Pre-Lithiated Cathode Coatings to Prevent Irreversible Lithium Loss

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Solution Overview

Problem

Conventional lithium-ion batteries face issues with irreversible lithium loss and inefficient cycling performance due to in-situ lithiation of cathode active materials, leading to reduced initial cycle efficiency and limited control over coating composition and morphology.

Innovation Solution

Development of pre-lithiated coated cathode active materials with an amorphous lithiated coating, formed through a controlled lithiation process, which includes a core of cathode active materials like lithium cobalt oxides or lithium iron phosphates, coated with lithiated metal oxides, metal halides, or sulfur-based materials, allowing for improved cycling performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If in-situ lithiation is used to form coating on cathode active materials, then lithium ions can be incorporated into the materials during battery operation, but irreversible lithium loss occurs and initial cycle efficiency is reduced

Engineering Contradiction:

Improvecycling performanceVSAvoidlithium loss

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent applies preliminary action by pre-forming the lithiated coating on cathode active materials before battery assembly through wet chemical coating processes. This allows the coating to be lithiated in advance under controlled conditions, preventing irreversible lithium loss during initial battery cycling while maintaining improved cycling performance throughout battery operation.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If wet chemical coating processes are used to form coatings on cathode active materials, then coating composition and morphology can be controlled, but the lithiated product results in irreversible lithium loss

Engineering Contradiction:

Improvecoating composition and morphology controlVSAvoidlithium loss

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent performs the lithiation action in advance during the coating formation process itself, using wet chemical coating methods to deposit precursor materials that are then lithiated before battery assembly. This preliminary lithiation enables precise control over coating composition and morphology while avoiding subsequent lithium loss during battery operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes parameter changes by controlling the chemical composition, pH, and processing conditions of wet chemical coating solutions to achieve desired coating morphology and composition. By adjusting these parameters during the coating process, the patent optimizes both the structural properties of the coating and its lithiation characteristics.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If conventional coating methods are used on cathode active materials, then some performance enhancement is achieved, but cycling performance remains insufficient

Engineering Contradiction:

Improveperformance enhancementVSAvoidcycling performance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies composite materials by combining cathode active materials with lithiated coating layers formed through wet chemical processes. This composite structure integrates the core cathode material with a functional lithiated coating that enhances both productivity (performance) and reliability (cycling performance) simultaneously.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent achieves improved cycling performance by changing the chemical and structural parameters of the coating through controlled lithiation. The lithiated coating exhibits modified electrochemical properties compared to non-lithiated coatings, enabling superior cycling stability and performance enhancement.

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 pre-lithiated coatings enhance cycling performance and enable efficient production of coated cathode active materials, providing stable and controlled lithiation without irreversible lithium loss.

Implementation Method 1

with such in-situ formation the lithiated product can be a lithiated organic compound which results in irreversible loss of lithium in formation and cycling

Methodology Applied

Scientific EffectLithiation:

Implementation Method 2

The lithiated coating has a portion having amorphous morphology

Methodology Applied

Scientific EffectAmorphous morphology:

Implementation Method 3

During cell operation, materials in the cathode can become lithiated (i.e., lithium can be incorporated into such materials)

Methodology Applied

Scientific EffectIon incorporation:

Data Source

PatentUS20250323244A1Pre-lithiated coated cathode active materials, a method of making such cathode active materials, and batteries including such cathode active materials

Publication Date: 2025.10.16 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A powder includes particles of having a core of cathode active material bearing a coating of an amorphous lithiated material. The powder can be prepared by providing a dispersion of particles having the core and a non-lithiated coating in the presence of a lithium source, applying a voltage or a current across the dispersion or applying a current across a lithiated amorphous region in the coating, and recovering the particles having the lithiated coating in a solid powder form. Batteries including such particles can have good cycling performance.