U.S. patent application number 17/719523 was filed with the patent office on 2022-08-04 for positive electrode active material for lithium rechargeable battery, method of producing the same, and lithium rechargeable battery including the same.
This patent application is currently assigned to LG Chem, Ltd.. The applicant listed for this patent is LG Chem, Ltd.. Invention is credited to Gi Beom Han, Hyuck Hur, Chi Ho Jo, Wang Mo Jung, Seul Ki Kim.
Application Number | 20220246928 17/719523 |
Document ID | / |
Family ID | 1000006269323 |
Filed Date | 2022-08-04 |
United States Patent
Application |
20220246928 |
Kind Code |
A1 |
Jo; Chi Ho ; et al. |
August 4, 2022 |
Positive Electrode Active Material for Lithium Rechargeable
Battery, Method of Producing the Same, and Lithium Rechargeable
Battery Including the Same
Abstract
A surface of a LiCoO.sub.2-based positive electrode active
material to have a rock salt crystal structure is provided.
Specifically, a positive electrode active material for a lithium
rechargeable battery is provided, including: a core particle
containing lithium cobalt oxide doped with aluminum (Al); and a
coating layer positioned on a surface of the core particle and
containing a cobalt (Co)-based compound having a rock salt crystal
structure. A method of producing the positive electrode active
material is also provided using a solid-phase method. The positive
electrode active material can be applied to a positive electrode,
lithium rechargeable battery, battery module, battery pack, and the
like.
Inventors: |
Jo; Chi Ho; (Daejeon,
KR) ; Hur; Hyuck; (Daejeon, KR) ; Kim; Seul
Ki; (Daejeon, KR) ; Jung; Wang Mo; (Daejeon,
KR) ; Han; Gi Beom; (Daejeon, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LG Chem, Ltd. |
Seoul |
|
KR |
|
|
Assignee: |
LG Chem, Ltd.
Seoul
KR
|
Family ID: |
1000006269323 |
Appl. No.: |
17/719523 |
Filed: |
April 13, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
16549545 |
Aug 23, 2019 |
11342557 |
|
|
17719523 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01M 10/0525 20130101;
H01M 2004/021 20130101; H01M 4/525 20130101; H01M 2004/028
20130101; H01M 4/366 20130101 |
International
Class: |
H01M 4/525 20060101
H01M004/525; H01M 4/36 20060101 H01M004/36; H01M 10/0525 20060101
H01M010/0525 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 24, 2018 |
KR |
10-2018-0099115 |
Claims
1. A method of producing a positive electrode active material for a
lithium rechargeable battery, comprising: mixing a core particle
comprising lithium cobalt oxide doped with Al and a cobalt raw
material comprising tricobalt tetraoxide (Co.sub.3O.sub.4), cobalt
(II) hydroxide (Co(OH).sub.2), or a mixture thereof; and calcining
the mixture of the cobalt raw material and the core particle.
2. The method of claim 1, wherein: in the calcining of the mixture
of the cobalt raw material and the core particle, a phase of the
cobalt raw material is changed into a cobalt-based compound having
a rock salt crystal structure and a surface of the core particle is
coated with the cobalt-based compound having a rock salt crystal
structure.
3. The method of claim 1, wherein: in the mixing of the cobalt raw
material with the core particle, a weight ratio (core
particle:cobalt raw material) of the core particle to the cobalt
raw material is 1,000:0.2 to 1,000:10.
4. The method of claim 1, wherein: in the calcining of the mixture
of the cobalt raw material and the core particle, a calcination
temperature is 800 to 1,200.degree. C.
5. The method of claim 1, wherein: in the calcining of the mixture
of the cobalt raw material and the core particle, a calcination
time is 2 to 10 hours.
6. The method of claim 1, wherein: the positive electrode active
material comprises: the core particle comprising lithium cobalt
oxide doped with aluminum (Al); and a coating layer on a surface of
the core particle, wherein the coating layer comprises a
cobalt-based compound having a rock salt crystal structure.
7. The method of claim 6, wherein: the cobalt-based compound having
the rock salt crystal structure is cobalt(II) oxide.
8. The method of claim 6, wherein: the core particle comprises: a
first region in which a crystal structure of the lithium cobalt
oxide doped with Al is a layered structure; and a second region in
which a crystal structure of the lithium cobalt oxide doped with Al
is a spinel structure.
9. The method of claim 8, wherein: the first region is represented
by the following Formula 1,
Li.sub.aCo.sub.(1-x-y-z)Al.sub.xM1.sub.yM2.sub.zO.sub.2 [Formula 1]
wherein M1 and M2 are each independently one selected from the
group consisting of Ti, Mg, Zr, Ba, Ca, Ta, Nb, and Mo, and a, x,
y, and z are values satisfying 0.95.ltoreq.a.ltoreq.1.05,
0<x.ltoreq.0.02, 0.ltoreq.y.ltoreq.0.02, and
0.ltoreq.z.ltoreq.0.02, respectively.
10. The method of claim 8, wherein: the second region is
represented by the following Formula 2,
Li.sub.a-mCo.sub.(1-x-y-z)Al.sub.xM1.sub.yM2.sub.zO.sub.2 [Formula
2] wherein M1 and M2 are each independently one selected from the
group consisting of Ti, Mg, Zr, Ba, Ca, Ta, Nb, and Mo, and a, x,
y, z, and m are values satisfying 0.95.ltoreq.a.ltoreq.1.05,
0<x.ltoreq.0.02, 0.ltoreq.y.ltoreq.0.02, 0.ltoreq.z.ltoreq.0.02,
and 0<m<0.75, respectively.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a divisional of U.S. application
Ser. No. 16/549,545, filed on Aug. 23, 2019, which claims priority
to and the benefit of Korean Patent Application No. 10-2018-0099115
filed in the Korean Intellectual Property Office on Aug. 24, 2018,
the entire contents of which are incorporated herein by
reference.
BACKGROUND OF THE INVENTION
(a) Field of the Invention
[0002] The present invention relates to a positive electrode active
material for a lithium rechargeable battery, a method of producing
the same, and a lithium rechargeable battery including the
same.
(b) Description of the Related Art
[0003] In recent years, the demand for a large-capacity power
storage device as well as a small electronic device has increased
significantly. In accordance with the demand, there is a growing
interest in an electrochemical device exhibiting a high capacity
and high power.
[0004] In this regards, attempts have been made to increase a
capacity of a lithium rechargeable battery by making a charge
voltage thereof higher than that of a commercial lithium
rechargeable battery having a charge and discharge region of 3.0 to
4.2 V.
[0005] Specifically, a positive electrode active material is a
component by which the capacity of the lithium rechargeable battery
is implemented. As a positive electrode active material, lithium
cobalt oxide (LiCoO.sub.2, so-called "LCO") is applied to the
commercial lithium rechargeable battery.
[0006] LiCoO.sub.2 is a compound having a layered crystal
structure, and the battery has a high rolling density and
relatively excellent electrochemical characteristics such as cycle
characteristics and the like when using LiCoO.sub.2.
[0007] Since LiCoO.sub.2 is a compound having a low charge and
discharge current amount of about 150 mAh/g, in a case where a
charge voltage of higher than 4.2 V is applied to a battery to
which LiCoO.sub.2 is applied, a crystal structure of the
LiCoO.sub.2 becomes unstable and Co.sup.3+ ions are eluted from the
inside of the battery. Accordingly, a side reaction between the
eluted Co.sup.3+ ions and an electrolyte occurs on a surface of the
LiCoO.sub.2, resulting in deterioration of the battery
lifespan.
[0008] Therefore, in order to implement a lithium rechargeable
battery exhibiting a high capacity and high power and having
stability, a positive electrode active material should be improved
in advance.
[0009] The above information disclosed in this Background section
is only for enhancement of understanding of the background of the
invention and therefore it may contain information that does not
form the prior art that is already known in this country to a
person of ordinary skill in the art.
SUMMARY OF THE INVENTION
[0010] The present invention has been made in an effort to provide
a technology of modifying a surface of a LiCoO.sub.2-based positive
electrode active material to have a rock salt crystal
structure.
[0011] An exemplary embodiment of the present invention provides a
positive electrode active material for a lithium rechargeable
battery, including: a core particle containing lithium cobalt oxide
doped with aluminum (Al); and a coating layer positioned on a
surface of the core particle and containing a cobalt (Co)-based
compound having a rock salt crystal structure.
