Cathode active material and manufacturing method thereof

Abstract

The present invention relates to a cathode active material for a secondary battery and a preparation method thereof, and more particularly, to a lithium composite oxide including a secondary particle formed as primary particles cohere, in which a manganese (Mn) oxide is present in the periphery of the primary particles, a concentration of an Mn oxide in the primary particle has a concentration gradient from the center of the primary particle to a surface of the particle, a concentration of an Mn oxide in the secondary particle has a concentration gradient from a surface of the secondary particle to the center thereof, and a lithium ion migration path is formed in the primary particle, and a preparation method thereof. A secondary battery including the cathode active material for a secondary battery may have high safety, while exhibiting high capacity and high output.

Claims

1. A cathode active material for a secondary battery, the cathode active material comprising: a secondary particle formed as a plurality of primary particles cohere and including a manganese oxide on a surface portion of each of the primary particles, wherein a Mn concentration at the surface portion of the primary particle is higher than a Mn concentration inside the primary particle, and wherein the cathode active material is represented by Chemical Formula 1 below:
Li.sub.1+aNi.sub.1(x+y+z)Co.sub.xAl.sub.yMn.sub.zM1.sub.bO.sub.2[Chemical Formula 1] where 0<x0.1, 0y0.02, 0<z0.0006, 0a0.1, 0b0.1 and M1 is one or more elements selected from the group consisting of Al, Ni, Mn, Cr, Fe, Mg, Sr, V, Zn, W, Zr, B, Ba, Sc, Cu, Ti, Co, a rare earth element, and combinations thereof.

2. The cathode active material of claim 1, wherein a manganese (Mn) oxide is present between the primary particles inside the secondary particle.

3. The cathode active material of claim 1, wherein the Mn concentration of the primary particle has a gradient from a central portion to the surface portion of the primary particle.

4. The cathode active material of claim 1, wherein the Mn oxide is selected from the group consisting of Li.sub.2MnO.sub.3, LiMn.sub.2O.sub.4, MnO.sub.2, Li.sub.w, Mn.sub.2O.sub.4 (0<w<1), and Li.sub.2MnO.sub.3(1v)LiMn.sub.2O.sub.4(0<v<1).

5. The cathode active material of claim 1, wherein the Mn oxide is present within 1 m from the surface of the secondary particle.

6. The cathode active material of claim 1, wherein the cathode active material has peaks at positions of (020), (003), (101), (006), (102), (104), (005), (009), (107), (018), (110), and (113) when XRD-analyzed.

7. The cathode active material of claim 1, wherein the cathode active material has the peak (020) based on Li.sub.2MnO.sub.3 between 2=20 and 21 when XRD-analyzed.

8. The cathode active material of claim 1, wherein the cathode active material has a peak of Li.sub.1xMn.sub.2O.sub.4 between 2=36 and 38, between 44 and 45, and between 65 and 66, when XRD-analyzed, where 0<x<1.

9. The cathode active material of claim 1, wherein a peak intensity increase rate at the position (104) of the cathode active material when XRD-analyzed after charging is 3% or less, as compared with XRD analysis before charging.

10. The cathode active material of claim 1, wherein the cathode active material includes a lithium ion migration path arranged toward the center of the secondary particle in the primary particle.

11. A secondary battery including the cathode active material for a secondary battery according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above and other aspects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

(2) FIGS. 1 and 2 illustrate results of measuring metal concentrations of a cathode active material of a secondary battery prepared according to an embodiment of the present invention by an energy dispersive X-Ray spectroscopy (EDX).

(3) FIG. 3 illustrates results of measuring a metal concentration from a surface of particles to the center thereof in a cathode active material for a secondary battery according to an embodiment of the present invention.

(4) FIG. 4 illustrates results of measuring a metal concentration from a surface of particles the center thereof in a cathode active material for a secondary battery according to an embodiment of the present invention.

(5) FIGS. 5 and 6 illustrate results of measuring a metal concentration from a surface of a secondary particle to the center thereof and from a boundary between primary particles to the inside of the primary particles in a cathode active material for a secondary battery according to an embodiment of the present invention.

(6) FIGS. 7 and 8 illustrate results of XRD measurements of a cathode active material for a secondary battery according to an embodiment of the present invention.

(7) FIG. 9 illustrates results of checking diffusion paths of lithium ions present at various positions of primary particles in a cathode active material for a secondary battery according to an embodiment of the present invention.

(8) FIG. 10 is a graph illustrating an initial capacity of a battery manufactured using a cathode active material for a secondary battery according to an embodiment of the present invention.

