Lithium Nickelate Particles Coating for Cycle Stability

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Solution Overview

Problem

Current lithium nickelate-based positive electrode active substance particles face challenges in maintaining high repeated charge/discharge cycle characteristics and preventing gas generation under high-temperature conditions due to high contents of lithium hydroxide and lithium carbonate impurities, which also make mass production costly and inefficient.

Innovation Solution

The development of lithium nickelate-based positive electrode active substance particles with a coating compound comprising Al, Mg, Zr, Ti, or Si, and a lithium-containing coating compound, produced using a vapor phase epitaxy method and humidification followed by heat treatment, to reduce impurity content and enhance stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If conventional lithium nickelate-based positive electrode active substance particles are used, then high output characteristics are achieved, but repeated charge/discharge cycle characteristics deteriorate at high voltage and gases are generated upon storage under high-temperature conditions

Engineering Contradiction:
Improveoutput characteristicsVSAvoidrepeated charge/discharge cycle characteristics
Core Design Contradiction:
PowerVSReliability

Solution Approach 1:

The patent applies composite materials by forming a coating layer on the lithium nickelate particles that contains both an aluminum-containing compound (Al2O3, Al(OH)3, or aluminum carbonate) and a lithium-containing compound (Li2CO3, LiOH, or Li2O). This composite coating structure prevents ion elution and maintains structural stability during charge/discharge cycles, thereby improving repeated cycle characteristics at high voltage while preserving the high output characteristics of the lithium nickelate core material.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by creating a coating layer with specific local composition and structure on the surface of the lithium nickelate particles. The coating layer has different chemical properties than the core material, with aluminum and lithium compounds concentrated at the surface to prevent ion elution locally, while the interior lithium nickelate maintains its high output characteristics. This localized modification resolves the contradiction between power and reliability.

Inventive Principle:
Principle #3Local quality

2Power

If conventional lithium nickelate-based positive electrode active substance particles are used, then high output characteristics are achieved, but gas generation occurs upon storage under high-temperature conditions

Engineering Contradiction:
Improveoutput characteristicsVSAvoidgas generation
Core Design Contradiction:
PowerVSObject-generated harmful factors

Solution Approach 1:

The patent uses composite materials in the coating layer containing both aluminum-containing compounds and lithium-containing compounds. This composite structure suppresses gas generation during high-temperature storage by preventing constitutional ion elution and stabilizing the particle structure, while the lithium nickelate core maintains its high output characteristics.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent converts the potentially harmful effect of high-temperature storage (which causes gas generation through ion elution) into a beneficial outcome by using the coating layer to prevent ion loss. The aluminum-containing compound forms a stable surface structure that resists thermal degradation, turning the high-temperature condition from harmful to manageable, while preserving the high output characteristics.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If conventional production methods are used, then production cost is reduced, but manufacturing precision and productivity are insufficient due to incomplete reaction and high impurity content

Engineering Contradiction:
Improveproduction costVSAvoidimpurity content
Core Design Contradiction:
Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by conducting the reaction in a sealed atmosphere-pressure container that maintains high pressure and temperature conditions throughout the reaction process. This preliminary setup ensures complete reaction between raw materials, preventing the formation of unreacted impurities such as lithium carbonate and lithium hydroxide, while keeping the process economically viable through a single-step synthesis method.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent applies parameter changes by conducting the reaction under elevated pressure and temperature conditions in a sealed container. These changed parameters (higher pressure and temperature) ensure complete reaction and high purity product formation, while the sealed container design maintains ease of manufacture by enabling a single-step process that produces particles with controlled size distribution and minimal impurities.

Inventive Principle:
Principle #35Parameter changes

4Ease of manufacture

If conventional production methods are used, then production cost is reduced, but productivity is insufficient due to incomplete reaction

Engineering Contradiction:
Improveproduction costVSAvoidreaction completeness
Core Design Contradiction:
Ease of manufactureVSProductivity

Solution Approach 1:

The patent applies preliminary action by pre-setting the sealed atmosphere-pressure container conditions before initiating the reaction. The high pressure and temperature environment is established beforehand to ensure complete reaction kinetics, allowing the synthesis to proceed to completion in a single step without requiring additional processing stages, thereby improving productivity while maintaining ease of manufacture.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent applies parameter changes by utilizing elevated pressure and temperature conditions in the sealed container to accelerate and complete the reaction. These parameter changes ensure that the reaction goes to completion, maximizing productivity by eliminating unreacted materials and reducing the need for reprocessing, while the sealed container design keeps the manufacturing process simple and cost-effective.

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 solution effectively inhibits side reactions with the electrolyte, reduces gelation of electrode slurry, and suppresses gas generation, resulting in a non-aqueous electrolyte secondary battery with improved high-voltage cycle performance and extended service life.

Implementation Method 1

forming the coating compound Y on a surface of the core particle X by a vapor phase epitaxy method

Methodology Applied
Scientific EffectVapor phase epitaxy: Epitaxy

Implementation Method 2

subjecting the resulting particle to humidification treatment and heat treatment in atmospheric air

Methodology Applied
Scientific EffectHumidification: Absorption (physical)

Implementation Method 3

subjecting the resulting particle to humidification treatment and heat treatment in atmospheric air at a temperature of 150 to 450° C.

Methodology Applied
Scientific EffectHeat treatment: Heat Treatment

Data Source

PatentUS11552292B2Lithium nickelate-based positive electrode active substance particles and process for producing the same, and non-aqueous electrolyte secondary battery
Publication Date: 2023.01.10 BASF SE
  • US11552292B2 patent drawing
  • US11552292B2 patent drawing
  • US11552292B2 patent drawing

AI summary

The present invention provides lithium nickelate-based positive electrode active substance particles having a high energy density which are excellent in charge/discharge cycle characteristics when highly charged, and hardly suffer from generation of gases upon storage under high-temperature conditions, and a process for producing the positive electrode active substance particles, as well as a non-aqueous electrolyte secondary battery. The present invention relates to positive electrode active substance particles each comprising a core particle X comprising a lithium nickelate composite oxide having a layer structure which is represented by the formula: Li1+aNi1−b−cCobMcO2 wherein M is at least one element selected from the group consisting of Mn, Al, B, Mg, Ti, Sn, Zn and Zr; a is a number of −0.1 to 0.2 (−0.1•a•0.2); b is a number of 0.05 to 0.5 (0.05•b•0.5); and c is a number of 0.01 to 0.4 (0.01•c•0.4); a coating compound Y comprising at least one element selected from the group consisting of Al, Mg, Zr, Ti and Si; and a coating compound Z comprising an Li element, in which a content of lithium hydroxide LiOH in the positive electrode active substance particles is not more than 0.40% by weight, a content of lithium carbonate Li2CO3 in the positive electrode active substance particles is not more than 0.65% by weight, and a weight ratio of the content of lithium carbonate to the content of lithium hydroxide is not less than 1.