CA2880876C

CA2880876C - Production of a spinel material

Info

Publication number: CA2880876C
Application number: CA2880876A
Authority: CA
Inventors: Kenneth Ikechukwu Ozoemena; Charl Jeremy Jafta
Original assignee: CSIR
Priority date: 2012-08-10
Filing date: 2013-07-25
Publication date: 2020-07-07
Anticipated expiration: 2033-07-25
Also published as: ZA201501121B; JP2015525734A; EP2882690B1; KR20150056542A; BR112015002884B1; CN104703920A; EP2882690A1; KR102085903B1; US9834854B2; US20150197872A1; AR092069A1; JP6316812B2; CA2880876A1; BR112015002884A2; WO2014024075A1

Abstract

A process for producing a lithium-manganese-nickel oxide spinel material includes maintaining a solution comprising a dissolved lithium compound, a dissolved manganese compound, a dissolved nickel compound, a hydroxycarboxylic acid, a polyhydroxy alcohol, and, optionally, an additional metallic compound, at an elevated temperature T1, where T1 is below the boiling point of the solution, until the solution gels. The gel is maintained at an elevated temperature until it ignites and burns to form a Li-Mn-Ni-O powder. The Li-Mn-Ni-O powder is calcined to burn off carbon and/or other impurities present in the powder. The resultant calcined powder is optionally subjected 1 to microwave treatment, to obtain a treated powder, which is annealed to crystallize the powder. The resultant annealed material is optionally subjected to microwave treatment. At least one of the microwave treatments is carried out. The lithium-manganese-nickel oxide spinel material is thereby obtained.

