High energy cathodes for lithium ion batteries

Abstract

An electrode formed from a material represented by Li.sub.1-xM.sub.xCo.sub.1-yM.sub.yO.sub.2-d where 0<x0.2, 0y<1, and 0<d0.2. M and M each independently comprises a metal selected from the group consisting of transition metals, Group I elements, and Group II elements.

Claims

1. An electrode, comprising: a material represented by Li.sub.1-xM.sub.xCo.sub.1-yM.sub.yO.sub.2-d where 0<x0.2, 0y<1, and 0<d0.2; wherein M and M each independently comprises a metal selected from the group consisting of transition metals, Group I elements, and Group II elements and wherein M is present in a lithium site of the material.

2. The electrode of claim 1, wherein M is magnesium.

3. The electrode of claim 1, wherein M is zirconium.

4. The electrode of claim 1, wherein M is niobium.

5. The electrode of claim 1, wherein M is sodium.

6. The electrode of claim 1, wherein 0<x0.01.

7. The electrode of claim 1, wherein 0.01<x0.02.

8. The electrode of claim 1, wherein 0.02<x0.03.

9. The electrode of claim 1, wherein 0.03<x0.04.

10. The electrode of claim 1, wherein 0.04<x0.05.

11. The electrode of claim 1, wherein 0.05<x0.06.

12. The electrode of claim 1, wherein y=0.

13. The electrode of claim 1, wherein the material comprises Li.sub.0.95Zr.sub.0.05CoO.sub.2.

14. The electrode of claim 1, wherein the material comprises Li.sub.0.99Mg.sub.0.01CoO.sub.2.

15. The electrode of claim 1, wherein M is a transition metal.

16. The electrode of claim 1, wherein 0<y0.01.

17. The electrode of claim 1, wherein 0.01<y0.02.

18. The electrode of claim 1, wherein 0.02<y0.03.

19. The electrode of claim 1, wherein 0.03<y0.04.

20. The electrode of claim 1, wherein 0.04<y0.05.

21. The electrode of claim 1, wherein 0.05<y0.06.

Description

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

(1) FIG. 1A illustrates characterization of the specific capacity as a function of cycle for certain active materials, including a control active material and two active materials formed according to embodiments of the present invention.

(2) FIG. 1B illustrates characterization of the capacity retention as a function of cycle for certain active materials, including a control active material and two active materials formed according to embodiments of the present invention.

(3) FIG. 2A illustrates characterization of the specific capacity as a function of cycle for certain active materials, including a control active material and an active material formed according to embodiments of the present invention.

(4) FIG. 2B illustrates characterization of the capacity retention as a function of cycle for certain active materials, including a control active material and an active material formed according to embodiments of the present invention.

(5) FIGS. 3A and 3B illustrates characterization of differential capacity as a function of voltage for certain active materials, including a control active material and two active materials formed according to embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(6) The following definitions apply to some of the aspects described with respect to some embodiments of the invention. These definitions may likewise be expanded upon herein. Each term is further explained and exemplified throughout the description, figures, and examples. Any interpretation of the terms in this description should take into account the full description, figures, and examples presented herein.

(7) The singular terms a, an, and the include the plural unless the context clearly dictates otherwise. Thus, for example, reference to an object can include multiple objects unless the context clearly dictates otherwise.

(8) The terms substantially and substantial refer to a considerable degree or extent. When used in conjunction with an event or circumstance, the terms can refer to instances in which the event or circumstance occurs precisely as well as instances in which the event or circumstance occurs to a close approximation, such as accounting for typical tolerance levels or variability of the embodiments described herein.

(9) The term about refers to the range of values approximately near the given value in order to account for typical tolerance levels, measurement precision, or other variability of the embodiments described herein.

(10) A rate C refers to either (depending on context) the discharge current as a fraction or multiple relative to a 1 C current value under which a battery (in a substantially fully charged state) would substantially fully discharge in one hour, or the charge current as a fraction or multiple relative to a 1 C current value under which the battery (in a substantially fully discharged state) would substantially fully charge in one hour.

(11) The term LCO refers to a lithium cobalt oxide cathode material of Formula (i) above.

(12) The term doped LCO refers to a lithium cobalt oxide material with dopants added. The term undoped LCO refers to lithium cobalt oxide.

