Improved Cycling Stability of Li[Ni0.90Co0.05Mn0.05]O2 Through Microstructure Modification by Boron Doping for Li‐Ion Batteries

Boron‐doped Li[Ni_0.90Co_0.05Mn_0.05]O₂ cathodes are synthesized by adding B₂O₃ during the lithiation of the hydroxide precursor. Density functional theory confirms that boron doping at a level as low as 1 mol% alters the surface energies to produce a highly textured microstructure that can partially relieve the intrinsic internal strain generated during the deep charging of Li[Ni_0.90Co_0.05Mn_0.05]O₂. The 1 mol% B‐Li[Ni_0.90Co_0.05Mn_0.05]O₂ cathode thus delivers a discharge capacity of 237 mAh g^?1 at 4.3 V, with an outstanding capacity retention of 91% after 100 cycles at 55 °C, which is 15% higher than that of the undoped Li[Ni_0.90Co_0.05Mn_0.05]O₂ cathode. This proposed synthesis strategy demonstrates that an optimal microstructure exists for extending the cycle life of Ni‐rich Li[Ni_1‐x‐yCo_xMn_y]O₂ cathodes that have an inadequate cycling stability in electric vehicle applications and indicates that an optimal microstructure can be achieved through surface energy modification.     

Cobalt‐Free High‐Capacity Ni‐Rich Layered Li[Ni0.9Mn0.1]O2 Cathode

Li[Ni_0.9Co_0.1]O₂ (NC90), Li[Ni_0.9Co_0.05Mn_0.05]O₂ (NCM90), and Li[Ni_0.9Mn_0.1]O₂ (NM90) cathodes are synthesized for the development of a Co‐free high‐energy‐density cathode. NM90 maintains better cycling stability than the two Co‐containing cathodes, particularly under harsh cycling conditions (a discharge capacity of 236 mAh g^?1 with a capacity retention of 88% when cycled at 4.4 V under 30 °C and 93% retention when cycled at 4.3 V under 60 °C after 100 cycles). The reason for the enhanced stability is mainly the ability of NM90 to absorb the strain associated with the abrupt anisotropic lattice contraction/extraction and to suppress the formation of microcracks, in addition to enhanced chemical stability from the increased presence of stable Mn⁴⁺. Although the absence of Co deteriorates the rate capability, this can be overcome as the rate capability of the NM90 approaches that of the NCM90 when cycled at 60 °C. The long‐term cycling stability of NM90 is confirmed in a full cell, demonstrating that it is one of the most promising Co‐free cathodes for high‐energy‐density applications. This study not only provides insight into redefining the role of Mn in a Ni‐rich cathode, it also represents a clear breakthrough in achieving a commercially viable Co‐free Ni‐rich layered cathode.     

Spinel‐Layered Core‐Shell Cathode Materials for Li‐Ion Batteries

In an attempt to overcome the problems associated with LiNiO₂, the solid solution series of lithium nickel‐metal oxides, Li[Ni_1–xM_x]O₂ (with M = Co, Mn, Al, Ti, Mg, etc.), have been investigated as favorable cathode materials for high‐energy and high‐power lithium‐ion batteries. However, along with the improvement in the electrochemical properties in Ni‐based cathode materials, the thermal stability has been a great concern, and thus violent reaction of the cathode with the electrolyte needs to be avoided. Here, we report a heterostructured Li[Ni_0.54Co_0.12Mn_0.34]O₂ cathode material which possesses both high energy and safety. The core of the particle is Li[Ni_0.54Co_0.12Mn_0.34]O₂ with a layered phase (R3‐m) and the shell, with a thickness of < 0.5 μm, is a highly stable Li_1+x[CoNi_xMn_2–x]₂O₄ spinel phase (Fd‐3m). The material demonstrates reversible capacity of 200 mAhg‐1 and retains 95% capacity retention under the most severe test condition of 60 °C. In addition, the amount of oxygen evolution from the lattice in the cathode with two heterostructures is reduced by 70%, compared to the reference sample. All these results suggest that the bulk Li[Ni_0.54Co_0.12Mn_0.34]O₂ consisting of two heterostructures satisfy the requirements for hybrid electric vehicles, power tools, and mobile electronics.     

New Class of Ni‐Rich Cathode Materials Li[NixCoyB1−x−y]O2 for Next Lithium Batteries

A new class of layered cathodes, Li[Ni_xCo_yB_1?x?y]O₂ (NCB), is synthesized. The proposed NCB cathodes have a unique microstructure in which elongated primary particles are tightly packed into spherical secondary particles. The cathodes also exhibit a strong crystallographic texture in which the a–b layer planes are aligned along the radial direction, facilitating Li migration. The microstructure, which effectively suppresses the formation of microcracks, improves the cycling stability of the NCB cathodes. The NCB cathode with 1.5 mol% B delivers a discharge capacity of 234 mAh g^?1 at 0.1 C and retains 91.2% of its initial capacity after 100 cycles (compared to values of 229 mAh g^?1 at 0.1 C and 78.8% for pristine Li[Ni_0.9Co_0.1]O₂). This study shows the importance of controlling the microstructure to obtain the required cycling stability, especially for Ni‐rich layered cathodes, where the main cause of capacity fading is related to mechanical strain in their charged state.     