[0012] Another exemplary embodiment of the present invention
provides a method of producing the positive electrode active
material of the embodiment described above using a solid-phase
method.
[0013] Yet another exemplary embodiment of the present invention
provides various examples (positive electrode, lithium rechargeable
battery, battery module, battery pack, and the like) of applying
the positive electrode active material of the embodiment described
above.
[0014] Hereinafter, embodiments of the present invention will be
described in detail. However, the embodiments are only provided by
way of example, and the present invention is not limited thereto,
but may be defined by the scope of the appended claims.
[0015] In addition, in the specification, a particle diameter D0.9
indicates a particle diameter when active material particles with
various particle diameter distributions of 0.1, 0.2, 0.3, . . . ,
3, 5, 7, . . . , 10, 20, and 30 .mu.m are accumulated up to 0.9% at
a volume ratio, D10 indicates a particle diameter when the active
material particles are accumulated up to 10% at a volume ratio, D50
indicates a particle diameter when the active material particles
are accumulated up to 50% at a volume ratio, D6 indicates a
particle diameter when the active material particles are
accumulated up to 6% at a volume ratio, and D95 indicates a
particle diameter when the active material particles are
accumulated up to 95% at a volume ratio.
[0016] Hereinafter, embodiments of the present invention will be
described in detail. However, the embodiments are only provided by
way of example, and the present invention is not limited thereto,
but may be defined by the scope of the appended claims.
[0017] Positive Electrode Active Material
[0018] In an embodiment of the present invention, a lithium cobalt
oxide particle whose surface is modified to have a rock salt
crystal structure is provided as a positive electrode active
material.
[0019] Problems of Commercial LiCoO.sub.2
[0020] As pointed out above, the theoretical capacity of
LiCoO.sub.2 is about 275 mAh/g, and a capacity of the LiCoO.sub.2
when using 4.2 V as an upper limit voltage is about 150 mAh/g. In a
case where the upper limit voltage is increased to 4.4 V in order
to increase the capacity, battery performance is significantly
reduced due to a structure change of the LiCoO.sub.2. In order to
solve the problem, doping is performed to prevent the structure
change, such that the battery performance is significantly improved
and a 4.4 V battery is recently in mass production.
[0021] Meanwhile, in order to increase an electrode density for
increasing a capacity of a battery, LiCoO.sub.2 with a small
particle diameter (D50 particle diameter of about 5 to 10 .mu.m)
applied to a commercial lithium rechargeable battery may be
replaced with LiCoO.sub.2 with a large particle diameter (D50
particle diameter of about 12 to 25 .mu.m) or a positive electrode
active material having a form in which LiCoO.sub.2 with a small
particle diameter and LiCoO.sub.2 with a large particle diameter
are mixed (so-called "a bimodal form") may be applicable to a
lithium rechargeable battery.
[0022] However, since the kinetic characteristics of LiCoO.sub.2
with a large particle diameter are inferior to that of LiCoO.sub.2
with a small particle diameter, a lithium (Li) deficient layer may
be artificially formed in a partial area of a surface of the
LiCoO.sub.2 with a large particle diameter so as to improve the
kinetic characteristics of the LiCoO.sub.2 with a large particle
diameter to the level of the LiCoO.sub.2 with a small particle
diameter.
[0023] Here, a general crystal structure of LiCoO.sub.2 is a
layered structure regardless of a particle diameter. However, in
the Li deficient layer, the crystal structure is changed into a
spinel structure similar to LiMn.sub.2O.sub.4 depending on a change
in Li/Co molar ratio.
[0024] Such a Li deficient layer is uniformly formed from the
surface of the LiCoO.sub.2 with a large particle diameter up to a
certain depth, such that a core having a layered structure and a
shell having a spinel structure may be obtained. Meanwhile, a
layered structure and a spinel structure are formed to be mixed
from the surface of the LiCoO.sub.2 with a large particle diameter
up to a certain depth, such that a core having a layered structure
and a shell having both a layered structure and a spinel structure
may be obtained.
[0025] In a case where a Li deficient layer is artificially formed
in a partial area of a surface of LiCoO.sub.2 with a large particle
diameter into any form, the kinetic characteristics thereof may be
improved to the level of LiCoO.sub.2 with a small particle
diameter, and even in a case where a charge voltage of 4.4 V is
applied to a battery to which the above LiCoO.sub.2 is applied, an
elution of internal metal (Co) may not occur.
[0026] In accordance with the continuous demand for increase in
capacity of a battery, a cell has been developed according to the
demand for 4.45 V and 4.5 V batteries. However, as an upper limit
voltage is increased, surface stability of LiCoO.sub.2 is reduced
and Co is thus eluted. The eluted Co is deposited on a negative
electrode surface, resulting in degradation of the battery
performance. In particular, it is confirmed that the Co elution
amount is rapidly increased as the voltage of the battery is
increased to 4.45 V or 4.5 V from 4.4 V. Accordingly, since a new
concept of LiCoO.sub.2 is required for 4.45 V and 4.5V batteries, a
method of improving battery performance by reducing an elution of
Co is suggested.
[0027] Note that when the charge voltage is about 4.45 V or higher,
internal metal (Co) is eluted even in a state where a Li deficient
layer is artificially formed in a partial area of a surface of
LiCoO.sub.2 with a large particle diameter. That is, the spinel
structure present in the partial area of the surface of LiCoO.sub.2
with a large particle diameter also becomes unstable at the charge
voltage of about 4.45 V or higher, which causes the same problems
as the existing LiCoO.sub.2 with a small particle diameter.
[0028] Surface Modification by Rock Salt Crystal Structure
[0029] In an embodiment of the present invention, a surface of
lithium cobalt oxide doped with Al is modified to have a rock salt
crystal structure and the surface-modified lithium cobalt oxide is
provided as a positive electrode active material. In the positive
electrode active material of the embodiment, the elution of
internal metal (Co) may not occur even in a case where a charge
voltage of higher than 4.2 V, 4.4 V or higher, or further 4.45 V or
higher is applied to a lithium rechargeable battery to which the
positive electrode active material is applied regardless of a
particle diameter of LiCoO.sub.2.
[0030] More specifically, the positive electrode active material of
the embodiment includes a core particle containing lithium cobalt
oxide doped with Al; and a coating layer positioned on a surface of
the core particle and containing a cobalt-based compound having a
rock salt crystal structure.
[0031] The coating layer further contains cobalt, lithium cobalt
oxide, or a combination thereof.
[0032] Here, the rock salt crystal structure may maintain surface
structure stability thereof even in a case where a charge voltage
of higher than 4.2 V, 4.4 V or higher, or further 4.45 V or higher
is applied. Specifically, cobalt(II) oxide (CoO) which is a
cobalt-based compound may be selected as a compound having a rock
salt crystal structure.
[0033] This is because cobalt(II) oxide has a low reactivity with
an electrolyte as compared to Al.sub.2O.sub.3 well known as a
coating agent for a surface of LiCoO.sub.2 and improves the surface
stability, such that the elution of Co is reduced. Specifically,
when using an upper limited voltage of 4.4 V, the battery
performance may be improved by performing a surface coating with
Al.sub.2O.sub.3, but it is difficult to expect the surface
stability with only Al.sub.2O.sub.3 coating when using an upper
limited voltage of 4.45 V or higher.
[0034] Meanwhile, the core particle contains lithium cobalt oxide
doped with Al, and Al may serve to stabilize a crystal (lattice)
structure of the lithium cobalt oxide and prevent a structure
change at a high voltage. The structure of the lithium cobalt oxide
may be further stabilized by using Al as compared with the case of
using other dopants. In a case where the lithium cobalt oxide in
the core particle is not doped with Al, in spite of the presence of
the surface modification (that is, the coating layer) by the rock
salt crystal structure, the crystal (lattice) structure of the
lithium cobalt oxide may be collapsed at a voltage of 4.4 V to 4.5
V.
[0035] In other words, it is possible to maintain a more solid and
stable structure of the positive electrode active material of the
embodiment at a high voltage by a synergistic effect between Al
doped on the lithium cobalt oxide in the core particle and the
surface modification (that is, the coating layer) by the rock salt
crystal structure.