(9) FIG. 11 is a graph illustrating a life time of a battery manufactured using a cathode active material for a secondary battery according to an embodiment of the present invention checked at room temperature (25 C.) (A) or high temperature (45 C.) (B).

(10) FIGS. 12 and 13 are graphs illustrating results of charge/discharge characteristics after a battery manufactured using a cathode active material for a secondary battery according to an embodiment of the present invention is charged and discharged for one time (A) and 50 times (B) at room temperature (25 C.).

(11) FIG. 14 illustrates results of X-ray diffraction (XRD) measurement of a cathode active material for a secondary battery according to an inventive example of the present invention and a comparative example 50 times before and after charging and discharging.

(12) FIG. 15 is a schematic diagram illustrating cation migration generated due to charge and discharge in a layered type secondary battery.

(13) FIG. 16 are graphs illustrating the XPS of a secondary battery including a cathode active material for a secondary battery according to an inventive example (A) of the present invention and a comparative example (B) after 50 times of charging and discharging.

(14) FIG. 17 illustrates results of measurement of LiF in particles in a cathode active material for a secondary battery according to an embodiment of the present invention before and after 50 times of charging and discharging.

DETAILED DESCRIPTION

(15) Hereinafter, the present invention will be described in detail by the following embodiments. However, the following embodiments are merely illustrative and are not intended to limit the scope of the present invention. Any concept having substantially the same constitution and achieving the same operational effect as those of technical concept described in the claims of the present invention is included in the scope of the present invention.

Inventive Example 1. Preparation of Lithium Composite Oxide

(16) A precursor represented by Ni0.98Co0.02(OH)2 was prepared by co-precipitation reaction. LiOH as a lithium compound and 1.4 mol of Al2O3 as an aluminum compound were added to the prepared precursor and heat-treated to prepare a cathode active material for a lithium secondary battery.

(17) The prepared composite metal compound was rinsed with a washing solution containing 0.01 mol % of Mn and dried under the condition of 150 C. and 400 mmHg for 5 hours to prepare a cathode active material for a secondary battery represented by Li.sub.1.01Ni.sub.0.913CO.sub.0.07Al.sub.0.014Mn.sub.0.0001O.sub.2.

Inventive Example 2

(18) A cathode active material for a secondary battery represented by Chemical Formula of Li.sub.1.01Ni.sub.0.912C.sub.0.07Al.sub.0.014Mn.sub.0.0002O.sub.2 was prepared under the same conditions and by the same method as those of Inventive Example 1, except that the prepared composite metal compound was rinsed with a washing solution containing 0.02 mol % of Mn.

Inventive Example 3

(19) A cathode active material for a secondary battery represented by Chemical Formula of Li.sub.1.01Ni.sub.0.911Co.sub.0.07Al.sub.0.014Mn.sub.0.0003O.sub.2 was prepared under the same conditions and by the same method as those of Inventive Example 1, except that the prepared composite metal compound was rinsed with a washing solution containing 0.03 mol % of Mn.

Inventive Example 4

(20) A cathode active material for a secondary battery represented by Chemical Formula of Li.sub.1.01Ni.sub.0.911Co.sub.0.07Al.sub.0.014Mn.sub.0.0003O.sub.2 was prepared under the same conditions and by the same method as those of Inventive Example 1, except that the prepared composite metal compound was rinsed with a washing solution containing 0.04 mol % of Mn.

Inventive Example 5

(21) A cathode active material for a secondary battery represented by Chemical Formula of Li.sub.1.01Ni.sub.0.909Co.sub.0.07Al.sub.0.014Mn.sub.0.0005O.sub.2 was prepared under the same conditions and by the same method as those of Inventive Example 1, except that the prepared composite metal compound was rinsed with a washing solution containing 0.05 mol % of Mn.

Inventive Example 6

(22) A cathode active material for a secondary battery represented by Chemical Formula of Li.sub.1.01Ni.sub.0.908Co.sub.0.07Al.sub.0.014Mn.sub.0.0006O.sub.2 was prepared under the same conditions and by the same method as those of Inventive Example 1, except that the prepared composite metal compound was rinsed with a washing solution containing 0.06 mol % of Mn.

Comparative Example 1. Preparation of a Lithium Composite Oxide not Rinsed with Manganese

(23) A lithium composite oxide represented by Chemical Formula Li.sub.1.01Ni.sub.0.914Co.sub.0.07Al.sub.0.014O.sub.2 was prepared under the same conditions and by the same method as those of Inventive Example 1, except that it was immersed in a manganese-containing solution for rinsing.