Description

CA 02880876 2015-02-03 WO 2014/024075 PCT/IB2013/056103 1 PRODUCTION OF A SPINEL MATERIAL THIS INVENTION relates to the production of a spinel material. More particularly, it relates to a process for producing a lithium-manganese-nickel oxide spinel material suitable for use as a cathode material in a lithium-ion electrochemical cell or battery. Lithium-ion batteries are viewed as the next generation of energy-storage devices for a variety of everyday applications such as hybrid electric vehicles, laptop computers, cell phones, etc. A particular lithium-manganese-nickel oxide material, LiMn1.5Ni0 504, has been receiving major research attention as a spinel cathode material for lithium-ion electrochemical cells or batteries because of its high operating voltage (-4.8 V) and its high intrinsic rate capability. Despite its many advantages, LiMn1.5Ni0.504, still encounters many obstacles for high-rate applications. For example, it is very difficult to synthesize a pure, stoichiometric Li1_x[Nio5Mn1.5]04 spinel as LiyNi1_y0 (an impurity) appears as a second phase, negatively impacting on the electrochemical behaviour. It is hence an object of this invention to provide an improved process for producing or synthesizing LiMn1.5Nio.504 and enhancing its electrochemical performance. A process for producing a lithium-manganese-nickel oxide spinel material, which process comprises maintaining a solution comprising a dissolved lithium compound, a dissolved manganese compound, a dissolved nickel compound, a hydroxycarboxylic acid, a polyhydroxy alcohol, and, optionally, an additional metallic compound, at an elevated temperature T1, where T1 is below the boiling point of the solution, until the solution gels; CA 02880876 2015-02-03 WO 2014/024075 PCT/IB2013/056103 2 maintaining the gel at an elevated temperature until it ignites and burns to form a Li-Mn-Ni-0 powder; calcining the Li-Mn-Ni-0 powder to burn off carbon and/or other impurities present in the powder, thereby obtaining a calcined powder; optionally, subjecting the calcined powder to microwave treatment, to obtain a treated powder; annealing the calcined powder or the treated powder to crystallize the powder, thereby obtaining an annealed material; and optionally, subjecting the annealed material to microwave treatment, with the proviso that at least one of the microwave treatments is effected, thereby to obtain the lithium-manganese-nickel oxide spinel material. Thus, when the calcined material is microwave treated, and the annealed material is not microwave treated, the annealed material will be the lithium- manganese-nickel oxide spinel material that is the product of the process. However, when the calcined powder is not subjected to microwave treatment, then the annealed material will be subjected to microwave treatment, with the thus microwaved material then being the lithium-manganese-nickel oxide spinel material that is the product of the process. Naturally, if desired, both the microwave treatment of the calcined material and the microwave treatment of the annealed material, can be employed. In one embodiment of the invention, the lithium-manganese-nickel oxide spinel material may be undoped. The lithium-manganese-nickel oxide spinel material may then, in particular, be LiMn1.5Ni0.504, which, as indicated hereinbefore, is particularly suited for use as a cathode material in a lithium- ion electrochemical cell or battery. However, in another embodiment of the invention, the lithium-manganese- nickel oxide spinel material may be doped. While the effect of such doping could be to control the amount of Mn3+ in the final lattice structure or the degree of disorder, as discussed hereunder, the primary aim thereof would be to improve other properties of the spinel material such as cycle stability. CA 02880876 2015-02-03 WO 2014/024075 PCT/IB2013/056103 3 The lithium-manganese-nickel oxide spinel material may be ordered, i.e. not be oxygen deficient. However, instead, the spinel material produced by the process of the invention could be disordered or oxygen-deficient. For example, the lithium-manganese-nickel oxide spinel material may be LiMni.5Ni0504_6X5 where b<1 and X is an anion such as fluoride. This compound is both doped and disordered. The process may include forming the solution of the lithium compound, the manganese compound, the nickel compound, the hydroxycarboxylic acid, and the polyhydroxy alcohol. The formulation of the solution may then include admixing a solution of the lithium compound dissolved in a solvent, a solution of the manganese compound dissolved in a solvent, a solution of the nickel compound dissolved in