Lithium-ion secondary battery

Abstract

In one embodiment, an active cathode material comprises a mixture that includes: at least one of a lithium cobaltate and a lithium nickelate; and at least one of a manganate spinel represented by an empirical formula of Li (1+x1) (Mn 1−y1 A′ y1 ) 2−x1 O z1 and an olivine compound represented by an empirical formula of Li (1−x2) A″ x2 MPO 4 . In another embodiment, an active cathode material comprises a mixture that includes: a lithium nickelate selected from the group consisting of LiCoO 2 -coated LiNi 0.8 Co 0.15 Al 0.05 O 2 , and Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 ; and a manganate spinel represented by an empirical formula of Li (1+x7) Mn 2−y7 O z7 . A lithium-ion battery and a battery pack each independently employ a cathode that includes an active cathode material as described above. A method of forming a lithium-ion battery includes the steps of forming an active cathode material as described above; forming a cathode electrode with the active cathode material; and forming an anode electrode in electrical contact with the cathode via an electrolyte. A system comprises a portable electronic device and a battery pack or lithium-ion battery as described above.

1 - 56 . (canceled)  
   
   
       57 . A lithium-ion battery having a cathode that includes an active cathode material, the active cathode material comprising: 
 a) a mixture that includes 
 i) at least one of a lithium cobaltate and a lithium nickelate, wherein the lithium cobaltate represented by an empirical formula of Li x6 M′ (1−y6) Co (1−z6) M″ z6 O 2  where: 
 x6 is greater than 0.05 and less than 1.2,  
 y6 is greater than or equal to 0 and less than 0.1,  
 z6 is equal to or greater than 0 and less than 0.5,  
 M′ is at least one of magnesium (Mg) and sodium (Na), and  
 M″ is at least one member of the group consisting of manganese, aluminum, boron, titanium, magnesium, calcium and strontium,  
 
 and wherein the lithium nickelate is selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 ; a lithium nickelate that includes at least one Li atom modifier selected from the group consisting of barium, magnesium, calcium and strontium; and a lithium nickelate represented by an empirical formula of Li x3 Ni (1−z3) M′ z3 O 2  coated with LiCoO 2  as a gradient coating or a spot-wise coating where: 
 x3 is greater than 0.05 and less than 1.2,  
 z3 is greater than 0 and less than 0.5, and  
 M′ is at least one member of the group consisting of cobalt, manganese, aluminum, boron, titanium, magnesium, calcium and strontium; and  
 
 ii) at least one of a manganate spinel and an olivine compound, wherein the manganate spinel is represented by an empirical formula of Li (1+x1) (Mn 1−y1 A′ y1 ) 2−x1 O z1  where: 
 x1 is equal to or greater than 0.01 and equal to or less than 0.3,  
 y1 is greater than 0.0 and equal to or less than 0.3,  
 z1 is equal to or greater than 3.9 and equal to or less than 4.1, and  
 A′ is at least one member of the group consisting of magnesium, aluminum, cobalt, nickel and chromium,  
 
 and wherein the olivine compound is represented by an empirical formula of Li (1−x2) A″ x2 MPO 4  where: 
 x2 is equal to or greater than 0.05 and equal to or less than 0.2, or x2 is equal to or greater than 0.0 and equal to or less than 0.1,  
 M is at least one member of the group consisting of iron, manganese, cobalt and magnesium, and  
 A″ is at least one member of the group consisting of sodium, magnesium, calcium, potassium, nickel and niobium; or  
 
   b) a mixture that includes 
 i) a lithium nickelate selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 ; a lithium nickelate that includes at least one Li atom modifier selected from the group consisting of barium, magnesium, calcium and strontium; and a lithium nickelate represented by an empirical formula of Li x3 Ni (1−z3) M′ z3 O 2  coated with LiCoO 2  as a gradient coating or a spot-wise coating where: 
 x3 is greater than 0.05 and less than 1.2,  
 z3 is greater than 0 and less than 0.5, and  
 M′ is at least one member of the group consisting of cobalt, manganese, aluminum, boron, titanium, magnesium, calcium and strontium; and  
 
 ii) a manganate spinel represented by an empirical formula of Li (1+x7) Mn 2−y7 O z7  where x7 and y7 are each independently equal to or greater than 0.0 and equal to or less than 1.0; and z7 is equal to or greater than 3.9 and equal to or less than 4.2  
   
   
   
       58 . The lithium-ion battery of  claim 57 , wherein the active cathode material includes a mixture that includes: 
 i) at least one of the lithium cobaltate represented by an empirical formula of Li x6 M′ (1−y6) Co (1−z6) M″ z6 O 2 , and the lithium nickelate selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 , the Li-modifier-containing lithium nickelate, and the LiCoO 2 -coated lithium nickelate; and    ii) at least one of the manganate spinel represented by an empirical formula of Li (1+x1) (Mn 1−y1 A′ y1 ) 2−x1 O z1  and the olivine compound represented by an empirical formula of Li (1−x2) A″ x2 MPO 4 .    
   