(24) TABLE-US-00001 TABLE 1 Classification Empirical Formula Comparative Example 1 Li.sub.1.01Ni.sub.0.914Co.sub.0.07Al.sub.0.014O.sub.2 Inventive Example 1 Li.sub.1.01Ni.sub.0.913Co.sub.0.07Al.sub.0.014Mn.sub.0.0001O.sub.2 Inventive Example 2 Li.sub.1.01Ni.sub.0.912Co.sub.0.07Al.sub.0.014Mn.sub.0.0002O.sub.2 Inventive Example 3 Li.sub.1.01Ni.sub.0.911Co.sub.0.07Al.sub.0.014Mn.sub.0.0003O.sub.2 Inventive Example 4 Li.sub.1.01Ni.sub.0.91Co.sub.0.07Al.sub.0.014Mn.sub.0.0004O.sub.2 Inventive Example 5 Li.sub.1.01Ni.sub.0.909Co.sub.0.07Al.sub.0.014Mn.sub.0.0005O.sub.2 Inventive Example 6 Li.sub.1.01Ni.sub.0.908Co.sub.0.07Al.sub.0.014Mn.sub.0.006O.sub.2

<Experimental Example> EDX Measurement

(25) Concentrations of metals of the cathode active materials prepared in the above inventive examples were measured by an energy dispersive spectrometer (EDX) by varying measurement ratios and results thereof are illustrated in FIGS. 1 and 2.

(26) In FIG. 1, in the case of the cathode active material of the present invention, which was rinsed with the Mn-containing solution, Mn was present on the surface of the secondary particle, and in FIG. 2 illustrating the cathode active material measured at an increased measurement ratio, it can be seen that Mn was present even in the boundaries between the primary particles present on the surface of the secondary particle.

<Experimental Example> Measurement of Metal Concentration in Particle

(27) Changes in the concentrations of manganese, cobalt, nickel, and aluminum of the cathode active material for a secondary battery of Inventive Example 4 were checked from the surface of the secondary particle to the center of the secondary particle on the basis of TEM measurement results, and results thereof are illustrated in FIG. 3.

(28) In FIG. 3, it can be seen that manganese was largely positioned within 1 m from the surface of the secondary particle, has a maximum concentration of 5 wt % or less, and has a concentration gradient decreased from the surface to the center.

(29) Weight percent (wt %) and atomic percent (at %) of manganese, cobalt, nickel, and aluminum in the TEM measurement range were measured and illustrated in Table 2 and FIG. 4.

(30) TABLE-US-00002 TABLE 2 Element Weight percent (wt %) Atom percent (at %) Nickel 91.35 90.98 Cobalt 8.06 7.99 Aluminum 0.37 0.8 Manganese 0.21 0.22 Total 100 100

<Experimental Example> Checking of Concentration Gradient of Mn

(31) Changes in the concentrations of nickel, cobalt, aluminum and manganese included in the cathode active material for a secondary battery of Inventive Example 4 were measured on the surface of the secondary particle (surface, line data 2) and in a portion (grain boundary, line data 6) in contact with a boundary between the primary particles inside the secondary particle, and results thereof are illustrated in FIGS. 5 and 6. FIG. 6 is an enlarged view illustrating a result of measuring a concentration gradient from a surface of the secondary particle to the inside of the particle in FIG. 5.

(32) In FIGS. 5 and 6, a concentration gradient appeared as the Mn concentration was decreased from the surface of secondary particle to the center thereof. Manganese was positioned within 1 m from the surface of secondary particle and was not detected from the inside of the secondary particle.

(33) As illustrated in FIG. 5, Mn was detected on the surface of the secondary particle and a boundary between the primary particles, i.e., a grain boundary. Mn was not detected from the inside of the primary particle, and a concentration gradient that the Mn concentration was decreased to the inside of the primary particle was observed.

<Experimental Example> XRD Measurement

(34) XRD measurement is made for the cathode active materials prepared in the above Inventive Examples and Comparative Example, and results thereof are illustrated in FIGS. 7 and 8.

(35) In FIG. 7, in the case of the cathode active material of the present invention treated with the Mn-containing solution according to the embodiment of the present invention, the XRD analysis showed that peaks appeared at positions of (020), (003), (101), (006), (102), (104), (005), (009), (107), (018), (110), and (113).

