One-Pot Synthesis for Lithium Ion Battery Cathode Material Precursors

Abstract

Provided is an improved method for forming lithium ion cathode materials specifically for use in a battery. The method comprises forming a first solution comprising a digestible feedstock of a first metal suitable for formation of a cathode oxide precursor and a multi-carboxylic acid. The digestible feedstock is digested to form a first metal salt in solution wherein the first metal salt precipitates as a salt of deprotonated multi-carboxylic acid thereby forming an oxide precursor. The oxide precursor is heated to form the lithium ion cathode material.

1 - 56 . (canceled) 
     
     
         57 . A lithium metal oxide cathode comprising:
 a core comprising Ni and Mn in a first molar ratio; and   at least one shell around said core comprising Ni and Mn in a second molar ratio wherein said second molar ratio is different from said first molar ratio wherein said core has a higher ratio of Ni to Mn than said shell.   
     
     
         58 . (canceled) 
     
     
         59 . The lithium metal oxide cathode of claim  55  wherein at least one of said core or said shell has a composition defined by the Formula I:
   LiNi x Mn y Co z E e O 4    Formula I
 
 wherein E is a dopant; 
 x+y+z+e=2; and
 0≤e≤0.2 
 
 
     
     
         60 . The lithium metal oxide cathode of  claim 59  wherein said Formula I is in a spinel crystalline form. 
     
     
         61 . The lithium metal oxide cathode of claim  56  wherein neither x nor y are zero. 
     
     
         62 . The lithium metal oxide cathode of  claim 61  wherein said lithium ion cathode material is LiNi 0.5 Mn 1.5 O 4 . 
     
     
         63 . The lithium metal oxide cathode of  claim 59  wherein said cathode material is defined by the formula LiNi x Mn y O 4  wherein 0.5≤x≤0.6 and 1.4≤y≤1.5.
 More preferably 
 
     
     
         64 . The lithium metal oxide cathode of  claim 63  wherein said 0.5≤x≤0.55 and 1.45≤y≤1.5. 
     
     
         65 . The lithium metal oxide cathode of  claim 59  wherein said cathode material has a molar ratio of Mn to Ni of no more than 3. 
     
     
         66 . The lithium metal oxide cathode of  claim 65  wherein said cathode material has a molar ratio of Mn to Ni of at least 2.33 to less than 3. 
     
     
         67 . The lithium metal oxide cathode of  claim 66  wherein said cathode material has a molar ratio of Mn to Ni of at least 2.64 to less than 3. 
     
     
         68 . The lithium metal oxide cathode of  claim 59  wherein said dopant is selected from the group consisting of Al, Gd, Ti, Zr, Mg, Ca, Sr, Ba, Mg, Cr Fe, Cu, Zn, V, Bi, Nb and B. 
     
     
         69 . The lithium metal oxide cathode of  claim 59  wherein said dopant is selected from the group consisting of Al and Gd. 
     
     
         70 . The lithium metal oxide cathode of  claim 57  wherein said cathode material is defined by the Formula II:
   LiNi a Mn b X c G d O 2    Formula II
 
 wherein G is a dopant; 
 X is Co or Al; 
 wherein a+b+c+d=1; and 
 0≤d≤0.1. 
 
     
     
         71 . The lithium metal oxide cathode of  claim 70  wherein 0.5≤a≤0.9. 
     
     
         72 . The lithium metal oxide cathode of  claim 71  wherein 0.58≤a≤0.62 or 0.78≤a≤0.82. 
     
     
         73 . The lithium metal oxide cathode of  claim 70  wherein a=b=c. 
     
     
         74 . A battery comprising the lithium metal oxide of  claim 57 .