   
       59 . The lithium-ion battery of  claim 58 , wherein the cathode material includes the Li-modifier-containing lithium nickelate.  
   
   
       60 . The lithium-ion battery of  claim 59 , wherein the Li-modifier-containing lithium nickelate further includes at least one Ni atom modifier selected from the group consisting of barium, magnesium, calcium, strontium, aluminum, manganese and boron.  
   
   
       61 . The lithium-ion battery of  claim 58 , wherein the cathode material includes the LiCoO 2 -coated lithium nickelate.  
   
   
       62 . The lithium-ion battery of  claim 61 , wherein the LiCoO 2 -coated lithium nickelate is LiNi 0.8 Co 0.15 Al 0.05 O 2  coated with LiCoO 2  as a gradient coating or a spot-wise coating.  
   
   
       63 . The lithium-ion battery of  claim 58 , wherein the cathode material includes Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 .  
   
   
       64 . The lithium-ion battery of  claim 58 , wherein the cathode material includes the olivine compound of Li (1−x2) A″ x2 MPO 4  where M is iron or manganese.  
   
   
       65 . The lithium-ion battery of  claim 64 , wherein the olivine compound is LiFePO 4  or LiMnPO 4 .  
   
   
       66 . The lithium-ion battery of  claim 58 , wherein the cathode material includes one of the lithium nickelate selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 , the Li-modifier-containing lithium nickelate, and the LiCoO 2 -coated lithium nickelate; and further includes the manganate spinel of Li (1+x1) (Mn 1−y1 A′ y1 ) 2−x1 O z1 .  
   
   
       67 . The lithium-ion battery of  claim 58 , wherein the cathode material includes one of the lithium nickelate selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 , the Li-modifier-containing lithium nickelate, and the LiCoO 2 -coated lithium nickelate; and further includes the manganate spinel of Li (1+x1) (Mn 1−y1 A′ y1 ) 2−x1 O z1  and the lithium cobaltate of Li x6 M′ (1−z6) Co (1−z6) M″ z6 O 2 .  
   
   
       68 . The lithium-ion battery of  claim 58 , wherein the cathode material includes the lithium cobaltate of Li x6 M′ (1−y6) Co (1−z6) M″ z6 O 2  and the manganate spinel of Li (1+x1) (Mn 1−y1 A′ y1 ) 2−x1 O z1 .  
   
   
       69 . The lithium-ion battery of  claim 58 , wherein the cathode material includes the lithium cobaltate of Li x6 M′ (1−y6) Co (1−z6) M″ z6 O 2  and/or one of the lithium nickelate selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 , the Li-modifier-containing lithium nickelate, and the LiCoO 2 -coated lithium nickelate; and further includes the olivine compound of Li (1−x2) A″ x2 MPO 4 .  
   
   
       70 . The lithium-ion battery of  claim 58 , wherein the cathode material includes one of the lithium nickelate selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 , the Li-modifier-containing lithium nickelate, and the LiCoO 2 -coated lithium nickelate; and further includes the olivine compound of Li (1−x2) A″ x2 MPO 4 .  
   
   
       71 . The lithium-ion battery of  claim 57 , wherein the active cathode material includes a mixture that includes 
 i) the lithium nickelate selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 , the Li-modifier-containing lithium nickelate, and the LiCoO 2 -coated lithium nickelate; and    ii) the manganate spinel represented by an empirical formula of Li (1+x7) Mn 2−y7 O z7 .    
   
   
       72 . The lithium-ion battery of  claim 71 , wherein the cathode material includes the Li-modifier-containing lithium nickelate.  
   
   
       73 . The lithium-ion battery of  claim 72 , wherein the Li-modifier-containing lithium nickelate further includes at least one Ni atom modifier selected from the group consisting of barium, magnesium, calcium, strontium, aluminum, manganese and boron.  
   
   
       74 . The lithium-ion battery of  claim 71 , wherein the manganate spinel is LiMn 2 O 4 .  
   
   
       75 . The lithium-ion battery of  claim 71 , further comprising a lithium cobaltate.  
   
   
       76 . The lithium-ion battery of  claim 75 , wherein the lithium cobaltate is LiCoO 2 .  
   