[0036] The coating layer containing the cobalt-based compound
having a rock salt crystal structure may be obtained by mixing
tricobalt tetraoxide (Co.sub.3O.sub.4), cobalt(II) hydroxide
(Co(OH).sub.2), or a cobalt raw material containing a mixture
thereof with an object to be coated (that is, the core particle)
and performing calcination, as described later.
[0037] In the calcination process, a phase change of the cobalt raw
material and a coating of cobalt(II) oxide (CoO) formed by the
phase change may be simultaneously performed. In addition, the
phase change of the cobalt raw material may be performed in a state
where the surface of the core particle is coated with the cobalt
raw material, and the coating may be performed after the phase
change is performed in advance. However, in a case where the
calcination is performed in a state in which the cobalt raw
material and the core particle are mixed in a powder form, the
phase change and the coating may be simultaneously performed in
multiple times, such that it is difficult to distinguish the order
of the phase change and the coating. In this sense, it may be
considered that the phase change and the coating are simultaneously
performed.
[0038] More specifically, a phase of the cobalt raw material may be
changed into the cobalt(II) oxide (CoO) having a rock salt crystal
structure. The surface of the core particle may be coated with the
phase-changed cobalt(II) oxide (CoO). Metal cobalt which is an
inevitable impurity contained in the cobalt raw material or lithium
cobalt oxide produced by a reaction of the cobalt(II) oxide with
the surface of the core particle may be also coated together, but
the present invention is not limited thereto.
[0039] The coating layer formed by using the solid-phase method may
have an island form in which the surface of the core particle is
coated with the cobalt-based compound having a rock salt crystal
structure. That is, the cobalt(II) oxide having a rock salt crystal
structure may be coated in a particle form.
[0040] Characteristics of a production method will be described
later. Hereinafter, components constituting the positive electrode
active material of the embodiment will be described in more
detail.
[0041] Weight Ratio of Core Particle to Coating Layer, Thickness of
Coating Layer, and D50 Particle Diameter of Core Particle
[0042] In the positive electrode active material of the embodiment,
a weight ratio (core particle:coating layer) of the core particle
to the coating layer may be 1,000:0.2 to 1,000:10, and specifically
1,000:0.5 to 1,000:2. That is a content of the coating layer may be
200 to 10,000 ppm, and specifically 500 to 2,000 ppm based on 1 kg
of the core particles. Within the content range, the inside of the
coating layer is effectively protected by the rock salt crystal
structure thereof, such that the elution of internal metal (Co) and
the side reaction with the electrolyte may be suppressed, but the
present invention is not limited thereto.
[0043] Meanwhile, a D50 particle diameter of the core particle may
be 12 to 25 .mu.m, and specifically 15 to 20 .mu.m, and in this
case, the core particle may correspond to the LiCoO.sub.2 with a
large particle diameter described above.
[0044] In consideration of the D50 particle diameter of the core
particle and the weight ratio of the core particle to the coating
layer, a thickness of the coating layer may be in a range of 1 to
50 nm, and specifically 2 to 20 nm. Such a thickness of the coating
layer may be derived from a comprehensive consideration of the D50
particle diameter of the core particle (12 to 25 .mu.m) which is an
absolute numerical value, and the weight ratio of the core particle
to the coating layer, the weight ratio being 1,000:0.2 to 1,000:10,
and specifically 1,000:0.5 to 1,000:2 and a relative concept with
respect to the D50 particle diameter.
[0045] Meanwhile, the core particle may be one obtained by
artificially forming a Li deficient layer in a partial area of a
surface of LiCoO.sub.2 with a large particle diameter as described
above.
[0046] In this case, the core particle may have a first region in
which a crystal structure of the lithium cobalt oxide is a layered
structure; and a second region in which a crystal structure of the
lithium cobalt oxide is a spinel structure or a mixed structure of
a spinel structure and a layered structure from an interface with
the first region to a surface of the core particle.
[0047] Here, the first region may be represented by the following
Formula 1 and the second region may be represented by the following
Formula 2.
Li.sub.aCo.sub.(1-x-y-z)Al.sub.xM1.sub.yM2.sub.zO.sub.2 [Formula
1]
Li.sub.a-mCo.sub.(1-x-y-z)Al.sub.xM1.sub.yM2.sub.zO.sub.2 [Formula
2]
[0048] (M1 and M2 each independently are one selected from the
group consisting of Ti, Mg, Zr, Ba, Ca, Ta, Nb, and Mo; and a, x,
y, z, and m are values satisfying 0.95.ltoreq.a.ltoreq.1.05,
0<x.ltoreq.0.02, 0.ltoreq.y.ltoreq.0.02, 0.ltoreq.z.ltoreq.0.02,
and 0<m<0.75, respectively.)
[0049] A difference between Formulas 1 and 2 is a Li/Co molar
ratio, a Li/Co molar ratio in Formula 1 is a/(1-x-y-z) and a Li/Co
molar ratio in Formula 2 is (a-m)/(1-x-y-z). That is, the
difference of the Li/Co molar ratios between Formulas 1 and 2 means
that the second region is a lithium deficient layer.
[0050] In each of Formulas 1 and 2, each of Al, M1, and M2
corresponds to a dopant which is substituted in the cobalt site in
the crystal (lattice) structure of the lithium cobalt oxide. In
addition, x, y, and z each mean a doping amount of each Al, M1, and
M2. In a case of introducing the dopant, the crystal (lattice)
structure of the lithium cobalt oxide forming the first region and
the second region may be stabilized and the structure change at a
high voltage may be prevented.
[0051] In particular, in each of Formulas 1 and 2,
0<x.ltoreq.0.02 means that Al is essentially doped in each of
the first region and the second region. As described above, the
structure of the lithium cobalt oxide may be further stabilized by
using Al as compared with the case of using other dopants. In a
case where the first region and the second region are not doped
with Al, in spite of the presence of the coating layer, the crystal
(lattice) structure of the lithium cobalt oxide may be collapsed at
a voltage of 4.4 V to 4.5 V.
[0052] In each of Formulas 1 and 2, one of M1 and M2 may be Ti, the
other one of M1 and M2 may be Mg, 0<y.ltoreq.0.02 and
0.ltoreq.z.ltoreq.0.02, 0.ltoreq.y.ltoreq.0.02 and
0<z.ltoreq.0.02, or 0<y.ltoreq.0.02 and 0<z.ltoreq.0.02.
This means that at least one of Ti and Mg may be co-doped together
with Al. As such, in the case where at least one of Ti and lo Mg is
co-doped together with Al, structure stabilization and resistance
reduction effects may be further improved as compared to the case
of doping only Al. In particular, growth of the core particle is
suppressed by Ti, such that a size of a single crystal becomes
small, which contributes to reducing a battery resistance and
extending the lifespan of the battery. In addition, Mg is an
element capable of implementing a so-called pillar effect and may
contribute to further stabilizing the crystal structure of the core
particle. Accordingly, in the case where at least one of Ti and Mg
is co-doped together with Al, it may be advantageous to improve
electrochemical characteristics of a battery, as compared to the
case where the core particle is doped with only Al.
[0053] In the case of doping only Al, the doping amount of Al may
be 1,000 to 8,000 ppm, and specifically 2,000 to 6,000 ppm based on
based on 1 kg of the core particles. In the case of co-doping at
least one of Ti and Mg together Al, the doping amount of Al may be
1,000 to 4,000 ppm, the doping amount of Ti or Mg may be 400 to
1,500 ppm, and specifically 500 to 1,000 ppm, based on 1 kg of the
core particles.
[0054] Regardless of whether only Al is doped or at least one of Ti
and Mg is co-doped together with Al, in the case of using a core
particle obtained by artificially forming a Li deficient layer in a
partial area of a surface of LiCoO.sub.2 with a large particle
diameter doped with Al, the kinetic characteristics thereof may be
improved, and even in a case where a charge voltage of 4.4 V is
applied to a battery to which the core particle is applied, an
elution of internal metal (Co) may not occur.
[0055] Furthermore, in a case where a core particle obtained by
artificially forming a Li deficient layer in a partial area of a
surface of LiCoO.sub.2 with a large particle diameter doped with Al
is used, a dopant is introduced into the core particle, and a
surface of the core particle is modified to have the rock salt
crystal structure, a strong synergistic effect appears. Therefore,
even in a case where a charge voltage of higher than 4.2 V, 4.4 V
or higher, or further 4.45 V or higher is applied, an elution of
internal metal (Co) is further suppressed, which may possible to
implement a lithium rechargeable battery exhibiting a high capacity
and high power and having stability.