Ni‐Rich Layered Cathode Materials with Electrochemo‐Mechanically Compliant Microstructures for All‐Solid‐State Li Batteries

While Ni‐rich cathode materials combined with highly conductive and mechanically sinterable sulfide solid electrolytes are imperative for practical all‐solid‐state Li batteries (ASLBs), they suffer from poor performance. Moreover, the prevailing wisdom regarding the use of Li[Ni,Co,Mn]O₂ in conventional liquid electrolyte cells, that is, increased capacity upon increased Ni content, at the expense of degraded cycling stability, has not been applied in ASLBs. In this work, the effect of overlooked but dominant electrochemo‐mechanical on the performance of Ni‐rich cathodes in ASLBs are elucidated by complementary analysis. While conventional Li[Ni_0.80Co_0.16Al_0.04]O₂ (NCA80) with randomly oriented grains is prone to severe particle disintegration even at the initial cycle, the radially oriented rod‐shaped grains in full‐concentration gradient Li[Ni_0.75Co_0.10Mn_0.15]O₂ (FCG75) accommodate volume changes, maintaining mechanical integrity. This accounts for their different performance in terms of reversible capacity (156 vs 196 mA h g^?1), initial Coulombic efficiency (71.2 vs 84.9%), and capacity retention (46.9 vs 79.1% after 200 cycles) at 30 °C. The superior interfacial stability for FCG75/Li₆PS₅Cl to for NCA80/Li₆PS₅Cl is also probed. Finally, the reversible operation of FCG75/Li ASLBs is demonstrated. The excellent performance of FCG75 ranks at the highest level in the ASLB field.     

Al Doping for Mitigating the Capacity Fading and Voltage Decay of Layered Li and Mn‐Rich Cathodes for Li‐Ion Batteries

Li and Mn‐rich layered cathodes, despite their high specific capacity, suffer from capacity fading and discharge voltage decay upon cycling. Both specific capacity and discharge voltage of Li and Mn‐rich cathodes are stabilized upon cycling by optimized Al doping. Doping Li and Mn‐rich cathode materials Li_1.2Ni_0.16Mn_0.56Co_0.08O₂ by Al on the account of manganese (as reflected by their stoichiometry) results in a decrease in their specific capacity but increases pronouncedly their stability upon cycling. Li_1.2Ni_0.16Mn_0.51Al_0.05Co_0.08O₂ exhibits 96% capacity retention as compared to 68% capacity retention for Li_1.2Ni_0.16Mn_0.56Co_0.08O₂ after 100 cycles. This doping also reduces the decrease in the average discharge voltage upon cycling, which is the longstanding fatal drawback of these Li and Mn‐rich cathode materials. The electrochemical impedance study indicates that doping by Al has a surface stabilization effect on these cathode materials. The structural analysis of cycled electrodes by Raman spectroscopy suggests that Al doping also has a bulk stabilizing effect on the layered LiMO₂ phase resulting in the better electrochemical performance of Al doped cathode materials as compared to the undoped counterpart. Results from a prolonged systematic work on these cathode materials are presented and the best results that have ever been obtained are reported.     

High‐Capacity Concentration Gradient Li[Ni0.865Co0.120Al0.015]O2 Cathode for Lithium‐Ion Batteries

A Ni‐rich concentration‐gradient Li[Ni_0.865Co_0.120Al_0.015]O₂ (NCA) cathode is prepared with a Ni‐rich core to maximize the discharge capacity and a Co‐rich particle surface to provide structural and chemical stability. Compared to the conventional NCA cathode with a uniform composition, the gradient NCA cathode exhibits improved capacity retention and better thermal stability. Even more remarkably, the gradient NCA cathode maintains 90% of its initial capacity after 100 cycles when cycled at 60 °C, whereas the conventional cathode exhibits poor capacity retention and suffers severe structural deterioration. The superior cycling stability of the gradient NCA cathode largely stemmed from the gradient structure combines with the Co‐rich surface, which provides chemical stability against electrolyte attack and reduces the inherent internal strain observed in all Ni‐rich layered cathodes in their charged state, thus providing structural stability against the repeated anisotropic volume changes during cycling. The high discharge capacity of the proposed gradient NCA cathode extends the driving range of electric vehicles and reduces battery costs. Furthermore, its excellent capacity retention guarantees a long battery life. Therefore, gradient NCA cathodes represent one of the best classes of cathode materials for electric vehicle applications that should satisfy the demands of future electric vehicles.     