   
       77 . The lithium-ion battery of  claim 71 , wherein the mixture further includes an olivine compound represented by an empirical formula of  
       Li (1−x2) A″ x2 MPO 4  where:  x2 is equal to or greater than 0.05 and equal to or less than 0.2, or    x2 is equal to or greater than 0.0 and equal to or less than 0.1; and    M is at least one member of the group consisting of iron, manganese, cobalt and magnesium; and    A″ is at least one member of the group consisting of sodium, magnesium, calcium, potassium, nickel and niobium.    
   
   
       78 . A method of forming a lithium-ion battery, comprising: 
 forming an active cathode material;    forming a cathode electrode with the active cathode material; and    forming an anode electrode in electrical contact with the cathode via an electrolyte, thereby forming a lithium-ion battery,    wherein the active cathode material includes    a) a mixture that includes 
 i) at least one of a lithium cobaltate and a lithium nickelate, wherein the lithium cobaltate represented by an empirical formula of Li x6 M′ (1−y6) CO (1−z6) M″ z6 O 2  where: 
 x6 is greater than 0.05 and less than 1.2,  
 y6 is greater than or equal to 0 and less than 0.1,  
 z6 is equal to or greater than 0 and less than 0.5,  
 M′ is at least one of magnesium (Mg) and sodium (Na), and  
 M″ is at least one member of the group consisting of manganese, aluminum, boron, titanium, magnesium, calcium and strontium,  
 
 and wherein the lithium nickelate is selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 ; a lithium nickelate that includes at least one Li atom modifier selected from the group consisting of barium, magnesium, calcium and strontium; and a lithium nickelate represented by an empirical formula of Li x3 Ni (1−   z3) M′ z3 O 2  coated with LiCoO 2  as a gradient coating or a spot-wise coating where: 
 x3 is greater than 0.05 and less than 1.2,  
 z3 is greater than 0 and less than 0.5, and  
 M′ is at least one member of the group consisting of cobalt, manganese, aluminum, boron, titanium, magnesium, calcium and strontium; and  
 
 ii) at least one of a manganate spinel and an olivine compound, wherein the manganate spinel is represented by an empirical formula of Li (1+x1) (Mn 1−y1 A′ y1 ) 2−x1 O z1  where: 
 x1 is equal to or greater than 0.01 and equal to or less than 0.3,  
 y1 is greater than 0.0 and equal to or less than 0.3,  
 z1 is equal to or greater than 3.9 and equal to or less than 4.1, and  
 A′ is at least one member of the group consisting of magnesium, aluminum, cobalt, nickel and chromium,  
 
 and wherein the olivine compound is represented by an empirical formula of Li (1−x2) A″ x2 MPO 4  where: 
 x2 is equal to or greater than 0.05 and equal to or less than 0.2, or x2 is equal to or greater than 0.0 and equal to or less than 0.1,  
 M is at least one member of the group consisting of iron, manganese, cobalt and magnesium, and  
 A″ is at least one member of the group consisting of sodium, magnesium, calcium, potassium, nickel and niobium; or  
 
   b) a mixture that includes 
 i) a lithium nickelate selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 ; a lithium nickelate that includes at least one Li atom modifier selected from the group consisting of barium, magnesium, calcium and strontium; and a lithium nickelate represented by an empirical formula of Li x3 Ni (1−z3) M′ z3 O 2  coated with LiCoO 2  as a gradient coating or a spot-wise coating where: 
 x3 is greater than 0.05 and less than 1.2,  
 z3 is greater than 0 and less than 0.5, and  
 M′ is at least one member of the group consisting of cobalt, manganese, aluminum, boron, titanium, magnesium, calcium and strontium; and  
 
 ii) a manganate spinel represented by an empirical formula of  
   Li (1+x7) Mn 2−y7 O z7  where x7 and y7 are each independently equal to or greater than 0.0 and equal to or less than 1.0; and z7 is equal to or greater than 3.9 and equal to or less than 4.2.    
   