(13) The term transition metal refers to a chemical element in groups 3 through 12 of the periodic table, including scandium (Sc), titanium (Ti), vanadium (V), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), zinc (Zn), yttrium (Y), zirconium (Zr), niobium (Nb), molybdenum (Mo), technetium (Tc), ruthenium (Ru), rhodium (Rh), palladium (Pd), silver (Ag), cadmium (Cd), hafnium (Hf), tantalum (Ta), tungsten (W), rhenium (Re), osmium (Os), iridium (Ir), platinum (Pt), gold (Au), mercury (Hg), rutherfordium (Rf), dubnium (Db), seaborgium (Sg), bohrium (Bh), hassium (Hs), and meitnerium (Mt).

(14) The term Group I element refers to a chemical element in group 1 of the periodic table, including sodium (Na), potassium (K), rubidium (Rb), caesium (Cs), and francium (Fr).

(15) The term Group II element refers to a chemical element in group 2 of the periodic table, beryllium (Be), magnesium (Mg), calcium (Ca), strontium (Sr), barium (Ba), and radium (Ra).

(16) The terms milling and mixing are used interchangeably, except in the instances where low energy mixing processes are specified. In such instances, the materials would be predominantly mixed rather than milled.

(17) The term cycle life refers to the change in discharge capacity of a battery as a function of cycle number. That is, a battery with adequate cycle life will substantially maintain its discharge capacity at higher cycle numbers. Cycle life does not necessarily refer to battery properties other than discharge capacity.

(18) Ranges presented herein are inclusive of their endpoints. Thus, for example, the range 1 to 3 includes the values 1 and 3 as well as intermediate values. However, ranges given using symbols (e.g. 5<x10) should be interpreted according to the accepted mathematical definitions of those ranges.

(19) In certain embodiments, an electrode material is formed in which some atomic sites are doped with at least one dopant. The dopants can be selected from Group I elements, Group II elements, and transition metals. The doping site can be a lithium site.

(20) The doped material can be prepared by suitable synthetic methods, including solid state chemical reaction, ion exchange substitution, and the like. Non-limiting examples of synthetic methods are presented herein.

(21) For example, magnesium can be doped into lithium sites in an electrode material. The material in this preferred embodiment can have a composition according to Formula (ii):
Li.sub.1-xM.sub.xCoO.sub.2-d(ii)
where 0<x0.2, 0<d0.2 and M is magnesium, zirconium, niobium, sodium, or combinations thereof. For example, the undoped material can have the formula LiCoO.sub.2. With this starting material, dopants can be added according to suitable methods such as milling to yield doping of magnesium, zirconium, niobium, and/or sodium at the lithium site. In Formula (ii), The formulas below represent a range of possible preferred doping levels according to Formula (ii) wherein M is magnesium:

(22) Li.sub.0.99Mg.sub.0.01CoO.sub.2

(23) Li.sub.0.98Mg.sub.0.02CoO.sub.2

(24) Li.sub.0.97Mg.sub.0.03CoO.sub.2

(25) Li.sub.0.96Mg.sub.0.04CoO.sub.2

(26) Li.sub.0.95Mg.sub.0.05CoO.sub.2

(27) Li.sub.0.94Mg.sub.0.06CoO.sub.2

(28) Li.sub.0.93Mg.sub.0.07CoO.sub.2

(29) Li.sub.0.92Mg.sub.0.08CoO.sub.2

(30) Li.sub.0.91Mg.sub.0.09CoO.sub.2

(31) Li.sub.0.90Mg.sub.0.10CoO.sub.2

(32) In other embodiments, there is a range of possible preferred doping levels according to Formula (ii) wherein M is zirconium:

(33) Li.sub.0.99Zr.sub.0.01CoO.sub.2

(34) Li.sub.0.98Zr.sub.0.02CoO.sub.2

(35) Li.sub.0.97Zr.sub.0.03CoO.sub.2

(36) Li.sub.0.96Zr.sub.0.04CoO.sub.2

(37) Li.sub.0.95Zr.sub.0.05CoO.sub.2

(38) Li.sub.0.94Zr.sub.0.06CoO.sub.2

(39) Li.sub.0.93Zr.sub.0.07CoO.sub.2

(40) Li.sub.0.92Zr.sub.0.08CoO.sub.2

(41) Li.sub.0.91Zr.sub.0.09CoO.sub.2

(42) Li.sub.0.90Zr.sub.0.10CoO.sub.2

(43) In other embodiments, there is a range of possible preferred doping levels according to Formula (ii) wherein M is niobium:

(44) Li.sub.0.99Nb.sub.0.01CoO.sub.2

(45) Li.sub.0.98Nb.sub.0.02CoO.sub.2

(46) Li.sub.0.97Nb.sub.0.03CoO.sub.2

(47) Li.sub.0.96Nb.sub.0.04CoO.sub.2

(48) Li.sub.0.95Nb.sub.0.05CoO.sub.2

(49) Li.sub.0.94Nb.sub.0.06CoO.sub.2

(50) Li.sub.0.93Nb.sub.0.07CoO.sub.2

(51) Li.sub.0.92Nb.sub.0.08CoO.sub.2

(52) Li.sub.0.91Nb.sub.0.09CoO.sub.2

(53) Li.sub.0.90Nb.sub.0.10CoO.sub.2

(54) In other embodiments, there is a range of possible preferred doping levels according to Formula (ii) wherein M is sodium:

(55) Li.sub.0.99Na.sub.0.01CoO.sub.2

(56) Li.sub.0.98Na.sub.0.02CoO.sub.2

(57) Li.sub.0.97Na.sub.0.03CoO.sub.2

(58) Li.sub.0.96Na.sub.0.04CoO.sub.2

(59) Li.sub.0.95Na.sub.0.05CoO.sub.2

(60) Li.sub.0.94Na.sub.0.06CoO.sub.2

(61) Li.sub.0.93Na.sub.0.07CoO.sub.2

(62) Li.sub.0.92Na.sub.0.08CoO.sub.2

(63) Li.sub.0.91Na.sub.0.09CoO.sub.2

(64) Li.sub.0.90Na.sub.0.10CoO.sub.2

(65) The above formulas are not intended to be limiting and merely illustrate one range of doping combinations. The present disclosure embraces the full range of possible combinations of elements that are mathematically possible given the ranges of Formula (ii). The above formulas can have variations in d independent of the value of x.

(66) In certain preferred embodiments, M and x are chosen such that M is magnesium and x is 0.01. In other preferred embodiments, M and x are chosen such that M is zirconium and x is 0.05.

(67) In other embodiments, the cobalt site can also have a dopant and the material in this embodiment can have a composition according to Formula (iii):
Li.sub.1-xM.sub.xCo.sub.1-yM.sub.yO.sub.2-d(iii)
where 0<x0.2, 0y<1, and 0<d0.2. In this embodiment, M and M are independently selected from transition metals, Group I elements, and Group II elements. M is preferably magnesium, zirconium, niobium, sodium, or combinations thereof. M is preferably a transition metal.

(68) Advantageously, the doped materials disclosed herein maintain the crystal structure of the undoped electrode material. The layered oxide phase is composed of Li.sub.1-xM.sub.xCoO.sub.2 or Li.sub.1-xM.sub.xCo.sub.1-yM.sub.yO.sub.2-d while x varies with the level of doping.

(69) The preferred doped materials disclosed herein maintain a layered oxide phase in the doped electrode material. A preferred doping site for magnesium, zirconium, niobium, or sodium in an electrode material would be the lithium site in the layered oxide phase. The examples herein demonstrate the particular suitability of magnesium and zirconium with LiCoO.sub.2 materials.

(70) Without being bound by particular theories or mechanisms of action, the dopants disclosed herein may modify the lattice parameters and local chemical bond energy of the lithium cobalt oxide cathode materials as those materials lose lithium ions. As the lithium cobalt oxide cathode material loses lithium ions, and in particular as the amount of lithium ions in the lithium cobalt oxide cathode material decreases to less than about 50% of its original stoichiometric amount. In a conventional lithium cobalt oxide cathode material, a substantial amount of lithium is needed to stabilize the trigonal crystallographic structure of a conventional lithium cobalt oxide cathode material. Structurally, certain of the metal cations doped in the lithium sites with an ionic radius larger than lithium may help maintain the trigonal structure as the lithium ion concentration decreases. And, the greater negative charge on certain of the metal cations doped in the lithium sites can similarly help maintain the trigonal structure. The metal cations will be kinetically more difficult to transport and act as pillars in the structure and thereby stabilize the structure. Thus, by compensating for the physical and chemical stresses that occur in a conventional lithium cobalt oxide cathode material, the dopants disclosed herein can help to maintain the trigonal structure of lithium cobalt oxide cathode materials and improve the cycle life (i.e., reduce capacity fade).

(71) Indeed, data presented herein demonstrate a comparatively low capacity fade (high capacity retention) for a doped electrode material. The compositions of the present invention can improve at least the capacity, capacity retention, and rate capability of electrode materials while retaining the other favorable performance and commercial attributes of such materials.

(72) The following examples describe specific aspects of some embodiments of the invention to illustrate and provide a description for those of ordinary skill in the art. The examples should not be construed as limiting the invention, as the examples merely provide specific methodology useful in understanding and practicing some embodiments of the invention.

