Single-Crystal Cathode Material Processing for Uniform Li Battery Particles

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Solution Overview

Problem

Existing methods for manufacturing lithium secondary battery cathode active materials face challenges in achieving sufficient operational stability and reliability due to process difficulties and increased polycrystalline particle ratios, which affect the life-span properties and efficiency.

Innovation Solution

A method involving mixing a transition metal macro precursor and a lithium precursor to form a preliminary composite oxide particle, followed by calcination and pulverization to create lithium-transition metal composite oxide particles with a controlled average diameter of 1 to 3 μm, forming a single crystal structure, and optionally coating with metal salts for enhanced stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If single crystal structure cathode active material particles are prepared, then energy density per volume and structural stability are improved, but process difficulty increases and polycrystalline particle ratio increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidprocess difficulty

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by using a transition metal macro precursor with a predetermined large particle size (7 μm or more) and specific BET surface area (3 to 11 m2/g) before the calcination process. This preliminary preparation of the precursor with optimized physical properties enables the subsequent formation of single crystal particles with reduced process difficulty and lower polycrystalline content, directly resolving the technical contradiction between structural stability and ease of manufacture.

Inventive Principle:

Principle #10Preliminary action

2Volume of moving object

If minute-sized single crystal particles are prepared, then energy density per volume is improved, but process efficiency decreases

Engineering Contradiction:

Improveenergy density per volumeVSAvoidprocess efficiency

Core Design Contradiction:

Volume of moving objectVSProductivity

Solution Approach 1:

The patent applies parameter changes by optimizing the BET specific surface area of the transition metal macro precursor to a specific range (3 to 11 m2/g) and controlling its particle size (7 μm or more). These parameter optimizations enable the calcination process to efficiently form minute-sized single crystal particles with high energy density while maintaining high process efficiency, resolving the contradiction between energy density per volume and productivity.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If existing manufacturing methods are used, then cathode active material is produced, but life-span properties and operational stability are insufficient

Engineering Contradiction:

Improveoperational stabilityVSAvoidlife-span properties

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The patent applies preliminary action by preparing a transition metal macro precursor with specifically optimized physical properties (particle size of 7 μm or more and BET surface area of 3 to 11 m2/g) before calcination. This preliminary optimization of the precursor enables the formation of cathode active material with enhanced single crystal structure and reduced polycrystalline content, directly improving both operational stability and life-span properties that were insufficient in existing methods.

Inventive Principle:

Principle #10Preliminary action

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 process reduces process difficulty, enhances efficiency, and improves the life-span and operational stability of the lithium secondary battery by ensuring uniform particle size and mechanical stability, thereby increasing energy density and reducing gas generation.

Implementation Method 1

calcining the preliminary lithium-transition metal composite oxide particle

Methodology Applied

Scientific EffectCalcination: Heat Treatment

Implementation Method 2

pulverizing the calcined preliminary lithium-transition metal composite oxide particle to form lithium-transition metal composite oxide particle

Methodology Applied

Scientific EffectPulverization: Mechanical Force

Data Source

PatentUS12592383B2Method of manufacturing cathode active material for lithium secondary battery

Publication Date: 2026.03.31 SK ON CO LTD

AI summary

Provided is a method of manufacturing a cathode active material for a lithium secondary battery. The method of manufacturing a cathode active material for a lithium secondary battery includes mixing a transition metal macro precursor and a lithium precursor to prepare a preliminary lithium-transition metal composite oxide particle; calcining the prepared preliminary lithium-transition metal composite oxide particle; and pulverizing the calcined preliminary lithium-transition metal composite oxide particle to form lithium-transition metal composite oxide particle. Accordingly, the process may be easily performed and a single crystal cathode active material having a uniform size may be manufactured.