   
       79 . An active cathode material comprising: 
 a) a mixture that includes 
 i) at least one of a lithium cobaltate and a lithium nickelate, wherein the lithium cobaltate represented by an empirical formula of Li x6 M′ (1−y6) Co (1−z6) M″ z6 O 2  where: 
 x6 is greater than 0.05 and less than 1.2,  
 y6 is greater than or equal to 0 and less than 0.1,  
 z6 is equal to or greater than 0 and less than 0.5,  
 M′ is at least one of magnesium (Mg) and sodium (Na), and  
 M″ is at least one member of the group consisting of manganese, aluminum, boron, titanium, magnesium, calcium and strontium,  
 
 and wherein the lithium nickelate is selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 ; a lithium nickelate that includes at least one Li atom modifier selected from the group consisting of barium, magnesium, calcium and strontium; and a lithium nickelate represented by an empirical formula of Li x3 Ni (1−z3) M′ z3 O 2  coated with LiCoO 2  as a gradient coating or a spot-wise coating where: 
 x3 is greater than 0.05 and less than 1.2,  
 z3 is greater than 0 and less than 0.5, and  
 M′ is at least one member of the group consisting of cobalt, manganese, aluminum, boron, titanium, magnesium, calcium and strontium; and  
 
 ii) at least one of a manganate spinel and an olivine compound, wherein the manganate spinel is represented by an empirical formula of Li (1+x1) (Mn 1−y1 A′ y1 ) 2−x1 O z1  where: 
 x1 is equal to or greater than 0.01 and equal to or less than 0.3,  
 y1 is greater than 0.0 and equal to or less than 0.3,  
 z1 is equal to or greater than 3.9 and equal to or less than 4.1, and  
 A′ is at least one member of the group consisting of magnesium, aluminum, cobalt, nickel and chromium,  
 
 and wherein the olivine compound is represented by an empirical formula of Li (1−x2) A″ x2 MPO 4  where: 
 x2 is equal to or greater than 0.05 and equal to or less than 0.2, or x2 is equal to or greater than 0.0 and equal to or less than 0.1,  
 M is at least one member of the group consisting of iron, manganese, cobalt and magnesium, and  
 A″ is at least one member of the group consisting of sodium, magnesium, calcium, potassium, nickel and niobium; or  
 
   b) a mixture that includes 
 i) a lithium nickelate selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 ; a lithium nickelate that includes at least one Li atom modifier selected from the group consisting of barium, magnesium, calcium and strontium; and a lithium nickelate represented by an empirical formula of Li x3 Ni (1−z3) M′ z3 O 2  coated with LiCoO 2  as a gradient coating or a spot-wise coating where: 
 x3 is greater than 0.05 and less than 1.2,  
 z3 is greater than 0 and less than 0.5, and  
 M′ is at least one member of the group consisting of cobalt, manganese, aluminum, boron, titanium, magnesium, calcium and strontium; and  
 
 ii) a manganate spinel represented by an empirical formula of Li (1+x7) Mn 2−y7 O z7  where x7 and y7 are each independently equal to or greater than 0.0 and equal to or less than 1.0; and z7 is equal to or greater than 3.9 and equal to or less than 4.2.  
   
   
   
       80 . A battery pack comprising a plurality of cells, wherein each of the cells includes an active cathode material that includes: 
 a) a mixture that includes 
 i) at least one of a lithium cobaltate and a lithium nickelate, wherein the lithium cobaltate represented by an empirical formula of Li x6 M′ (1−y6) CO (1−z6) M″ z6 O 2  where: 
 x6 is greater than 0.05 and less than 1.2,  
 y6 is greater than or equal to 0 and less than 0.1,  
 z6 is equal to or greater than 0 and less than 0.5,  
 M′ is at least one of magnesium (Mg) and sodium (Na), and  
 M″ is at least one member of the group consisting of manganese, aluminum, boron, titanium, magnesium, calcium and strontium,  
 
 and wherein the lithium nickelate is selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 ; a lithium nickelate that includes at least one Li atom modifier selected from the group consisting of barium, magnesium, calcium and strontium; and a lithium nickelate represented by an empirical formula of Li x3 Ni (1−z3) M′ z3 O 2  coated with LiCoO 2  as a gradient coating or a spot-wise coating where: 
 x3 is greater than 0.05 and less than 1.2,  
 z3 is greater than 0 and less than 0.5, and  
 M′ is at least one member of the group consisting of cobalt, manganese, aluminum, boron, titanium, magnesium, calcium and strontium; and  
 
 ii) at least one of a manganate spinel and an olivine compound, wherein the manganate spinel is represented by an empirical formula of Li (1+x1) (Mn 1−y1 A′ y1 ) 2−x1 O z1  where: 
 x1 is equal to or greater than 0.01 and equal to or less than 0.3,  
 y1 is greater than 0.0 and equal to or less than 0.3,  
 z1 is equal to or greater than 3.9 and equal to or less than 4.1, and  
 A′ is at least one member of the group consisting of magnesium, aluminum, cobalt, nickel and chromium,  
 
