
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The patent applies local quality by creating a core-shell structure where the center region contains lithium nickel composite oxide with high nickel content for high capacity, while the outer peripheral region contains lithium nickel composite oxide with lower nickel content and higher aluminum content for enhanced stability. This spatial differentiation of composition allows each region to fulfill its specific function: the core provides capacity while the shell provides stability and safety.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by combining lithium nickel composite oxide particles with different compositions to form a heterogeneous structure. The composite consists of inner core particles rich in nickel and outer shell particles rich in aluminum, creating a multi-component system that exhibits both high capacity (from nickel-rich core) and high stability (from aluminum-rich shell).

Inventive Principle:
Principle #40Composite materials

2Duration of action of stationary object

If additional elements are added to improve durability, then cycling characteristics are improved, but capacity retention after long-term use still deteriorates

Engineering Contradiction:
Improvecycling characteristicsVSAvoidcapacity retention
Core Design Contradiction:
Duration of action of stationary objectVSReliability

Solution Approach 1:

The patent applies local quality by concentrating aluminum addition in the outer peripheral region rather than uniformly distributing it throughout the particle. This localized aluminum enrichment at the surface specifically addresses the interface between electrode material and electrolyte, where degradation occurs most, thereby improving cycling characteristics while preserving the high-capacity nickel-rich core.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent applies preliminary action by pre-forming the core-shell structure with stabilized outer layers before battery assembly and use. The aluminum-rich outer region acts as a pre-established protective barrier that prevents degradation mechanisms from affecting the inner high-capacity core during cycling, thereby maintaining capacity retention over long-term use.

Inventive Principle:
Principle #10Preliminary action

3Object-affected harmful factors

If aluminum content is increased to improve safety, then thermal stability is improved, but discharge capacity deteriorates

Engineering Contradiction:
Improvethermal stabilityVSAvoiddischarge capacity
Core Design Contradiction:
Object-affected harmful factorsVSQuantity of substance

Solution Approach 1:

The patent applies local quality by restricting high aluminum content to the outer peripheral region of the particle, where it provides thermal stability and safety without significantly impacting the overall discharge capacity. The inner core maintains high nickel content for high capacity, while the outer shell provides safety functions, thus resolving the contradiction between safety and capacity.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by creating a heterogeneous particle structure where aluminum-rich phases are combined with nickel-rich phases in specific spatial arrangements. The aluminum-containing outer shell provides thermal stability while the nickel-containing core provides discharge capacity, allowing the composite particle to exhibit both properties simultaneously.

Inventive Principle:
Principle #40Composite materials

4Ease of manufacture

If uniform concentration of added elements is used to simplify manufacturing, then manufacturing process is simplified, but cycling characteristics and safety deteriorate

Engineering Contradiction:
Improvemanufacturing processVSAvoidcycling characteristics
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent applies local quality by implementing a controlled concentration gradient of aluminum from the particle center to the surface, with higher aluminum content at the periphery. This non-uniform distribution is achieved through controlled precipitation processes during manufacturing, creating a core-shell structure that improves cycling characteristics and safety while using relatively simple wet chemistry methods.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent applies parameter changes by systematically varying the aluminum concentration as a function of radial position within the particle. The aluminum content increases from the center toward the surface, creating a gradient that optimizes both performance and stability. This parameter variation is controlled through precipitation conditions such as pH gradients or sequential addition of precursors.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS10629891B2Cathode active material for non-aqueous electrolyte secondary battery, manufacturing method thereof, and non-aqueous electrolyte secondary battery
Publication Date: 2020.04.21 SUMITOMO METAL MINING CO LTD

AI summary

A non-aqueous electrolyte secondary battery is provided that has both good safety and durability characteristics while at the same time has high charge/discharge capacity. The cathode active material for a non-aqueous electrolyte secondary battery of the present invention is a lithium nickel composite oxide to which at least two or more kinds of metal elements including aluminum are added, and comprises secondary particles that are composed of fine secondary particles having an average particle size of 2μm to 4 μm, and rough secondary particles having an average particle size of 6 μm to 15 μm, with an overall average particle size of 5 μm to 15 μm; where the aluminum content of fine secondary particles (metal mole ratio: SA) is greater than the aluminum content of rough secondary particles (metal mole ratio: LA), and preferably the aluminum concentration ratio (SA/LA) is within the range 1.2 to 2.6.