a solid, the hydroxycarboxylic acid and the polyhydroxy alcohol. While the lithium compound, the manganese compound, and the nickel compound can initially each be in the form of a separate solution in which each is dissolved, they are preferably all dissolved in the same solvent so that a single solution containing the dissolved lithium, manganese and nickel compounds is then admixed with the hydroxycarboxylic acid and the polyhydroxy alcohol. The lithium, manganese and nickel compounds are preferably water soluble so that water, preferably deionized water, can be used as the solvent of the solution. Thus, in particular, nitrates of lithium, manganese and nickel may be used, i.e. LiNO3, Mn(NO3)2 (more particularly Mn(NO3)2.4H20) and Ni(NO3)2 (more particularly Ni(NO3)2.6H20) may be used. The solution may thus contain the necessary stoichiometric amounts of LiNO3, Mn(NO3)2.4H20 and Ni(NO3)2.6H20 to obtain LiMn1.5Ni0.504 as the end product. The additional metallic compound, when present, will be selected to improve stability of the resultant spinel material. Thus, for example, the additional metallic compound may be a compound of aluminium or zirconium. Such CA 02880876 2015-02-03 WO 2014/024075 PCT/IB2013/056103 4 additional metallic compound will thus also be water soluble, and may be a nitrate of the metal in question. The metallic compounds, i.e. the lithium, manganese, nickel, and additional metal compounds, may instead be any other metallic salts (derived from both weak and strong acids such as the sulphates, carbonates, halides, and the acetates) other than the nitrates. The hydroxycarboxylic acid acts as a reduction agent, and may be citric acid. The polyhydroxy alcohol may be ethylene glycol or polyethylene glycol. The citric acid and the ethylene glycol may be present in the solution in an appropriate molar ratio of citric acid to ethylene glycol, e.g. about 1:4. The citric acid may initially be in the form of a solution thereof in water, particularly deionized water. The process may comprise initially heating the mixture of the citric acid solution and the ethylene glycol to the temperature T1 with stirring; thereafter, the solution of the lithium, manganese and nickel nitrates may be added slowly, e.g. dropwise, to the citric acid/ethylene glycol solution. As set out hereinbefore, T1 is below the boiling point of the solution comprising the solvent for the lithium, manganese and nickel compounds; the dissolved lithium, manganese and nickel compounds; the hydroxycarboxylic acid and the polyhydroxy alcohol. It is important that T1 be below the boiling point of the solution, to prevent premature evaporation of the solvent and other components of the solution, i.e. to prevent such evaporation before the gel-forming reaction (polymer gel formation) is complete. When the solvent is water as hereinbefore set out, then 90 C.T1<100 C. Preferably, T1 may then be about 90 C. CA 02880876 2015-02-03 WO 2014/024075 PCT/IB2013/056103 The elevated temperature at which the gel is maintained may be T2, where 90 C.T2<100 C. Preferably, T2 is the same as T1. In other words, preferably the solution is maintained at T1 until there has been complete or adequate gel formation, and the gel is then maintained at T1 until it ignites and burns to form 5 .. the Li-Mn-Ni-0 powder. The time t1 that the solution must be maintained at T1 for complete gel formation and evaporation of liquid components of the solution, and that the gel must be maintained at until it ignites, is dependent on factors such as the volume of the solution, T1, etc, but is typically at least 30 minutes. To form the Li-Mn-Ni-0 powder, a modified, one-step, powder-forming Pechini method is thus used. The calcination of the Li-MN-Ni-0 powder may be effected at a temperature T3. T3 will thus be sufficiently high for carbon and/or other impurities present in the powder to burn off. The calcination will thus be effected in a non- reducing atmosphere, preferably in an oxidizing atmosphere. Thus, T3 may be as low as 300 C to 350 C. However, more preferred is 400 C-f3<600 C; typically, T3 is about 500 C. The calcination may be continued for a period of time t2, with t2 thus being long enough to achieve burning off of carbon and/or other impurities to a desired degree, and with t2 also being dependent on factors such as the quantity of powder, T3, etc. Thus, preferably, t2<12 hours; typically, t2 may be about 6 hours. The annealing of the calcined or the treated powder may be effected at a temperature T4. T4 will thus be sufficiently high to crystallize the powder. Thus, preferably, 700 C-<145.900 C. Typically, T4 may be about 700 C or about 800 C. The