[0056] Co Elution Suppression Characteristics (Parameter)
[0057] When a battery is stored at a temperature range of 50 to
80.degree. C. for one week and then discharged at a voltage of 4.4
V, actually, the Co elution amount per 1 g of the positive
electrode active material may be 100 to 200 ppm/g, and specifically
130 to 160 ppm/g.
[0058] In addition, when a battery is stored at a temperature of
60.degree. C. for one week and then discharged at a voltage of 4.5
V, the Co elution amount per 1 g of the positive electrode active
material may be 1,500 to 2,500 ppm/g, and specifically 1,800 to
2,200 ppm/g.
[0059] This fact means that the Co elution amount is significantly
reduced at each voltage as compared to a case of a bare core
particle whose surface is not be modified to have the rock salt
crystal structure, and is supported by experimental examples
described later.
[0060] Here, the Co elution amount may be measured as follows. In
order to reduce measurement errors, the amount of positive
electrode mixture material loaded per surface area of an electrode
is set to be 60 to 80 mg/cm.sup.2 by increasing the loaded amount
than that when producing a general electrode, and the electrode
charged within a range of 4.4 V to 4.5 V is prepared and then put
into a Nalgene bottle together with a 4 ml electrolyte. The Nalgene
bottle is completely sealed with a parafilm and an aluminum pouch
so as to prevent evaporation of the electrolyte. The completely
sealed bottle is stored in a chamber at 60.degree. C. for one week.
After one week, for extracting only the electrolyte, the positive
electrode active material which may be present in the electrolyte
as a floating matter is completely removed by using a sealing sheet
as a filter. The electrolyte is evaporated to quantify the amount
of Co present, that is, eluted in the electrolyte through
inductively coupled plasma (ICP). The Co elution amount is
calculated by dividing the weight of Co of which quantification is
confirmed by the weight of LiCoO.sub.2 positive electrode active
material of the electrode impregnated with the electrolyte at the
beginning. Note that this is merely an example and the present
invention is not limited thereto.
[0061] Method of Producing Positive Electrode Active Material
[0062] In another embodiment of the present invention, there is
provided a method of producing the positive electrode active
material of the embodiment using the solid-phase method.
[0063] It is possible to obtain a positive electrode active
material having a surface modified in an island form by using the
solid-phase method as described above. On the other hand, in a case
of using a gas dispersion method, a wet method, and the like, the
surface of the positive electrode active material is modified in a
film form or a form in which a film form and an island form are
mixed, such that the surface of the positive electrode active
material is effectively passivated and surface reactivity with the
electrolyte may be thus effectively reduced, as compared with the
surface modification of the island form.
[0064] Specifically, the method of producing the embodiment may
include mixing a core particle containing lithium cobalt oxide with
tricobalt tetraoxide (Co.sub.3O.sub.4), cobalt(II) hydroxide
(Co(OH).sub.2), or a cobalt raw material containing a mixture
thereof; and calcining the mixture of the cobalt raw material and
the core particle containing the lithium cobalt oxide doped with
Al.
[0065] In the mixing of the cobalt raw material with the core
particle, a weight ratio (core particle:cobalt raw material) of the
core particle to the cobalt raw material may be 1,000:0.2 to
1,000:10, and specifically 1,000:0.5 to 1,000:2. That is, a content
of the cobalt raw material may be 200 to 10,000 ppm, and
specifically 500 to 2,000 ppm based on 1 kg of the core particles,
and in this case, the weight ratio of core particle:coating layer
may be satisfied as described above.
[0066] Although mixing conditions such as time, a speed, a
temperature, a device, and the like are not particularly limited in
the mixing of the cobalt raw material with the core particle, the
cobalt raw material and the core particle may be put into a mixer
to stir the mixture for 5 minutes to 30 minutes at room temperature
and 800 to 1,200 rpm.
[0067] As the mixer, a paste mixer may be used as the examples
described later, but is not limited thereto, and a mixer usually
used in the art when solid phase mixing may be used.
[0068] Thereafter, in the calcining of the mixture of the cobalt
raw material and the core particle, the crystal structure of the
core particle is not changed, but a phase of the cobalt raw
material is changed into a cobalt-based compound having a rock salt
crystal structure and a surface of the core particle may be coated
with the cobalt-based compound having a rock salt crystal
structure.
[0069] To this end, the mixture of the cobalt raw material and the
core particle may be calcined at a calcination temperature of 800
to 1,200.degree. C. for 2 to 10 hours. More specifically, the
calcination is started from a temperature of 900 to 1,000.degree.
C., and the calcination temperature is raised at a heating rate of
3 to 5.degree. C./min for 2 to 6 hours, and then may be maintained
at the reached temperature for 3 to 5 hours. Note that this is
merely an example and the present invention is not limited
thereto.
[0070] Meanwhile, when the weight ratio of the core particle to the
cobalt raw material (core particle:cobalt raw material) is
1,000:0.2 to 1,000:10, and specifically 1,000:0.5 to 1,000:2, a
coating layer having a thickness of 1 to 40 nm, and specifically 2
to 20 nm may be formed on the surface of the core particle
containing the lithium cobalt oxide. The description thereof is as
described above and a detailed description thereof will thus be
omitted.
[0071] An example of the core particle may include a core particle
having: a first region in which a crystal structure of the lithium
cobalt oxide doped with Al is a layered structure; and a second
region in which a crystal structure of the lithium cobalt oxide
doped with Al is a spinel structure or a mixed structure of a
spinel structure and a layered structure from an interface with the
first region to a surface of the core particle. A commercial core
particle may be used and a directly produced core particle may be
used. The latter may be produced by using methods of examples
described later or a method well known in the art. Since the
present invention is not limited to a method of producing the core
particle, a detailed description thereof will be omitted.
[0072] In yet another embodiment of the present invention, there is
provided various examples (positive electrode, lithium rechargeable
battery, battery module, battery pack, and the like) of applying
the positive electrode active material.
[0073] The lithium rechargeable battery according to the embodiment
includes: an electrode assembly including a positive electrode, a
negative electrode facing the positive electrode, a separator
disposed between the positive electrode and the negative electrode,
and an electrolyte with which the positive electrode, the negative
electrode, and the separator are impregnated; a battery container
accommodating the electrode assembly; and a sealing member sealing
the battery container.
[0074] The positive electrode includes a positive electrode current
collector and a positive electrode active material layer formed on
the positive electrode current collector, and the positive
electrode active material layer includes the positive electrode
active material described above. Accordingly, the electrochemical
device may exhibit high capacity and high power characteristics, as
well as excellent thermal stability and lifespan
characteristics.
[0075] The negative electrode includes a negative electrode current
collector and a negative active material layer formed on the
negative electrode current collector, and the negative active
material layer includes a negative active material.
[0076] Examples of the negative active material include a material
capable of reversibly intercalating/deintercalating lithium ions, a
lithium metal, a lithium metal alloy, a material capable of doping
and dedoping lithium, or a transition metal oxide.
[0077] The material capable of reversibly
intercalating/deintercalating lithium ions is a carbon material,
may be any generally-used carbon-based negative active material in
a lithium rechargeable battery, and representative examples thereof
may include crystalline carbon, amorphous carbon, or a combination
thereof. Examples of the crystalline carbon may include a graphite
such as a shapeless graphite, a sheet-shaped graphite, a
flake-shaped graphite, a spherical-shaped graphite, or a
fiber-shaped natural graphite or artificial graphite, and examples
of the amorphous carbon may include soft carbon (low temperature
calcined carbon), hard carbon, mesophase pitch carbide, calcined
cokes, and the like.
[0078] The lithium metal alloy may be an alloy of lithium and a
metal of Na, K, Rb, Cs, Fr, Be, Mg, Ca, Sr, Si, Sb, Pb, In, Zn, Ba,
Ra, Ge, Al, or Sn.
[0079] Examples of the material capable of doping and dedoping
lithium may include Si, SiO.sub.x (0<x<2), a Si--C composite,
a Si-Q alloy (wherein Q is an alkali metal, an alkaline earth
metal, Group 13 to 16 elements, a transition metal, a rare earth
element, or a combination thereof, and not Si), Sn, SnO.sub.2,
Sn--C composite, Sn--R (wherein R is an alkali metal, an alkaline
earth metal, Group 13 to 16 elements, a transition metal, a rare
earth element, or a combination thereof, and not Sn), and the like.