EXAMPLES

(73) Materials and Synthetic Methods. An electrode material is prepared via solid state chemistry methods. Precursors used include elemental metals, hydroxides, carbonates, oxides, nitrides, hydrides, and others. Certain preferred precursors of the dopants include Mg, Mg(OH).sub.2, MgCO.sub.3, Zr, Zr(OH).sub.4 Nb, Nb.sub.2O.sub.5 NaOH, and Na.sub.2CO.sub.3. The as-received precursors from commercial sources are milled with Li.sub.2CO.sub.3 and Co.sub.3O.sub.4 at stoichiometric ratios desired to make a target composition. After milling, the mixture was annealed at a temperature in a range of from about 600 to about 1200 degrees Celsius for a time in a range of from about 3 to about 24 hours. This was done under an air flow of about 20 L/min. Metals such as Mn, Fe, Ni, Cu, Zn, Mo, and Ti can be accommodated by this method, amongst others. Some electrode materials were also prepared through ion exchange substitution by mixing the above prepared LiCoO.sub.2 mixture and a eutectic composition of MgCl.sub.2 and KCl at desired ratios For example, the methods described in the following reference, which is incorporated by reference herein, may be applicable: Yoshiyuki Inaguma, Nozomi Okuyama, Yuri Atsumi, and Tetsuhiro Katsumata, Mg.sup.2+ Ion-exchange with the L.sup.+ Ion in a Fast Li Ion-conducting Perovskite La.sub.0.55Li.sub.0.35TiO.sub.3, Chemistry Letters 2002, 1106-1107. The resulting material was then annealed at a temperature in the range of from about 300 degrees Celsius to about 450 degrees Celsius. The annealing time was from about 5 hours to about 20 hours in an atmosphere of nitrogen gas or air. The flow rate was about 20 L/min. The annealed material was then washed with water and dried in a vacuum.

(74) Electrode Formulation. An electrode was prepared using the dried powder and mixing it with conductive carbon, poly(vinylidene fluoride) (Sigma Aldrich), and 1-methyl-2-pyrrolidinone (Sigma Aldrich). This slurry was then deposited on a current collector. The current collector can be stainless steel or aluminum according to some embodiments. The slurry was then dried to form a composite cathode. Certain of the materials were analyzed by scanning electron microscopy and energy-dispersive X-ray spectroscopy. This analysis revealed a fairly homogenous material resulting from the synthetic methods disclosed herein.

(75) Electrochemical Characterization. Electrochemical cells were assembled in a high purity argon filled glove box (M-Braun, O.sub.2 and humidity contents <0.1 ppm), unless otherwise specified. Each cell contained a lithium foil anode, the above composite cathode, and a polypropylene separator. The electrolyte for these cells was a mixture of ethylene carbonate and ethyl methyl carbonate with LiPF.sub.6 as a lithium salt. The cells were sealed and cycled between 3V and 4.4V (or 4.55V in some cases) at 30 degrees Celsius with a 1C cycling rate at 160 mAh/g (or 215 mAh/g in some cases) with lithium counter electrode, and between 3V and 4.45V at 45 degrees Celsius with a 1C cycling rate at 205 mAh/g with graphite counter electrode to measure cell characteristics.

Results

(76) FIG. 1A illustrates characterization of the specific capacity as a function of cycle for certain active materials, including a control active material and two active materials formed according to embodiments of the present invention. In this figure, the specific capacity across multiple cycles of two tested compounds, Li.sub.0.99Mg.sub.0.01CoO.sub.2 (represented by boxes) and Li.sub.0.95Zr.sub.0.05CoO.sub.2 (represented by crosses) is improved as compared the undoped LCO (represented by circles).

(77) FIG. 1B illustrates characterization of the capacity retention as a function of cycle for certain active materials, including a control active material and two active materials formed according to embodiments of the present invention. This figure shows the capacity retention of both compounds in relation to undoped LCO across the same cycles, showing that specific capacity is better retained across cycles in the doped LCO (the boxes and crosses representing the same materials as in FIG. 1A) than the undoped LCO.

(78) FIGS. 1A and 1B provide support for the dopants providing resistance to structural degradation (e.g., phase transition) in the compounds having doping on the lithium site as compared to the undoped LCO.

(79) FIG. 2A illustrates characterization of the specific capacity as a function of cycle for certain active materials, including a control active material and an active material formed according to embodiments of the present invention. In this figure, the specific capacity across multiple cycles of Li.sub.0.99Mg.sub.0.01CoO.sub.2 (represented by boxes) is improved as compared to the undoped LCO (represented by circles). In both FIGS. 2A and 2B, the test battery was discharged at a 1C rate and cycled between 3V-4.45V versus a graphite anode at 45 degrees Celsius.