(36) In FIG. 8, in the case of the cathode active material of the present invention, it can be seen that the peak (020) based on Li2MnO3 appeared between 2=20 and 21 and the peak of Li1xMn2O4 appeared between 2=36 and 38, 44 and 45, and 65 and 66. That is, it was checked that, in the cathode active material coated with the manganese-containing solution according to the present invention, the manganese oxide exists in a spinel structure of Li2MnO3 and Li1xMn2O4 which are different from a crystal structure of the cathode active material.

<Experimental Example> Checking of Migration Path of Lithium Ion

(37) A diffusion path of lithium ions according to respective positions of the primary particles of the cathode active material for a secondary battery of Inventive Example 4 was checked from TEM measurement data and is illustrated in FIG. 9. In FIG. 9, A represents a surface position of the secondary particle, B represents a central position of the primary particle, and C represents a boundary between the primary particles in the secondary particle.

(38) In FIG. 9, it can be seen that, a lithium ion diffusion path is clearly present in the position B inside the particle and a crystal structure is distorted at lithium ion diffusion paths in the position A, the surface position of the secondary particle, and in the position C, which is a boundary between primary particles in the secondary particle.

(39) at the A position which is the surface position of the secondary particle and the C position which is the boundary between the primary particles in the secondary particle.

<Experimental Example> Measurement of Residual Lithium

(40) Residual lithium of the cathode active materials prepared in Inventive Examples 1 to 6 and the cathode active material prepared in Comparative Example were measured.

(41) Specifically, 1 g of a lithium composite oxide was immersed in 5 g of distilled water and stirred for 5 minutes. After stirring, the lithium composite oxide was filtered to obtain a filtrate, to which 0.1 M of a HCl solution was added so as to be titrated to have pH 5. Here, the volume of the added HCl solution was measured to analyze residual lithium of the used cathode active material, and results thereof are illustrated in Table 3 below.

(42) TABLE-US-00003 TABLE 3 Residual lithium (ppm) Classification LiOH Li.sub.2CO.sub.3 Total Comparative Example 1 2,641 3,198 5,839 Inventive Example 1 2,380 4,377 6,757 Inventive Example 2 2,529 2,207 4,736 Inventive Example 3 2,160 1,896 4,056 Inventive Example 4 1,901 1,945 3,846 Inventive Example 5 3,071 2,918 5,989 Inventive Example 6 2,951 3,174 6,125

<Manufacturing Example> Manufacturing of Battery

(43) Batteries were manufactured using the secondary battery cathode active materials prepared according to Inventive Examples 1 to 6 and Comparative Example 1.

(44) First, the secondary battery cathode active material, a super-P as a conductive material, and polyvinylidene fluoride (PVdF) as a binder were mixed at a weight ratio of 95:5:3 to prepare a slurry. The prepared slurry was uniformly applied to an aluminum foil having a thickness of 15 m and vacuum-dried at 135 C. to prepare a cathode for a lithium secondary battery.

(45) A coin battery was manufactured using the obtained cathode for a lithium secondary battery, a lithium foil as a counterpart electrode, a porous polyethylene film Celgard LLC., Celgard 2300) having a thickness of 25 m as a separator, and a solvent including LiPF6 having a concentration of 1.15 M as a liquid electrolyte and including a mixture of ethylene carbonate and ethylmethylcarbonate mixed in a volume ratio of 3:7.

<Experimental Example> Measurement of Battery CharacteristicsCapacity Characteristics

(46) Initial capacities of the batteries respectively including the cathode active materials of the present invention and the cathode active material of comparative example manufactured in Manufacturing Example were measured, and results thereof are illustrated in FIG. 10 and Table 4.

(47) TABLE-US-00004 TABLE 4 0.2 C Charge/discharge (3.0-4.3 V, 25 C.) Charge Discharge Efficiency Classification (mAh/g) (mAh/g) (%) Comparative Example 1 237.8 210.8 88.7 Inventive Example 1 239.5 212.8 88.9 Inventive Example 2 239.4 211.2 88.2 Inventive Example 3 241.1 212.1 88.0 Inventive Example 4 240.8 210.8 87.5 Inventive Example 5 241.9 209.6 86.6 Inventive Example 6 240.1 205.0 85.4

(48) As illustrated in FIG. 10 and Table 4, the batteries manufactured using the cathode active materials of the present invention have excellent charge/discharge efficiency.

<Experimental Example> Measurement of Battery CharacteristicsLife Characteristics

(49) Life characteristics of the coin batteries were measured at room temperature (25 C.) and high temperature (45 C.), and results thereof are illustrated in FIG. 11 and Table 5.