Examples of specific elements of Q and R may include Mg, Ca, Sr,
Ba, Ra, Sc, Y, Ti, Zr, Hf, Rf, V, Nb, Ta, Db, Cr, Mo, W, Sg, Tc,
Re, Bh, Fe, Pb, Ru, Os, Hs, Rh, Ir, Pd, Pt, Cu, Ag, Au, Zn, Cd, B,
Al, Ga, Sn, In, Ti, Ge, P, As, Sb, Bi, S, Se, Te, Po, or a
combination thereof.
[0080] Example of the transition metal oxide may include vanadium
oxide, lithium vanadium oxide, and the like.
[0081] The negative active material layer further includes a binder
and may optionally further include a conductive material.
[0082] The binder serves to bond negative active material particles
with one another well and bond the negative active material to the
current collector well. Representative examples of the binder may
include polyvinyl alcohol, carboxymethyl cellulose, hydroxypropyl
cellulose, polyvinyl chloride, carboxylated polyvinyl chloride,
polyvinyl fluoride, an ethylene oxide-containing polymer,
polyvinylpyrrolidone, polyurethane, polytetrafluoroethylene,
polyvinylidene fluoride, polyethylene, polypropylene,
styrene-butadiene rubber, acrylated styrene-butadiene rubber, an
epoxy resin, nylon, and the like, but are not limited thereto.
[0083] The conductive material is used for imparting electrical
conductivity to an electrode. Any conductive material may be used
as long as it is an electrically conductive material without
causing a chemical change. Examples of the conductive material may
include a carbon-based material such as natural graphite,
artificial graphite, carbon black, acetylene black, Ketjen black,
carbon fiber, and the like; a metal-based material such as metal
powder or metal fiber of copper, nickel, aluminum, silver, and the
like; a conductive polymer such as a polyphenylene derivative and
the like; or mixture thereof.
[0084] Examples of the current collector may include a copper foil,
a nickel foil, a stainless steel foil, a titanium foil, a nickel
foam, a copper foam, a polymer substrate coated with a conductive
metal, or a combination thereof.
[0085] The electrolyte includes a non-aqueous organic solvent and
lithium salt.
[0086] The non-aqueous organic solvent serves as a medium through
which ions involved in electrochemical reaction of a battery may
migrate.
[0087] Examples of the non-aqueous organic solvent may include a
carbonate-based solvent, an ester-based solvent, an ether-based
solvent, a ketone-based solvent, an alcohol-based solvent, or an
aprotic solvent. Examples of the carbonate-based solvent may
include dimethyl carbonate (DMC), diethyl carbonate (DEC), dipropyl
carbonate (DPC), methylpropyl carbonate (MPC), ethylpropyl
carbonate (EPC), methylethyl carbonate (MEC), ethylene carbonate
(EC), propylene carbonate (PC), butylene carbonate (BC), and the
like. Examples of the ester-based solvent may include methyl
acetate, ethyl acetate, n-propyl acetate, 1,1-dimethylethyl
acetate, methyl propionate, ethyl propionate,
.gamma.-butyrolactone, decanolide, valerolactone, mevalonolactone,
caprolactone, and the like. Examples of the ether-based solvent may
include dibutyl ether, tetraglyme, diglyme, dimethoxyethane,
2-methyl tetrahydrofuran, tetrahydrofuran, and the like. Examples
of the ketone-based solvent may include cyclohexanone and the like.
In addition, examples of the alcohol-based solvent may include
ethyl alcohol, isopropyl alcohol, and the like. Examples of the
aprotic solvent may include nitriles such as R--CN (wherein R is a
C2 to C20 linear, branched, or cyclic hydrocarbon group, and may
include a double bond, an aromatic ring, or an ether bond), amides
such as dimethylformamide, dioxolanes such as 1,3-dioxolane,
sulfolanes, and the like.
[0088] The non-aqueous organic solvent may be used alone or in a
mixture. When the non-aqueous organic solvent is used in a mixture,
a mixture ratio thereof may be adjusted depending on desired
battery performance, which may be widely understood by those
skilled in the art.
[0089] In addition, the carbonate-based solvent may be used by
mixing cyclic carbonate with chain carbonate. In this case, the
cyclic carbonate and the chain carbonate may be mixed with each
other at a volume ratio of about 1:1 to about 1:9, which may
enhance electrolyte performance.
[0090] The non-aqueous organic solvent may be obtained by further
adding an aromatic hydrocarbon-based organic solvent to the
carbonate-based solvent. In this case, the carbonate-based solvent
and the aromatic hydrocarbon-based organic solvent may be mixed
with each other at a volume ratio of about 1:1 to about 30:1.
[0091] The non-aqueous electrolyte may further include a vinylene
carbonate-based or ethylene carbonate-based compound to extend a
battery lifespan.
[0092] Representative examples of the ethylene carbonate-based
compound include difluoroethylene carbonate, chloroethylene
carbonate, dichloroethylene carbonate, bromoethylene carbonate,
dibromoethylene carbonate, nitroethylene carbonate, cyanoethylene
carbonate, fluoroethylene carbonate, vinylene ethylene carbonate,
and the like. In a case where the vinylene carbonate-based or
ethylene carbonate-based compound is further used, the amount
thereof may be properly adjusted to extend the battery
lifespan.
[0093] The lithium salt is dissolved in the non-aqueous organic
solvent, lo supplies lithium ions in the battery, facilitates the
basic operation of the lithium rechargeable battery, and promotes
lithium ion migration between the positive and negative electrodes.
Representative examples of the lithium salt include LiPF.sub.6,
LiBF.sub.4, LiSbF.sub.6, LiAsF.sub.6, LiC.sub.4F.sub.9SO.sub.3,
LiClO.sub.4, LiAlO.sub.2, LiAlCl.sub.4,
LiN(C.sub.xF.sub.2x+1SO.sub.2)(C.sub.yF.sub.2y+1SO.sub.2) (wherein
x and y are natural numbers), LiCl, LiI, LiB(C.sub.2O.sub.4).sub.2,
lithium bis(oxalato) borate (LiBOB), or combination thereof, which
is used as a supporting electrolytic salt. The lithium salt is
preferably used in a concentration of about 0.1 M to about 2.0 M.
When the concentration of the lithium salt falls within the above
range, an electrolyte has proper conductivity and viscosity, such
that excellent electrolyte performance may be exhibited and lithium
ions may effectively migrate.
[0094] The separator separates a negative electrode and a positive
electrode from each other and supplies a migration path for lithium
ions and any separator may be used as long as it is and usually
used in a lithium battery. That is, a separator having a low
resistance with respect to migration of ions in an electrolyte and
an excellent electrolyte-retaining ability. Examples of the
separator are glass fiber, polyester, Teflon, polyethylene,
polypropylene, polytetrafluoroethylene (PTFE), and a combination
thereof, each of which may be a non-woven or woven fabric. For
example, a separator formed of a polyolefin (such as polyethylene,
polypropylene, or the like)-based polymer, may be mainly used for a
lithium ion battery. In order to ensure thermal resistance or
mechanical strength, a coated separator including a ceramic
component or a polymer material may be used, and the separator may
have a mono-layered or multi-layered structure.
[0095] The lithium rechargeable battery of the embodiment may not
only used for a unit cell used as a power source of a small-sized
device but also be used for a unit battery used in a middle and
large sized battery module including a plurality of battery cells.
Furthermore, the battery modules may constitute a battery pack.
[0096] According to the embodiments of the present invention, the
lithium rechargeable battery exhibiting a high capacity and high
power and having stability may be implemented.
BRIEF DESCRIPTION OF THE DRAWINGS
[0097] FIG. 1 shows photographs obtained by observing each of
positive electrode active materials in Example 1 and Comparative
Example 3 with a field emission scanning electron microscope
(FE-TEM) and a transmission electron microscope (TEM).
[0098] FIG. 2 is a graph showing the results obtained by measuring
the amount of Co eluted in each of lithium rechargeable batteries
of Example 1 and Comparative Examples 1 to 3 after 2 charge and
discharge cycles under certain conditions.
[0099] FIG. 3 is a graph showing the results obtained by measuring
the amount of gas generated in each of lithium rechargeable
batteries of Example 1 and Comparative Examples 1 to 3 after 2
charge and discharge cycles under certain conditions.