(80) FIG. 2B illustrates characterization of the capacity retention as a function of cycle for certain active materials, including a control active material and an active material formed according to embodiments of the present invention. Both FIG. 2A and FIG. 2B demonstrate that certain dopants improve the cycle life of lithium cobalt oxide materials even at relatively high temperatures.

(81) FIGS. 3A and 3B illustrates characterization of differential capacity as a function of voltage for certain active materials, including a control active material and two active materials formed according to embodiments of the present invention. FIG. 3A shows the differential capacity (dQ/dV) traces versus voltage on cycle 4 of an undoped LiCoO.sub.2 (represented by diamonds), a test material Li.sub.0.99Mg.sub.0.01CoO.sub.2 (represented by filled circles), and a test material Li.sub.0.95Zr.sub.0.05CoO.sub.2 (represented by asterisks). The batteries were cycled between 3V and 4.55V versus a L.sup.+ anode. FIG. 3b is a magnification of the high voltage range of the plot of FIG. 3A and shows that both magnesium-doped LiCoO.sub.2 and zirconium-doped LiCoO.sub.2 have higher discharge voltage than pure LiCoO.sub.2, but much smaller charge voltage difference among them.

(82) Several investigations have identified phase transitions in layered LiCoO.sub.2 above 4.5 V. Most recently, these transitions were identified as being from the 03 phase to the H1-3 phase around 4.55 V and from the H1-3 phase to the 01 phase around 4.62 V. Some researchers have attributed poor cycling life above 4.2 V to these phase transitions. The better performance seen in FIG. 3 for the two doped LiCoO.sub.2 materials as compared to the pure LiCoO.sub.2 (higher discharge voltage around 4.4 V which corresponds to the charge around 4.55 V) is likely caused by improved structural stability (e.g., less phase change) at the high voltage.

(83) Many embodiments disclosed herein involve doping certain elements into the lithium sites of LCO materials. While doping is a known technique, the relevant prior art does not disclose the doping presented herein, either in ratio, location, or substance. While Zou et al. have experimented with doping LiCoO.sub.2 for high voltage cycling and found positive results for enhancing high voltage cycling performance, Zou et al. doped on the cobalt site. Zuo et al. do not disclose doping on the lithium site.

(84) Other research has been performed doping on both the Co site and the Li site, such as in Luo et al. Luo et al. examined thirty samples with formulas (Li.sub.1-z).sub.xMg.sub.z[Co.sub.1-zMg.sub.z]O.sub.2 and Li.sub.x[Co.sub.1-zMg.sub.z]O.sub.2 and categorized various properties thereof. However, no combination of these stoichiometric formulas can render the compounds tested or disclosed herein due to the ratio of Co and M being dependent on z.

(85) Koyama et al. explored doping of LCO compounds and theoretical results and limits for doing so. They discuss the theoretical possibilities from first principles of doping LiCoO.sub.2 with various compounds. However there is no suggestion of ratio or method for doping on the lithium site with any of the substances disclosed herein and no capacity stability results are posited for doing so.

(86) Kazada et al. doped LiCoO.sub.2 with both sodium and potassium, and found that sodium and potassium at levels of 1%, 5%, and 2.5% of total mixture by volume produced similar capacities across cycling to undoped LiCoO.sub.2. This is an antithetical result to those presented herein and the stoichiometric ratios presented herein where not utilized. Rather, Kazada et al. used volumetric ratios of sodium and potassium. Again, there is no indication that doping occurred on the lithium site.

(87) Wang et al. found improved capacity across a number of cycles when doping LiCoO.sub.2 with magnesium. However, this was only tested in conjunction with a zirconium oxyfluoride coating, not presented herein. Additionally, there is no doping of specifically the lithium site presented.

(88) Chandrasekaran et al. synthesized a cathode similar to LiCoO.sub.2 and various dopants, however this was with the addition of copper to the chemical structure tested.

(89) While the invention has been described with reference to the specific embodiments thereof, it should be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the true spirit and scope of the invention as defined by the appended claims. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, method, or process to the objective, spirit and scope of the invention. All such modifications are intended to be within the scope of the claims appended hereto. In particular, while the methods disclosed herein have been described with reference to particular operations performed in a particular order, it will be understood that these operations may be combined, sub-divided, or re-ordered to form an equivalent method without departing from the teachings of the invention. Accordingly, unless specifically indicated herein, the order and grouping of the operations are not limitations of the invention.