US2016087272A1PendingUtilityA1
Lithium Secondary Batteries with Positive Electrode Compositions and Their Methods of Manufacturing
Est. expiryNov 3, 2028(~2.3 yrs left)· nominal 20-yr term from priority
H01M 4/485H01M 4/1391H01M 2220/30H01M 2004/021H01M 4/131H01M 10/052H01M 10/0525H01M 2004/028H01M 4/02H01M 4/505H01M 4/525H01M 2220/20H01M 4/5825Y02E60/10Y02T10/70
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Claims
Abstract
Positive electrodes for secondary batteries formed with a plurality of substantially aligned flakes within a coating. The flakes can be formed from metal oxide materials and have a number average longest dimension of greater than 60 μm. A variety of metal oxide or metal phosphate materials may be selected such as a group consisting of LiCoO 2 , LiMn 2 O 4 , Li(M1 x1 M2 x2 Co 1-x1-x2 )O 2 where M1 and M2 are selected from among Li, Ni, Mn, Cr, Ti, Mg, or Al, 0≦x1≦0.5 and 0≦x2≦0.5, or alternatively, LiM1 (1-x) Mn x O 2 where 0<x<0.8 and M1 represents one or more metal elements. Methods for making positive electrode materials are also provided involving the formation of structures with a desired longest dimension, preferably polycrystalline flakes. A cathode coating containing polycrystalline flakes may be deposited onto a conductive substrate and pressed to a desired final electrode thickness.
Claims
exact text as granted — not AI-modified1 . A secondary battery having an electrode comprising a conductive substrate coated with a plurality of flakes that have a number average longest dimension greater than 60 μm, said flakes comprising a metal oxide or metal phosphate material.
2 . The secondary battery of claim 1 , wherein the plurality of flakes are aligned to form a cathode coating that is at least 30 μm thick.
3 . The secondary battery of claim 1 , wherein the flakes have a shortest dimension of about 17 μm or 25 μm.
4 . (canceled)
5 . (canceled)
6 . The secondary battery of claim 1 , further comprising a filler for filling in spaces or voids between the plurality of flakes, said filler comprising a powder with average particle size less than about 17 μm in any direction.
7 . The secondary battery of claim 6 , wherein the filler consists of a metal oxide or a metal phosphate material or a combination of metal oxide and metal phosphate materials.
8 . The secondary battery of claim 1 , wherein the metal oxide material is selected from the group consisting of LiCoO 2 , Li(Mn 1-x3 M3 x3 ) 2 O 4 , Li(M1 x1 M2 x2 Co 1-x1-x2 )O 2 where M1 and M2 are selected from among Li, Ni, Mn, Cr, Ti, Mg, or Al, M3 is selected from one or a combination of Li, Ni, Co, Cr, Ti, Mg, or Al, ≦x1≦0.5, 0≦x2≦0.5 and 0≦x3≦0.5.
9 . The secondary battery of claim 1 , wherein the metal oxide material is LiM1 (1-x) Mn x O 2 where 0<x<0.8 and M1 represents one or more metal elements.
10 . The secondary battery of claim 9 , wherein M1 includes nickel, cobalt or a combination thereof.
11 . The secondary battery of claim 9 , wherein the metal oxide is LiNi 0.33 Co 0.33 Mn 0.33 O 2 (NMC).
12 . The secondary battery of claim 9 , wherein the metal phosphate material is described by the formula LiMPO 4 , where M is selected from one or a combination of Fe, Mn, Ni or Co.
13 . A secondary battery having an electrode comprising a conductive substrate coated with a plurality of polycrystalline or monocrystalline flakes of one or more metal oxide or metal phosphate materials.
14 . The secondary battery of claim 13 , wherein the flakes have a shortest dimension of about 17 μm or 25 μm.
15 . The secondary battery of claim 13 , wherein the flakes have a longest dimension of greater than 60 μm.
16 . (canceled)
17 . (canceled)
18 . (canceled)
19 . The secondary battery of claim 13 , wherein the metal oxide material is selected from the group consisting of LiCoO 2 , Li(Mn 1-x3 M3 x3 ) 2 O 4 , Li(M1 x1 M2 x2 Co 1-x1-x2 )O 2 where M1 and M2 are selected from among Li, Ni, Mn, Cr, Ti, Mg, or Al, M3 is selected from one or a combination of Li, Ni, Co, Cr, Ti, Mg, or Al, ≦x1≦0.5, 0≦x2≦0.5 and 0≦x3≦0.5.
20 . The secondary battery of claim 13 , wherein the metal phosphate material is defined by the formula LiMPO 4 where M is selected from one of or a combination of Fe, Mn, Ni or Co.
21 . The secondary battery of claim 13 , wherein the metal oxide material is LiM1 (1-x) Mn x O 2 where 0<x<0.5 and M1 represents one or more metal elements.
22 . A positive electrode material comprising a plurality of flakes that have a longest dimension greater than 100 μm of a metal oxide or metal phosphate material.
23 . The positive electrode material of claim 22 , wherein the metal oxide material is selected from the group consisting of LiCoO 2 , Li(Mn 1-x3 M3 x3 ) 2 O 4 , Li(M1 x1 M2 x2 C 1-x1-x2 )O 2 where M1 and M2 are selected from among Li, Ni, Mn, Cr, Ti, Mg, or Al, M3 is selected from one or a combination of Li, Ni, Co, Cr, Ti, Mg, or Al, ≦x1≦0.5, 0≦x2≦0.5 and 0≦x3≦0.5.
24 . The positive electrode material of claim 22 , wherein the metal oxide material is LiM1 (1-x) Mn x O 2 where 0<x<0.5 and M1 represents one or more metal elements.
25 . The positive electrode material of claim 22 , wherein the metal phosphate material is defined by the formula LiMPO 4 , where M is selected from one of or a combination of Fe, Mn, Ni, or Co.
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