[0100] FIG. 4 is a graph showing the results obtained by evaluating
electrochemical characteristics of each of lithium rechargeable
batteries produced in Example 1 and Comparative Examples 1 to 3
after high temperature storage at 60.degree. C.
[0101] FIG. 5 is a graph showing the results obtained by evaluating
electrochemical characteristics of each of lithium rechargeable
batteries produced in Example 1 and Comparative Examples 1 to 3 at
room temperature of 25.degree. C.
[0102] FIG. 6 is a graph showing the results obtained by evaluating
electrochemical characteristics of each of lithium rechargeable
batteries produced in Examples 1 to 4 and Comparative Example 4 to
at room temperature of 25.degree. C.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0103] Hereinafter, preferred examples of the present invention,
comparative examples, and experimental examples for evaluating them
will be described. However, the following examples are merely
preferred examples of the present invention, and the present
invention is not limited to the following examples.
EXAMPLE 1
LCO with Large Particle Diameter Whose Surface is Modified with CoO
by Solid-Phase Method, Only Al Doping
(1) Production of Positive Electrode Active Material
[0104] 1) Production of Core Particle
[0105] A dry mixture of an Al doping raw material
(Al(OH).sub.3)Co.sub.3O.sub.4) and Li.sub.2CO.sub.3 was calcined in
a furnace at 1,050.degree. C. for 8 hours to form a lithium cobalt
oxide (LiCo.sub.0.98Al.sub.0.02O.sub.2) particle doped with Al. A
molar ratio of Li:Co in Co.sub.3O.sub.4 and Li.sub.2CO.sub.3 of the
dry mixture was 1:1, and Al(OH).sub.3 was 2 g with respect to the
total amount (500 g) of Co.sub.3O.sub.4 and Li.sub.2CO.sub.3.
[0106] Thereafter, a first region was formed by the lithium cobalt
oxide (LiCo.sub.0.98Al.sub.0.02O.sub.2) particle doped with Al. In
order to form a lithium deficient layer doped with Al on an outer
surface of the first region, an Al doping raw material,
Co.sub.3O.sub.4, and Li.sub.2CO.sub.3 were further added to the
furnace and dry-mixed, and then the mixture was calcined at
800.degree. C. for 6 hours. In the added materials when forming the
second region, a molar ratio of Li:Co in Co.sub.3O.sub.4 and
Li.sub.2CO.sub.3 was 0.3:1, and the Al doping raw material was 0.87
g with respect to the total amount (500 g) of Co.sub.3O.sub.4 and
Li.sub.2CO.sub.3.
[0107] Therefore, a core particle having the second region with a
thickness of 20 nm formed on the surface of the first region
(LiCoO.sub.2) could be obtained (D50 of the entire core particles:
18 .mu.m).
2) Formation of Coating Layer
[0108] 0.5 g of Co.sub.3O.sub.4 powder was mixed with 500 g of the
core particle doped with only Al and the mixture was calcined at
950.degree. C. for 4 hours to obtain a positive electrode active
material in which a CoO coating layer having a thickness of 20 nm
is formed on the surface of the core particle.
(2) Production of Lithium Rechargeable Battery
[0109] A positive electrode was produced using the positive
electrode active material of Example 1 and a negative electrode was
separately produced, and then they were assembled into a battery in
accordance with a method commonly known in the art.
1) Production of Positive Electrode
[0110] Specifically, the positive electrode active material of
Example 1 was lo used, carbon black was used as a conductive
material, and polyvinylidene fluoride (PVdF) was used as a binder.
They were mixed in a weight ratio of 96:2:2 (positive electrode
active material:conductive material:binder) an N-methylpyrrolidone
(NMP) solvent was used, thereby producing positive electrode
slurry.
[0111] The produced positive electrode slurry was applied onto a
surface of an aluminum foil having a thickness of 20 .mu.m in a
loading amount of 15 g/cm.sup.2, a positive electrode was produced
by performing drying at 130.degree. C. for 2 hours, and then roll
pressing was performed.
2-1) Production of Negative Electrode (Applied to Coin Full Cell
(CFC))
[0112] Natural graphite was used as a negative electrode active
material, carbon black was used as a conductive material, and
styrene-butadiene rubber (SBR) was used as a binder. They were
mixed in a weight ratio of 96:2:2 (negative electrode active
material:conductive material:binder) to produce negative electrode
slurry.
[0113] The produced negative electrode slurry was applied onto a
copper foil, a negative electrode was produced by performing vacuum
drying at 60.degree. C. for 12 hours, and then roll pressing was
performed.
2-2) Reference Electrode (Applied to Coin Half Cell (CHC))
[0114] A lithium (Li) metal foil having a thickness of 300 .mu.m
was used as a reference electrode.
3-1) Assembly of Battery (Coin Full Cell (CFC))
[0115] The positive electrode and the negative electrode were used,
a polyethylene separator (thickness of 12 .mu.m, manufactured by
Celgard LLC) was used as a separator, and an electrolyte (1 mole of
lithium hexafluorophosphate (LiPF.sub.6), ethylene carbonate
(EC)/dimethyl carbonate (DMC)=1/1 volume ratio) was injected to
produce a coin full cell type lithium rechargeable battery.
3-2) Assembly of Battery (Coin Half Cell (CHC))
[0116] A coin half cell type lithium rechargeable battery was
produced in the same manner as in 3-1) above, except that the
produced positive electrode was used as a working electrode and the
Li metal foil having a thickness of 300 .mu.m was used as a
reference electrode.
[0117] It should be noted that descriptions omitted in the
production of positive electrode, the production of negative
electrode, and the assembly of battery are in accordance with a
method commonly known in the art.
EXAMPLE 2
LCO with Large Particle Diameter Whose Surface is Modified with CoO
by Solid-Phase Method and LCO Bulk Co-Doped with Al and Ti
(1) Production of Positive Electrode Active Material
[0118] 1) Production of Core Particle
[0119] A dry mixture of an Al doping raw material (Al(OH).sub.3), a
Ti doping raw material (TiO.sub.2), Co.sub.3O.sub.4, and
Li.sub.2CO.sub.3 were calcined in a furnace at 1,050.degree. C. for
8 hours to form a lithium cobalt oxide
(LiCo.sub.0.983Al.sub.0.015Ti.sub.0.002O.sub.2) particle co-doped
with Al and Ti. A molar ratio of Li:Co in Co.sub.3O.sub.4 and
Li.sub.2CO.sub.3 of the dry mixture was 1:1. The Al doping raw
material was 0.87 g and the Ti doping raw material was 0.28 g, with
respect to the total amount (500 g) of Co.sub.3O.sub.4 and
Li.sub.2CO.sub.3.
[0120] Thereafter, a first region was formed by the lithium cobalt
oxide (LiCo.sub.0.983Al.sub.0.015Ti.sub.0.002O.sub.2) particle
co-doped with Al and Ti. In order to form a lithium deficient layer
co-doped with Al and Ti on an outer surface of the first region, an
Al doping raw material, a Ti doping raw material, Co.sub.3O.sub.4,
and Li.sub.2CO.sub.3 were further added to the furnace and
dry-mixed, and then the mixture was calcined at 800.degree. C. for
6 hours. In the added materials when forming the second region, a
molar ratio of Li:Co in Co.sub.3O.sub.4 and Li.sub.2CO.sub.3 was
0.3:1, and the Al doping raw material was 0.87 g and the Ti doping
raw material was 0.28 g, with respect to the total amount (500 g)
of Co.sub.3O.sub.4 and Li.sub.2CO.sub.3.
[0121] Therefore, a core particle having the second region having a
thickness of 20 nm formed on the surface of the first region
(LiCoO.sub.2) could be obtained (D50 of the entire core particles:
18 .mu.m).
2) Formation of Coating Layer
[0122] A positive electrode active material in which a CoO coating
layer with a thickness of 20 nm is formed on a surface of a core
particle was obtained in the same manner as in Example 1, except
for using the core particle co-doped with Al and Ti instead of the
core particle doped with only Al of Example 1.
(2) Production of Lithium Rechargeable Battery
[0123] A positive electrode and a lithium rechargeable battery were
produced in the same manner as in Example 1 except for using the
positive electrode active material of Example 2 instead of the
positive electrode active material of Example 1.