annealing may be effected for a period of time t3, with t3 thus being long enough to achieve a desired degree of annealing, i.e. to .. achieve a desired degree of crystallinity of the powder. Typically, t3 will be less than 12 hours, e.g. about 8 hours. The microwave treatment may comprise subjecting the calcined powder to microwaves (typically at A=0.12236m, 600W) at about 60 C for between 10 6 and 20 minutes, typically about 15 minutes. The microwave power may be less than or greater than 600W. As also discussed in more detail hereinafter, the inventors surprisingly found that by producing LiMn1.5Ni0.504 using a modified, one step, powder forming Pechini method, coupled with a microwave irradiation of the powder, the Mn3+ content and site disorder can be controlled, thereby enhancing/maintaining electrochemical performance, e.g. capacity, cyclability, elimination of impurities, etc. It is thus not necessary to partially substitute Ni and/or Mn with metallic elements such as Ti, Fe, Cr, Ru or Mg to achieve this purpose. The process of the invention is thus characterized thereby that it does not include adding to any of the solutions and/or to the powder a metallic element such as Ti, Fe, Cr, Ru or Mg for purposes of partially replacing some of the Ni and/or Mn in Li Mn1.5Ni0.504. Thus, the end product does not contain any Ti, Fe, Cr, Ru or Mg. The invention will now be described in more detail with reference to the following non-limiting example and accompanying drawings. In the drawings FIGURE 1 shows typical Field Emission Scanning Electron Microscope (FESEM) images of the mesoporous LMN-700, LMN-800, LMN-700-microwave and LMN-800-microwave samples of the Example; FIGURE 2 compares the X-Ray Diffraction (XRD) patterns of the LMN- 700, LMN-800, LMN-700-microwave and LMN-800-microwave samples of the Example; FIGURE 3 show Mn2p3/2 X-Ray Photoelectron Spectroscopy (XPS) peaks of LMN-700, LMN-800, LMN-700-microwave and LMN-800-microwave samples of the Example; FIGURE 4 compares the discharge evolutions or discharge curves of LMN-700, LMN-800, LMN-700-microwave and LMN-800-microwave samples of the Example; and FIGURE 5 show the cycling comparisons at 0.1 C rate of LiMni 5Nio.504 spinel (annealed at 700 C and 800 C) and the LiMn1.5Ni0.504 spinel radiated with microwaves samples (annealed at 700 C and 800 C) of the Example. CA 2880876 2019-12-12 CA 02880876 2015-02-03 WO 2014/024075 PCT/IB2013/056103 7 FIGURE 6 show the cycling comparisons at 1C rate of LiMn15Ni0.504 spinel (annealed at 700 C and 800 C) and the LiMn1.5Ni0.504 spinel radiated with microwaves (annealed at 700 C and 800 C) samples of the Example. FIGURE 7 show the cycling comparisons at different rates of the 800 C annealed LiMn1.5Ni0.504 spinel and the LiMn1.5Ni0.504 spinel radiated with microwaves samples of the Example. EXAMPLE LiMn1.5Ni0504 (LMN) was prepared by a one-step powder-forming, Pechini modified method involving the use of citric acid (CA), ethylene glycol (EG) and nitrate salts. The reducing agent, CA (dissolved in deionised water) and EG was mixed in the ratio 1:4 (CA : EG) and heated at 90 C while constantly stirred for 30 min. Stoichionnetric amounts of LiNO3, Ni(NO3)2=6H20 and Mn(NO3)24H20 were dissolved in deionised water and introduced drop-wise to the CA/EG solution. After heating the resultant solution to, and maintaining it at, 90 C with constant stirring, the viscosity of the solution increased constantly due to evaporation of the water; the viscous solution subsequently dehydrated into a gel. The gel was kept at a temperature of 90 C until the gel spontaneously burnt (typically about 30 minutes after the salt-containing solution was added to the reducing agent) to form the desired powder. The powder was pre-heated, i.e. calcined, at 500 C for 6 h to get rid of carbonaneous materials present on the powder from the burning, and then annealed at 700 C or 800 C for 8 h (herein referred to as LMN-700 or LMN- 800, respectively). To study the impact of microwave irradiation, two batches of the pre-heated powder at 500 C were subjected to microwave irradiation (using the Anton Paar Multiwave 3000 system, A = 0.12236 m) at 600 W for 15 min, where the temperature of the samples reached a maximum of 60 C (measured with an infrared thermometer, which was approximately 5 cm away from the bottom of the vessel containing the powders), and then annealed at 700 C or 800 C for 8 h (herein referred to as LMN-700-mic or LMN-800-mic, respectively). The structural characterization was done by XRD using a Bruker AXS D8 ADVANCE X-ray Diffractometer with Ni-filtered Cu Ka radiation (A = 1.5406 A) CA 02880876 2015-02-03 WO 2014/024075 