O2-Like Electrode Active Material for High-Potential Capacity

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Solution Overview

Problem

The existing electrode active materials with an O2-like structure have a limited ratio of capacity at high potentials to the total capacity, necessitating improvements for enhanced energy density.

Innovation Solution

The development of an electrode active material with specific O2-like structures, such as O2-type, T#2-type, and O6-type, featuring crystallite sizes between 400 Å and 1000 Å, and a chemical composition of LiaNabNix−pCoy−qMnz−rMp+q+rO2, where 0<a<1.00, 0≤b≤0.20, 0.15<x<0.35, 0.15<y<0.45, 0.25<z<0.55, x+y+z=1, and 0≤p+q+r<0.17, which includes elements like Li, O, Ni, Mn, and Co, and optionally B, Mg, Al, K, Ca, Ti, V, Cr, Fe, Cu, Zn, Ga, Ge, Sr, Y, Zr, Nb, Mo, and W, to optimize crystallite size and composition for improved performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the electrode active material has an O2-like structure obtained by ion exchange of Na into Li, then the material exhibits good electrochemical performance, but the ratio of capacity at high potential to total capacity is insufficient

Engineering Contradiction:
Improveelectrochemical performanceVSAvoidcapacity ratio at high potential
Core Design Contradiction:
ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent applies parameter changes by precisely controlling the crystallite size parameter within 400-1000 Å range and adjusting the chemical composition parameters (a, b, x, y, z, p, q, r) to optimize the electrode material's performance. This resolves the contradiction by finding the optimal parameter combination that achieves both good electrochemical performance and high capacity ratio at high potential.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent uses composite materials by combining multiple elements (Li, O, Ni, Mn, Co and optional B, Mg, Al, K, Ca, Ti, V, Cr, Fe, Cu, Zn, Ga, Ge, Sr, Y, Zr, Nb, Mo, W) in specific proportions to create a composite oxide with enhanced properties. This composite approach allows simultaneous achievement of structural stability and high high-potential capacity ratio.

Inventive Principle:
Principle #40Composite materials

2Use of energy by moving object

If the crystallite size is increased to improve high potential capacity ratio, then the capacity at high potential increases, but the material may lose structural stability

Engineering Contradiction:
Improvecapacity at high potentialVSAvoidstructural stability
Core Design Contradiction:
Use of energy by moving objectVSStability of the object's composition

Solution Approach 1:

The patent resolves this contradiction by establishing a specific parameter range for crystallite size (400-1000 Å) that balances both high potential capacity and structural stability. This optimized parameter range prevents excessive grain growth that would compromise stability while maintaining sufficient size for high capacity performance.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent applies local quality by creating a controlled distribution of crystallite sizes within the specified range, ensuring that different regions of the material have appropriate local structures. This localized optimization maintains structural stability while enabling high potential capacity in active regions.

Inventive Principle:
Principle #3Local quality

3Reliability

If the ion exchange process is used to convert Na-containing oxide to Li-containing oxide, then the material achieves O2-like structure, but the manufacturing complexity increases

Engineering Contradiction:
ImproveO2-like structure formationVSAvoidmanufacturing process complexity
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by first preparing the Na-containing oxide with the desired chemical composition and then performing the ion exchange process. This sequential approach, where the precursor is prepared in advance with controlled composition, simplifies the overall manufacturing process while ensuring the formation of the O2-like structure.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent resolves manufacturing complexity by optimizing the ion exchange parameters (temperature, time, Li source concentration) to achieve complete Na-to-Li conversion efficiently. This parameter optimization reduces process complexity and improves manufacturability while maintaining structural integrity.

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

The proposed electrode active material significantly increases the ratio of capacity at high potentials to the total capacity, enhancing energy density and providing improved rate characteristics and reversible capacity.

Implementation Method 1

the electrode active material having the O2-like structure is obtained by the ion exchange of at least some of Na in a Na-containing oxide having a P2-type structure into Li

Methodology Applied
Scientific EffectIon exchange: Ion Exchange

Implementation Method 2

a crystallite size of the O2-like structure is 400 Å or more and 1000 Å or less, the crystallite size being measured by XRD

Methodology Applied
Scientific EffectX-ray diffraction: X-Ray

Data Source

PatentUS20250364551A1Electrode active material
Publication Date: 2025.11.27 TOYOTA JIDOSHA KK
  • US20250364551A1 patent drawing
  • US20250364551A1 patent drawing
  • US20250364551A1 patent drawing

AI summary

An electrode active material in the present disclosure has at least one O2-like structure selected from among of an O2-type structure, a T#2-type structure, and an O6-type structure. The crystallite size of the O2-like structure that is measured by XRD is 400 Å or more and 1000 Å or less.