 and wherein the olivine compound is represented by an empirical formula of Li (1−x2) A″ x2 MPO 4  where: 
 x2 is equal to or greater than 0.05 and equal to or less than 0.2, or x2 is equal to or greater than 0.0 and equal to or less than 0.1,  
 M is at least one member of the group consisting of iron, manganese, cobalt and magnesium, and  
 A″ is at least one member of the group consisting of sodium, magnesium, calcium, potassium, nickel and niobium; or  
 
   b) a mixture that includes 
 i) a lithium nickelate selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 ; a lithium nickelate that includes at least one Li atom modifier selected from the group consisting of barium, magnesium, calcium and strontium; and a lithium nickelate represented by an empirical formula of Li x3 Ni (1−   z3) M′ z3 O 2  coated with LiCoO 2  as a gradient coating or a spot-wise coating where: 
 x3 is greater than 0.05 and less than 1.2,  
 z3 is greater than 0 and less than 0.5, and  
 M′ is at least one member of the group consisting of cobalt, manganese, aluminum, boron, titanium, magnesium, calcium and strontium; and  
 
 ii) a manganate spinel represented by an empirical formula of Li (1+x7) Mn 2−y7 O z7  where x7 and y7 are each independently equal to or greater than 0.0 and equal to or less than 1.0; and z7 is equal to or greater than 3.9 and equal to or less than 4.2.  
   
   
   
       81 . A system comprising a portable electronic device and a battery pack that includes a plurality of cells, wherein each of the cells includes an active cathode material that includes: 
 a) a mixture that includes 
 i) at least one of a lithium cobaltate and a lithium nickelate, wherein the lithium cobaltate represented by an empirical formula of Li x6 M′ (1−y6) Co (1−z6) M″ z6 O 2  where: 
 x6 is greater than 0.05 and less than 1.2,  
 y6 is greater than or equal to 0 and less than 0.1,  
 z6 is equal to or greater than 0 and less than 0.5,  
 M′ is at least one of magnesium (Mg) and sodium (Na), and  
 
   M″ is at least one member of the group consisting of manganese, aluminum, boron, titanium, magnesium, calcium and strontium, 
 and wherein the lithium nickelate is selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 ; a lithium nickelate that includes at least one Li atom modifier selected from the group consisting of barium, magnesium, calcium and strontium; and a lithium nickelate represented by an empirical formula of Li x3 Ni (1−z3) M′ z3 O 2  coated with LiCoO 2  as a gradient coating or a spot-wise coating where: 
 x3 is greater than 0.05 and less than 1.2,  
 z3 is greater than 0 and less than 0.5, and  
 M′ is at least one member of the group consisting of cobalt, manganese, aluminum, boron, titanium, magnesium, calcium and strontium; and  
 
 ii) at least one of a manganate spinel and an olivine compound, wherein the manganate spinel is represented by an empirical formula of Li (1+x1) (Mn 1−y1 A′ y1 ) 2−x1 O z1  where: 
 x1 is equal to or greater than 0.01 and equal to or less than 0.3,  
 y1 is greater than 0.0 and equal to or less than 0.3,  
 z1 is equal to or greater than 3.9 and equal to or less than 4.1, and  
 A′ is at least one member of the group consisting of magnesium, aluminum, cobalt, nickel and chromium,  
 
 and wherein the olivine compound is represented by an empirical formula of Li (1−x2) A″ x2 MPO 4  where: 
 x2 is equal to or greater than 0.05 and equal to or less than 0.2, or x2 is equal to or greater than 0.0 and equal to or less than 0.1,  
 M is at least one member of the group consisting of iron, manganese, cobalt and magnesium, and  
 A″ is at least one member of the group consisting of sodium, magnesium, calcium, potassium, nickel and niobium; or  
 
   b) a mixture that includes 
 i) a lithium nickelate selected from the group consisting of Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 ; a lithium nickelate that includes at least one Li atom modifier selected from the group consisting of barium, magnesium, calcium and strontium; and a lithium nickelate represented by an empirical formula of Li x3 Ni (1−z3) M′ z3 O 2  coated with LiCoO 2  as a gradient coating or a spot-wise coating where: 
 x3 is greater than 0.05 and less than 1.2,  
 z3 is greater than 0 and less than 0.5, and  
 M′ is at least one member of the group consisting of cobalt, manganese, aluminum, boron, titanium, magnesium, calcium and strontium; and  
 
 ii) a manganate spinel represented by an empirical formula of  
   Li (1+x7) Mn 2−y7 O z7  where x7 and y7 are each independently equal to or greater than 0.0 and equal to or less than 1.0; and z7 is equal to or greater than 3.9 and equal to or less than 4.2.