PCT/IB2013/056103 8 for the LMN-700 / LMN-700-mic and a PANalytical X'pert Pro Powder Diffractometer with Fe-filtered Co Ka, radiation (A = 1.7890 A) for the LMN- 800 / LMN-800-nnic. The scanning speed was 0.02 per step with a dwell time of 5 s for all samples. The LMN-700 / LMN-700-mic and LMN-800 / LMN-800- .. mic powders were mounted in a PHI 5400 ESCA and PHI 5000 Versaprobe¨ Scanning ESCA Microprobe vacuum chambers with base pressures 1 x 10-8 Torr. XPS was performed for LMN-700 / LMN-700-mic and LMN-800 / LMN- 800-mic using a non-monochromatic aluminium (Al) Ka source (1486.6 eV) and an Al monochromatic Ka source (1486.6 eV), respectively. The XPS data analysis was performed with the XPS Peak 4.1 program and a Shirley function was used to subtract the background. Electrochemical measurements were performed in a two-electrode coin cell (LIR-2032) assembled with the LMN materials as the positive electrode and lithium metal foil as the negative electrode using a MACCOR series 4000 tester. The cathodes were prepared by coating the slurry of a mixture composed of 80 (:)/0 active material, 10 % acetylene black, and 10 (:)/0 polyvinylidene fluoride onto cleaned and polished aluminium foil. Subsequently, the materials were dried at 90 C under vacuum (¨ 10-1 Torr) for 24 h. The cells were assembled in an argon-filled MBraun glovebox (02, H20 < 0.5 ppm). The electrolyte was 1M LiPF6 in a mixture of 1:1 (v/v) EC:DMC. A polypropylene film (Celgard 2300, Celgard LLC, Charlotte, North Carolina, USA) was used as the separator. SEM analysis (morphological analysis) Mesoporous structures were expected as already observed in the literature for LMN. As can be seen from Figure 1, all materials are nanostructured (-100nm size); however, the microwaved samples have a more interlinked structure. Clearly, the microwave irradiation has some impacts on the morphology and structure. CA 02880876 2015-02-03 WO 2014/024075 PCT/IB2013/056103 9 XRD analysis (structural analysis) Figure 2 compares the XRD patterns of the LMN and LMN-microwave samples. The diffraction peaks are ascribed to a cubic structure with a space group of Fd3m, indicating the formation of a single-phase LiMn1.5Ni0.504. All fundamental peaks are sharp, which indicates that the prepared powders are well crystallized. The ratio of the 4311) and 1(400) peaks (0.86-0.88) is an indication of the structural stability of the [Mn2]04 spinel framework. The high intensity ratio of the sample treated with microwave shows a better structural stability. An increase in the cubic lattice parameter is related to the large- sized Mn3+ ion, indicating the reduction of the Mn4+ to Mn3+ by microwave treatment. Note that such reduction of the inactive Mn4+ to the redox-active Mn3+ is (should be) accompanied by the loss of oxygen (disorderliness, signified by high value of the ratio /(311) and /(400) to maintain charge neutrality. Thus, microwave treatment clearly provides a facile approach to tune the Mn3+ concentration (and site orderliness), which allow for the evaluation of its influences on the electrochemical performances of the high-voltage LiMn1.5Nio504. Interestingly, as proved using XPS (see below), the LMN-microwave contains more Mn3+ ion than the parent LMN. Thus, the slight increase in the cubic lattice parameter for the LMN-microwave is due to the larger size of the Mn3+ ion. The powder XRD patterns (Figure 2) are characteristic of the cubic spinel structures with the microwave-treated samples showing sharper diffraction peaks than the bare samples, meaning that microwave irradiation enhanced crystallinity in the spinel. The impurity phase is virtually non-existent in the materials. The lattice parameters (a-value/A and unit cell volume/A3) were calculated as 8.153 A and 541.907 A3 for the LMN-700; 8.160 A and 543.170 A3 for the LMN-700-mic; 8.180 A and 547.417 A3 for the LMN-800; 8.179 A and 547.109 A3 for the LMN-800-mic. These values are comparable to values in literature. From the XRD patterns of the LMN-700 and LMN-700-mic, the latter shows preferential crystal growth according the (111) reflection, which may be ascribed to the microwave irradiation that changes the crystal growth kinetics. The slight increase in the lattice parameters for the pristine 800 sample compared to its 700 counterpart further proves that the 800 sample is CA 02880876 2015-02-03 WO 2014/024075 PCT/IB2013/056103 Mn3+-enriched (disordered phase). The increase in the lattice parameter for the LMN-700-mic indicates the creation of some oxygen vacancies in the spinel structure following the microwave irradiation process which causes some Mn4+ ions to be converted to Mn3+ due to