EXAMPLE 3
LCO with Large Particle Diameter Whose Surface is Modified with CoO
by Solid-Phase Method and LCO Bulk Co-Doped with Al and Mg
(1) Production of Positive Electrode Active Material
[0124] 1) Production of Core Particle
[0125] A dry mixture of an Al doping raw material (Al(OH).sub.3), a
Mg doping raw material (MgO), Co.sub.3O.sub.4, and Li.sub.2CO.sub.3
were calcined in a furnace at 1,050.degree. C. for 8 hours to form
a lithium cobalt oxide
(LiCo.sub.0.983Al.sub.0.015Mg.sub.0.002O.sub.2) particle co-doped
with Al and Mg. A molar ratio of Li:Co in Co.sub.3O.sub.4 and
Li.sub.2CO.sub.3 of the dry mixture was 1:1. The Al doping raw
material was 0.87 g and the Mg doping raw material was 0.28 g, with
respect to the total amount (500 g) of Co.sub.3O.sub.4 and
Li.sub.2CO.sub.3.
[0126] Thereafter, a first region was formed by the lithium cobalt
oxide (LiCo.sub.0.983Al.sub.0.015Mg.sub.0.002O.sub.2) particle
co-doped with Al and Mg. In order to form a lithium deficient layer
co-doped with Al and Mg on an outer surface of the first region, an
Al doping raw material, a Mg doping raw material, Co.sub.3O.sub.4,
and Li.sub.2CO.sub.3 were further added to the furnace and
dry-mixed, and then the mixture was calcined at 800.degree. C. for
6 hours. In the added materials when forming the second region, a
molar ratio of Li:Co in Co.sub.3O.sub.4 and Li.sub.2CO.sub.3 was
0.3:1, and the Al doping raw material was 0.87 g and the Mg doping
raw material was 0.28 g, with respect to the total amount (500 g)
of Co.sub.3O.sub.4 and Li.sub.2CO.sub.3.
[0127] Therefore, a core particle having the second region having a
thickness of 20 nm formed on the surface of the first region
(LiCoO.sub.2) could be obtained (D50 of the entire core particles:
18 .mu.m).
2) Formation of Coating Layer
[0128] A positive electrode active material in which a CoO coating
layer with a thickness of 20 nm is formed on a surface of a core
particle was obtained in the same manner as in Example 1, except
for using the core particle co-doped with Al and Mg instead of the
core particle doped with only Al of Example 1.
(2) Production of Lithium Rechargeable Battery
[0129] A positive electrode and a lithium rechargeable battery were
produced in the same manner as in Example 1 except for using the
positive electrode active material of Example 3 instead of the
positive electrode active material of Example 1.
EXAMPLE 4
LCO with Large Particle Diameter Whose Surface is Modified with CoO
by Solid-Phase Method and LCO Bulk Co-Doped with Al, Ti, and Mg
(1) Production of Positive Electrode Active Material
[0130] 1) Production of Core Particle
[0131] A dry mixture of an Al doping raw material (Al(OH).sub.3), a
Ti doping raw material (TiO.sub.2), a Mg doping raw material (MgO),
Co.sub.3O.sub.4, and Li.sub.2CO.sub.3 were calcined in a furnace at
1,050.degree. C. for 8 hours to form a lithium cobalt oxide
(LiCo.sub.0.983Al.sub.0.015Mg.sub.0.001Ti.sub.0.001O.sub.2)
particle co-doped with Al, Ti, and Mg. A molar ratio of Li:Co in
Co.sub.3O.sub.4 and Li.sub.2CO.sub.3 of the dry mixture was 1:1.
The Al doping raw material was 0.87 g, the Ti doping raw material
was 0.14 g, and the Mg doping raw material was 0.14 g, with respect
to the total amount (500 g) of Co.sub.3O.sub.4 and
Li.sub.2CO.sub.3.
[0132] Thereafter, a first region was formed by the lithium cobalt
oxide (LiCo.sub.0.983Al.sub.0.015Mg.sub.0.001Ti.sub.0.001O.sub.2)
particle co-doped with Al, Ti, and Mg. In order to form a lithium
deficient layer co-doped with Al, Ti, and Mg on an outer surface of
the first region, an Al doping raw material, a Ti doping raw
material, a Mg doping raw material, Co.sub.3O.sub.4, and
Li.sub.2CO.sub.3 were further added to the furnace and dry-mixed,
and then the mixture was calcined at 800.degree. C. for 6 hours. In
the added materials when forming the second region, a molar ratio
of Li:Co in Co.sub.3O.sub.4 and Li.sub.2CO.sub.3 was 0.3:1, and the
Al doping raw material was 0.87 g, the Ti doping raw material was
0.14 g, and the Mg doping raw material was 0.14 g, with respect to
the total amount (500 g) of Co.sub.3O.sub.4 and
Li.sub.2CO.sub.3.
[0133] Therefore, a core particle having the second region having a
thickness of 20 nm formed on the surface of the first region
(LiCoO.sub.2) could be obtained (D50 of the entire core particles:
18 .mu.m).
2) Formation of Coating Layer
[0134] A positive electrode active material in which a CoO coating
layer with a thickness of 20 nm is formed on a surface of a core
particle was obtained in the same manner as in Example 1, except
for using the core particle co-doped with Al, Ti, and Mg instead of
the core particle doped with only Al of Example 1.
(2) Production of Lithium Rechargeable Battery
[0135] A positive electrode and a lithium rechargeable battery were
produced in the same manner as in Example 1 except for using the
positive electrode active material of Example 4 instead of the
positive electrode active material of Example 1.
COMPARATIVE EXAMPLE 1
Bare, LCO with Large Particle Diameter Whose Surface is not
Modified
[0136] A lithium rechargeable battery was produced in the same
manner as in Example 1 except for using the core particle of
Example 1 itself as a positive electrode active material.
COMPARATIVE EXAMPLE 2
LCO with Large Particle Diameter Whose Surface is Modified with
Al.sub.2O.sub.3 Using Gas Dispersion Method
(1) Production of Positive Electrode Active Material
[0137] 1) Production of Core Particle
[0138] The same core particle as in Example 1 was produced.
[0139] 2) Formation of Coating Layer
[0140] An Al.sub.2O.sub.3 coating layer was formed on a surface of
the core particle using a gas reactor.
(2) Production of Lithium Rechargeable Battery
[0141] A positive electrode and a lithium rechargeable battery were
produced in the same manner as in Example 1 except for using the
positive electrode active material of Comparative Example 2 instead
of the positive electrode active material of Example 1.
COMPARATIVE EXAMPLE 3
LCO with Large Particle Diameter Whose Surface is Modified with
Al.sub.2O.sub.3 Using Solid-Phase Method, Non-Bulk-Doped LCO
(1) Production of Positive Electrode Active Material
[0142] 1) Production of Core Particle
[0143] A core particle having a second region (Li.sub.0.3CoO.sub.2)
having a thickness of 20 to 300 nm formed on a surface of a first
region (LiCoO.sub.2) was obtained (D50 of the entire core
particles: 18 .mu.m) in the same manner Example 1, except that only
an Al doping raw material (Al(OH).sub.3) was not used unlike
Example 1.
[0144] 2) Formation of Coating Layer
[0145] 0.755 g of Al.sub.2O.sub.3 powder was mixed with 200 g of
the core particle and the mixture was calcined at 450.degree. C.
for 4 hours to obtain a positive electrode active material in which
an Al.sub.2O.sub.3 coating layer is formed on a surface of the core
particle.
(2) Production of Lithium Rechargeable Battery
[0146] A positive electrode and a lithium rechargeable battery were
produced in the same manner as in Example 1 except for using the
positive electrode active material of Comparative Example 3 instead
of the positive electrode active material of Example 1.
COMPARATIVE EXAMPLE 4
LCO with Large Particle Diameter Whose Surface is Modified with CoO
Using Solid-Phase Method, Non-Bulk-Doped LCO
(1) Production of Positive Electrode Active Material
[0147] A positive electrode active material in which a CoO coating
layer with a thickness of 20 nm is formed on a surface of a core
particle was obtained in the same manner as in Example 1, except
for using non-doped core particle instead of the core particle
doped with only Al of Example 1.
(2) Production of Lithium Rechargeable Battery
[0148] A positive electrode and a lithium rechargeable battery were
produced in the same manner as in Example 1 except for using the
positive electrode active material of Comparative Example 4 instead
of the positive electrode active material of Example 1.