(50) TABLE-US-00005 TABLE 5 Maintaining Battery Life (50 times) Classification Room temperature (%) High temperature (%) Comparative Example 1 76.7 58.5 Inventive Example 1 78.1 66.3 Inventive Example 2 82.7 66.6 Inventive Example 3 82.9 72.0 Inventive Example 4 85.8 74.0 Inventive Example 5 78.5 56.8 Inventive Example 6 73.9 48.0

(51) As illustrated in FIG. 11 and Table 5, the batteries manufactured using the cathode active materials for a secondary battery according to the present invention had better life characteristics than the battery of Comparative Example 1. In particular, the batteries manufactured using the secondary battery cathode active materials of Inventive Examples 2 to 4 were excellent in the effect of maintaining the battery life at a high temperature, as well as at room temperature.

<Experimental Example> Measurement of Battery CharacteristicsHigh Temperature Charge/Discharge Characteristics

(52) Charge//discharge characteristics when the coin batteries were charged/discharged one time or 50 times were measured at room temperature (25 C.) and a high temperature (45 C.), and results thereof were converted into dQ/dV to voltage (V) 12 and illustrated in FIGS. 12 and 13.

(53) As illustrated in FIGS. 12 and 13, the batteries manufactured using the cathode active materials of the present invention has excellent charge/discharge characteristics even at a high temperature, as well as at room temperature.

<Experimental Example> XRD Measurement Before and after Charging/Discharging

(54) After the coin batteries manufactured using the cathode active materials prepared in the Inventive Example and Comparative Example were charged/discharged 50 times, the coin batteries were disassembled, XRD Measurement was made on the obtained cathode active materials and compared with XRD data measured for the active materials before the batteries were manufactured. Results thereof are illustrated in FIG. 14 and Table 6.

(55) TABLE-US-00006 TABLE 6 I(003)/I(104) Comparative Example 1 Inventive Example 4 Before charge/discharge 1.3064 1.3046 After charge/discharge 1.1533 1.1986 50 times Rate of increase of I(104) 11.7% 8.1%

(56) As illustrated in FIG. 14 and Table 6, as for the coin battery manufactured using the secondary battery cathode active material of Inventive Example 4 of the present invention, the value of 4104) thereof was changed by 5% or less even after charging and discharging 50 times, which is less than that of Comparative Example.

(57) In the case of a general battery, a crystal structure thereof deteriorates due to cation migration when the battery continues to be charged and discharged. As illustrated in FIG. 15, peak intensity at position (104) may be determined to indicate the extent of occurrent of cation migration.

(58) In the case of the cathode active material of the present invention, it can be seen that, the increase in the value of 4104) was merely 2.61% even after charging/discharging was continuously performed, which indicates that the extent of deterioration of the bulk structure even after charging/discharging was reduced.

<Experimental Example> XPS Checking of Battery

(59) XPS of the coin battery manufactured using the secondary battery cathode active material of Inventive Example 4 and XPS of the coil battery manufactured using the secondary battery cathode active material prepared in Comparative Example 1 in Manufacturing Example, before and after charging and discharging 50 times, were measured, and results thereof are illustrated in FIGS. 16 and 17 and Table 7.

(60) TABLE-US-00007 TABLE 7 Strength ratio I(CF)/I(LiF) Comparative Example 1 Inventive Example 4 Before charge/discharge 8.7032 8.6505 After charge/discharge 0.7682 0.7101 50 times Rate of increase of 8.8% 8.2% I(LiF)

(61) In FIG. 16 and Table 7, in the case of the coin battery manufactured using the secondary battery cathode active material of Inventive Example 4 according to the present invention, I (LiF), i.e., intensity of peak based on LiF was decreased.

<Experimental Example> Measurement of LiF Formation in Cathode Active Material

(62) The coin battery manufactured using the secondary battery cathode active material of Inventive Example 4 and the coin battery manufactured using the secondary battery cathode active material of Comparative Example 1 in Manufacturing Example were charged and discharged 50 times, cross-sections of the cathode active materials were measured by an EDX, and results thereof are illustrated in FIG. 17.

(63) As illustrated in FIG. 17, it was checked that, in the case of the cathode active material of the present invention, LiF in particles was detected to be less than that of Comparative Example.

(64) While the present invention has been illustrated and described in connection with the embodiments, it will be apparent to those skilled in the art that modifications and variations can be made without departing from the spirit and scope of the invention as defined by the appended claims