charge compensation. On the 5 other hand, the lattice parameters for the LMN-800 and LMN-800-mic suggests a slight decrease in the oxygen vacancies for the microwave- irradiated disordered material. This suggests that at the experimental conditions employed, microwave irradiation simply adjusts the Mn3+ content to a lower value. As set out hereinafter, these adjustments of the Mn3+/Mn4+ 10 ratios (or oxygen vacancy concentration) have profound effects on the electrochemical properties of the spinel as a cathode material for lithium ion battery. XPS analysis (oxidation states analysis) To determine the actual amounts of the Mn3+ and Mn4+ in the spinel, XPS experiments were performed for the powdered spinel samples. Figure 3 shows the deconvoluted, detailed XPS of the Mn 4312 peaks of the LMN-700 / LMN-700-mic and LMN-800 / LMN-800-mic samples. Two peaks (as marked) are attributed to Mn3+ and Me and another (in the LMN-700 / LMN-700-mic spectra) to a Ni Auger peak. The binding energy peak positions corresponding to Mn4+ and Mn3+ are comparable with other binding energy values reported in literature. As shown in Table 1, the ratio of Mn3+ to Me (i.e., Mn3+/Mn4+) is 2.2 and 3.3 for the LMN-700 and LMN-700-mic, respectively. This increase in the Mn3+ content in in good agreement with the XRD data of increased a- lattice parameter, further confirming that microwave irradiation causes oxygen deficiency causing the Mn4+ to be converted to Mn3+ in the ordered spinel. For the LMN-800 and LMN-800-mic, the Mn3+/Mn4+ is 2.6 and 1.7, respectively. Again, this is in good agreement with the XRD data that predicted a slight downward adjustment of the Mn3+ content of the disordered sample. CA 02880876 2015-02-03 WO 2014/024075 PCT/IB2013/056103 11 Table 1: Mn 2p312 peak positions and cation distribution Binding energy Cation distribution Sample position (eV) Mn4+ Mn3+ mn4+ ___________________ mn3+ Enn3ilmn4+ LMN-700 643.2 642.1 31.5% 68.5% 2.17 LMN-700-m ic 643.4 642.2 23.4 ()/0 76.6 % 3.27 LMN-800 643.4 642.1 27.9 % 72.1 % 2.58 LMN-800-mic 643.3 641.9 37.5 % 62.5 % 1.67 Discharge capacities Figure 4 compares the 1st and 25th discharge profiles of LMN-700 / LMN-700- mic and LMN-800 / LMN-800-mic discharged at 0.1C (14 mA.g-1). Unlike the materials obtained at 700 C, the samples from 800 C showed well-defined plateaus at 4 V due to the Mn3+/Mn4+ redox couple, signature of 'disordered' spinel. In addition, the Ni2+/Ni3+ and Ni3+/Ni4+ redox couples of the disordered spinel are activated upon cycling, suggesting some structural changes induced by electrochemical cycling. The Mn3+/Mn4+ peaks are well-defined in the 800 C compared to the 700 C samples. The capacity of the LMN-700 decreased from the 1st cycle (103 mAh/g) to the 25th cycle (96 mAh/g), which is typical of ordered spinel. However, upon microwave treatment, the initial capacity of the LMN-700-mic (117 mAh/g) increased to 130 mAh/g at the 25th cycle. For the 800 C samples, the initial cycles of the bare and the microwave-treated samples (105 and 125 mAh/g, respectively) increased upon cycling (117 and 138 mAh/g at the 25th cycle, respectively). This increase in capacity upon cycling could be atributed to the wetting process of the electrodes with the electrolytes prior to stabilisation of the electrochemical reactions. The higher performance of the LMN-800-mic over the bare sample suggests the intrinsic ability of microwave irradiation to adjust the Mn3+ concentration in the spinel for enhanced electrochemistry. CA 02880876 2015-02-03 WO 2014/024075 PCT/IB2013/056103 12 Capacity retention (cyclability) and rate capability The cycle stability of the spinel samples at 50 repetitive cycles was explored. Figure 5 compares the cycle stability of the bare and microwave-treated samples, which clearly proves that microwave irradiation improves the cyclability of the spinels (for both the ordered and disordered structures, with the latter benefitting the most). As shown in Figure 5a, for the LMN-700, the discharge capacities differ (103, 96 and 34 mAh/g for the 1st, 25th and 50th cycles, respectively). For the LMN-700-mic, it was 117, 130 and 110 mAh/g for the 18t, 25th and 50th cycles, respectively. From the results, it isevident that microwave irradiation may serve as a viable strategy to improve the capacity retention for such [MN at 700 C. However, for the LMN-800 (Figure 5b), the discharge capacities also differ (105, 117 and 113 mAh/g for the 1st, 25th and 50th cycles, respectively. For the LMN-800-nnic, it was 125, 138 and 136 mAh/g for the 1st, 25th and 50th cycles, respectively. As indicated by the Figure 5, the best performance is always obtained by the