EXPERIMENTAL EXAMPLE 1
Evaluation of Photograph by Field Emission Scanning Electron
Microscope (FE-TEM) and Transmission Electron Microscope (TEM)
[0149] Each of the positive electrode active materials in Example 1
and Comparative Example 3 was photographed with a field emission
scanning electron microscope (FE-TEM) and a transmission electron
microscope (TEM), and the results are shown FIG. 1.
[0150] In FIG. 1, it is observed that in the case of the LCO with a
large particle diameter whose surface is modified with
Al.sub.2O.sub.3 by the solid-phase method (Comparative Example 3),
a layered structure and a spinel structure are still mixed on a
surface portion (coating layer) in spite of the surface
modification.
[0151] On the other hand, it is observed in the case of LCO with a
large particle diameter whose surface is modified with CoO by the
solid-phase method (Example 1), in particular, a portion in which
CoO is present has a rock salt crystal structure and a portion in
which CoO is not present has a layered crystal structure. That is,
the crystal structure is clearly distinguished by the presence or
absence of CoO. This means that the crystal structure of the
portion in which CoO is not present becomes a layered
structure.
EXPERIMENTAL EXAMPLE 2
Evaluation of Co Elution Amount and Gas Generation Amount After
High Temperature Storage
(1) Difference Evaluation Depending on Surface Modification
Material and Method
[0152] The high temperature storage characteristics of the positive
electrode active materials of Example 1 and Comparative Examples 3
were evaluated. Evaluation items of the high temperature storage
characteristics are a Co elution amount and a gas generation amount
and an evaluation method for each item is as follows.
[0153] Co elution amount: The Co elution amount was measured as
described above. Specifically, the amount of positive electrode
mixture material loaded per surface area of an electrode was set to
be 80 mg/cm.sup.2, a positive electrode charged at 4.55 V was
prepared and put into a Nalgene bottle together with a 4 ml
electrolyte [EC:DMC=3:7, 2 wt % of VC]. The Nalgene bottle was
completely sealed with a parafilm and an aluminum pouch so as to
prevent evaporation of the electrolyte. The completely sealed
bottle was stored in a chamber at 60.degree. C. for one week. After
one week, for extracting only the electrolyte, the positive
electrode active material which may be present in the electrolyte
as a floating matter was completely removed by using a sealing
sheet as a filter. Thereafter, the electrolyte was evaporated to
quantify the amount of Co present, that is, eluted in the
electrolyte through inductively coupled plasma (ICP). Accordingly,
the Co elution amount was calculated by dividing the weight of Co
of which quantification was confirmed by the weight of the positive
electrode active material of the charged electrode impregnated with
the electrolyte at the beginning.
[0154] Gas generation amount: The amount of gas generated in each
of lithium rechargeable batteries of Example 1 and Comparative
Examples 1 to 3 was measured after 2 charge and discharge cycles
under certain conditions of a drive voltage range of 4.4 to 4.5 V
and 0.2 C/0.2 C.
[0155] Referring to FIG. 2 (Co elution amount) and FIG. 3 (gas
generation amount), it was confirmed that the Co elution amount and
the gas generation amount of LCO with a large particle diameter
whose surface is modified with CoO by the solid-phase method after
the high temperature storage were significantly reduced, as
compared to the LCO with a large particle diameter whose surface is
not modified (bare, Comparative Example 1) and the LCO with a large
particle diameter whose surface is modified with Al.sub.2O.sub.3
using the gas dispersion method (Comparative Example 2) or modified
with Al.sub.2O.sub.3 using the solid-phase method (Comparative
Example 3).
[0156] Specifically, it could be seen that the Co elution amount
and the gas generation amount may be reduced by the surface
modification itself regardless of a surface modification method or
material, as compared to Comparative Examples 1 to 3.
[0157] However, since the surface modification of the rock salt
phase may be modified with CoO unlike Al.sub.2O.sub.3, the Co
elution amount and the gas generation amount in Example 1 were
significantly reduced as compared to Comparative Examples 2 and 3.
This means that the crystal structure of the rock salt phase is not
easily changed even when high temperature storage.
(2) Difference Evaluation Depending on Whether or not Core Particle
Doping is Performed
[0158] Meanwhile, the Co elution amount and the gas generation
amount of each of Examples 1 to 4 and Comparative Example 4 were
evaluated.
EXPERIMENTAL EXAMPLE 3
Electrochemical Characteristic Evaluation of Battery
(1) Difference Evaluation Depending on Surface Modification
Material and Method
[0159] The electrochemical characteristics of each of the lithium
rechargeable batteries produced in Example 1 and Comparative
Examples 1 to 3 were evaluated using a charge and discharge device
capable of controlling a constant current and a constant
potential.
[0160] Specifically, drive conditions of each lithium rechargeable
battery are as follows.
[0161] 1) Coin half cell evaluation after high temperature storage
at 60.degree. C. (FIG. 4)
[0162] Charge: 0.5 C, CC/CV, 4.5 V, 1/20 C cut-off
[0163] Discharge: 1.0 C, CC, 3.0 V, cut-off
[0164] 2) Coin full cell evaluation at room temperature of
25.degree. C. (FIG. 5)
[0165] Charge: 0.5 C, CC/CV, 4.45 V, 1/20 C cut-off
[0166] Discharge: 1.0 C, CC, 3.0 V, cut-off
[0167] Referring to FIGS. 4 and 5, it can be confirmed that the
capacity of the battery of Example 1 is maintained for the longest
period of time by comparing the characteristics of the coin half
cell after high temperature storage at 60.degree. C. and the
characteristics of the coin full cell at room temperature of
25.degree. C.
[0168] By comprehensively evaluating these results with
Experimental Examples 1 and 2, it can be seen that the Co elution
amount and the gas generation amount may be reduced by the surface
modification itself regardless of the surface modification method
or material; however, in a case where CoO is selected as the
surface modification material, rather than Al.sub.2O.sub.3, to
modify the surface into a rock salt phase and coating (surface
modification) the surface into a island form using the solid-phase
method, rather than the gas dispersion method, as the surface
modification method, the amount of Co eluted from the core particle
is significantly reduced, such that a side reaction with the
electrolyte is suppressed and the battery lifespan may be thus
extended.
(2) Difference Evaluation Depending on Whether or not Core Particle
Doping is Performed
[0169] Meanwhile, the electrochemical characteristics of each of
the lithium rechargeable batteries produced in Examples 1 to 4 and
Comparative Example 4 were evaluated using a charge and discharge
device capable of controlling a constant current and a constant
potential (FIG. 6). The same evaluation conditions were set as the
room temperature evaluation conditions.
[0170] Referring to FIG. 6, in a case where non-doped LCO with a
large particle diameter is used as a core particle, it can be seen
that a capacity retention of the battery is significantly reduced
at a high voltage of 4.45 V even though the surface is modified
with CoO (Comparative Example 4). On the other hand, in a case
where LCO with a large particle diameter essentially doped with Al
and further doped with Ti and/or Mg selectively is used as a core
particle and the surface thereof is modified with CoO (Examples 1
to 4), it was confirmed that the capacity is maintained 85% or
higher of the initial capacity after 50 cycles even at the high
voltage of 4.45 V.
[0171] As a result, it could be seen that in a case where LCO with
a large particle diameter is not doped with Al, in spite of the
presence of the surface modification (that is, the coating layer)
by the rock salt crystal structure of CoO, the crystal (lattice)
structure of the LCO with a large particle diameter may be
collapsed at a high voltage.
[0172] On the other hand, in a case where LCO with a large particle
diameter is essentially doped with Al, the crystal structure of the
LCO with a large particle diameter becomes more solid, and a more
solid and stable structure may be maintained at a high voltage by a
synergistic effect with the surface modification by the rock salt
crystal structure of CoO.
[0173] Although embodiments of the present invention have been
described in detail hereinabove, the scope of the present invention
is not limited thereto, but may include several modifications and
alterations made by those skilled in the art using a basic concept
of the present invention as defined in the claims.
[0174] While this invention has been described in connection with
what is presently considered to be practical exemplary embodiments,
it is to be understood that the invention is not limited to the
disclosed embodiments. On the contrary, it is intended to cover
various modifications and equivalent arrangements included within
the spirit and scope of the appended claims.
* * * * *