LMN-800-mic sample, with a capacity retention of ca.100% between the 10th and 50th cycle, compared to the capacity retentions of ¨ 97 and 84% for LMN- 800 and LMN-700-nnic, respectively. The excellent capacity retention of the LMN-800-mic may be partly due to the higher connectivity of the nanoparticles as seen in the FESEM pictures, and partly to the 'appropriate' amount of Mn3+ induced by the microwave irradiation. In general, it is common knowledge that LMN sample obtained at higher temperature (800 C, disordered) shows better electrochemical performance than the 700 C (ordered). Some of the reasons may be due to the better crystallinity and increased conductivity due to the Mn3+ compared to the Mn4+. For high power applications, good rate capability is of utmost importance for any cathode materials for lithium ion battery. All the samples were charged at 14 mA/g (0.1C) and discharged at 140 mA/g (1C) and the 800 C samples showed the best performance (Figure 6). Thus, in this study, the 800 C samples were charged at 14 mA/g (0.1C) and discharged between 70 mA/g (0.5C) and 1400 mA/g (10C). Figure 7 clearly proves that microwave treatment greatly enhances the rate capability of the spinel material. CA 02880876 2015-02-03 WO 2014/024075 PCT/IB2013/056103 13 The electrochemical performance of LiMn1.5Ni0.504 as a lithium ion battery cathode material is intricately linked to the (i) presence of Mn3+ ions, (ii) doping/substitution, (iii) degree of disorder, and (iv) impurities, which explains why it still remains a huge challenge to correlate synthesis, structure and performance of this cathode material. It is common knowledge that the Mn3+ ion is electrochemically active, usually identified by the presence of a small plateau at around 4V; however, a portion of the Mn3+ ions may also form Mn2+ through the disproportion reaction; Mn2+ dissolves into the electrolyte at elevated temperatures, causing significant capacity loss during cycling (J. Xiao, X. Chen, P. V. Sushko, M.L. Sushko, L. Kovarik, J. Feng, Z. Deng, J. Zheng, G.L. Graff, Z. Nie, D. Choi, J. Liu, J.-G. Zhang, M.S. Whittingham, Adv. Mater. 24 (2012) 2109-2116). To enhance the cyclability and eliminate the impurities in the LiMn1.5Ni0.504, a commonly adopted approach hitherto has been to partially substitute Ni and/or Mn with metallic elements, such as Ti, Fe, Cr, Ru or Mg. A disordered or oxygen-defficient spinel (i.e. LiMni.5Ni0504_6) is usually accompanied by an impurity (LiyNi1_y0) that appears as a secondary phase in the products, which lowers the obtainable capacity. However, the cycling performance of the disordered spinel is better than the ordered spinel as the former gives a significantly higher Li + diffusion coefficient than the latter. In ordered P4332 phase, Me and Ni2+ ions are ordered on octahedral sites in a 3:1 ratio as opposed to random distribution in disordered Fdan phase. The Xiao et al reference referred to above, indicates 'careful control of the amount of Mn3 ions and, thus, the disordered phase, is the key for synthesis of high performance spinel and provides valuable clues for understanding the structure-property relationships in energy materials'. The electrochemical performance of any chemical material is strongly dependent on the synthesis strategy. It is evident from what is set out above that the preferred synthesis strategy for the high-voltage LiMn1.5Ni0.504 spinel should be able to (i) control the amount of the Mn3+ in the final lattice structure, and hence the site disorder, (ii) limit the amount of the LiyNi1_y0 CA 02880876 2015-02-03 WO 2014/024075 PCT/IB2013/056103 14 impurity, and (iii) maintain its high voltage (4.8-5V) and achieve capacity close or better than the theoretical value of ¨140nnAh/g-1. The inventors thus surprisingly found that by using a modified Pechini synthesis strategy coupled with microwave irradiation, a LiMn1.5Ni0.504 spinel cathode material with desired properties could be obtained. For example, the inventors proved, for the first time, that it is possible to control the Mn3+ content and site disorder by a simple microwave treatment. The inventors thus found that they could achieve the same or better results to those achievable by known processes, and using shorter processing times, by using low temperature annealing coupled with short duration 20 minutes) microwave irradiation. Simply stated, the microwave-assisted strategy introduced by the inventors for the preparation and enhancing the electrochemical performance of LiMn1.5Ni0.504 spinel materials promises to avoid many of the disadvantages associated with conventional procedures of making this spinel cathode material.

Claims

15 CLAIMS 1. A process for producing a lithium-manganese-nickel oxide spinel material, which process comprises maintaining a solution comprising a dissolved lithium compound, a dissolved manganese compound, a dissolved nickel compound, a hydroxycarboxylic acid, a polyhydroxy alcohol, and, optionally, an additional metallic compound, at an elevated temperature T1, where T1 is below the boiling point of the solution, until the solution gels; maintaining the gel at an elevated temperature until it ignites and burns to form a Li-Mn-Ni-O powder; calcining the Li-Mn-Ni-O powder to burn off carbon and/or other impurities present in the powder, thereby obtaining a calcined powder; subjecting the calcined powder to microwave treatment, to obtain a treated powder; and annealing the treated powder to crystallize the powder, thereby obtaining an annealed material; thereby to obtain the lithium-manganese-nickel oxide spinel material.

2. The process according to Claim 1, wherein the solution includes water as a solvent for the lithium compound, the manganese compound, and the nickel compound, which are thus water soluble salts thereof, with 90.degree.C.ltoreq.T1<100.degree.C.

3. The process according to Claim 2, wherein T1 is 90.degree.C.

4. The process according to any one of Claims 1 to 3, wherein the elevated temperature at which the gel is maintained is T2, where 90.degree.C.ltoreq.T2<100.degree.C.

5. The process according to Claim 4, wherein T2 is 90.degree.C. 16

6. The process according to any one of Claims 1 to 5, wherein the calcination of the Li-Mn-Ni-O powder is effected at a temperature T3, where 400.degree.C.ltoreq.T3<600.degree.C.

7. The process according to Claim 6, wherein T3 is about 500.degree.C.

8. The process according to any one of Claims 1 to 7, wherein the annealing of the treated powder is effected at a temperature T4, where 700.degree.C.ltoreq.T4.ltoreq.900.degree.C.

9. The process according to Claim 8, wherein 700.degree.C.ltoreq.T4.ltoreq.800.degree.C.

10. The process according to any one of Claims 1 to 9, wherein the lithium-manganese-nickel oxide spinel material is undoped, and is LiMn1.5Ni0.5O4.

11. The process according to any one of Claims 1 to 9, wherein the lithium-manganese-nickel oxide spinel material is doped.

12. The process according to Claim 11, wherein the lithium- manganese-nickel oxide spinel material is ordered so that it is not oxygen deficient.

13. The process according to any one of Claims 1 to 12, which includes using the additional metallic compound to improve stability of the spinel material, with the additional metallic compound being a compound of aluminium or zirconium.

14. The process according to any one of Claims 1 to 13, wherein the hydroxycarboxylic acid is citric acid.

15. The process according to Claim 14, wherein the polyhydroxy alcohol is ethylene glycol. 17

16. The process according to Claim 15, wherein the citric acid and the ethylene glycol are present in the solution in a molar ratio of citric acid to ethylene glycol of about 1:4.

17. The process according to any one of Claims 1 to 16, wherein the microwave treatment comprises subjecting the calcined powder to microwaves at about 60.degree.C for between 10 and 20 minutes.

18. The process according to any one of Claims 1 to 17, further comprising subjecting the annealed material to microwave treatment.