Li[Ni0.9Co0.09W0.01]O2: A New Type of Layered Oxide Cathode with High Cycling Stability

Substituting W for Al in the Ni‐rich cathode Li[Ni_0.885Co_0.10Al_0.015]O₂ (NCA89) produces Li[Ni_0.9Co_0.09W_0.01]O₂ (NCW90) with markedly reduced primary particle size. Particle size refinement considerably improves the cathode's cycling stability such that the NCW90 cathode retains 92% of its initial capacity after 1000 cycles (compared to 63% for NCA89), while the cathode produces a high initial discharge capacity of 231.2 mAh g^?1 (at 0.1 C). Thus, the proposed NCW90 can deliver high energy density and a long battery lifetime simultaneously, unlike other Ni‐rich layered oxide cathodes. This unprecedented cycling stability is mainly attributed to a series of interparticular microfractures that absorb the anisotropic lattice strain caused by a deleterious phase transition near the charge end, thereby improving the cathode's resistance to fracture. Microcrack suppression preserves the mechanical integrity of the cathode particles during cycling and protects the particle interior from detrimental electrolyte attack. The proposed NCW90 cathode provides an improved material from which a new series of Ni‐rich layered cathode can be developed for next‐generation electric vehicles.     

Study of Thermal Decomposition of Li1‐x(Ni1/3Mn1/3Co1/3)0.9O2 Using In‐Situ High‐Energy X‐Ray Diffraction

Safety has been a major technological concern hindering the deployment of lithium‐ion batteries for automobile applications. We investigated the decomposition mechanism of delithiated cathode materials at thermal abuse conditions using Li_1.1[Ni_1/3Mn_1/3Co_1/3]_0.9O₂ as a model cathode material. An in‐situ high‐energy X‐ray diffraction technique was established as an alternative to conventional thermal analysis techniques like differential scanning calorimetry and accelerating rate calorimetry. The X‐ray diffraction data revealed that the thermal decomposition pathway of delithiated Li_1‐x[Ni_1/3Mn_1/3Co_1/3]_0.9O₂ strongly depended on the exposed chemical environment, like solvents and lithium salts. A phase transformation of dry delithiated Li_1‐x[Ni_1/3Mn_1/3Co_1/3]_0.9O₂ was observed at about 278 °C, and its onset temperature was reduced to about 197°C with the presence of the electrolyte. It is suggested that the reduction in thermal stability is possibly related to proton intercalation into the delithiated material.     

An Ion‐Exchange Promoted Phase Transition in a Li‐Excess Layered Cathode Material for High‐Performance Lithium Ion Batteries

A new approach to intentionally induce phase transition of Li‐excess layered cathode materials for high‐performance lithium ion batteries is reported. In high contrast to the limited layered‐to‐spinel phase transformation that occurred during in situ electrochemical cycles, a Li‐excess layered Li[Li_0.2Mn_0.54Ni_0.13Co_0.13]O₂ is completely converted to a Li₄Mn₅O₁₂‐type spinel product via ex situ ion‐exchanges and a post‐annealing process. Such a layered‐to‐spinel phase conversion is examined using in situ X‐ray diffraction and in situ high‐resolution transmission electron microscopy. It is found that generation of sufficient lithium ion vacancies within the Li‐excess layered oxide plays a critical role for realizing a complete phase transition. The newly formed spinel material exhibits initial discharge capacities of 313.6, 267.2, 204.0, and 126.3 mAh g^?1 when cycled at 0.1, 0.5, 1, and 5 C (1 C = 250 mA g^?1), respectively, and can retain a specific capacity of 197.5 mAh g^?1 at 1 C after 100 electrochemical cycles, demonstrating remarkably improved rate capability and cycling stability in comparison with the original Li‐excess layered cathode materials. This work sheds light on fundamental understanding of phase transitions within Li‐excess layered oxides. It also provides a novel route for tailoring electrochemical performance of Li‐excess layered cathode materials for high‐capacity lithium ion batteries.     

Synthesis and Characterization of High‐Energy,High‐Power Spinel‐Layered Composite Cathode Materials for Lithium‐Ion Batteries

Spinel‐layered composites, where a high‐voltage spinel is incorporated in a layered lithium‐rich (Li‐rich) cathode material with a nominal composition x{0.6Li₂MnO₃ · 0.4[LiCo_0.333Mn_0.333Ni_0.333]O₂} · (1 – x) Li[Ni_0.5Mn_1.5]O₄ (x = 0, 0.3, 0.5, 0.7, 1) are synthesized via a hydroxide assisted coprecipitation route to generate high‐energy, high‐power cathode materials for Li‐ion batteries. X‐ray diffraction patterns and the cyclic voltammetry investigations confirm the presence of both the parent components in the composites. The electrochemical investigations performed within a wide potential window show an increased structural stability of the spinel component when incorporated into the composite environment. All the composite materials exhibit initial discharge capacities >200 mAh g^–1. The compositions with x = 0.5 and 0.7 show excellent cycling stability among the investigated materials. Moreover, the first cycle Coulombic efficiency achieve a dramatic improvement with the incorporation of the spinel component. More notably, the composite materials with increased spinel component exhibit superior rate capability compared with the parent Li‐rich material especially together with the highest capacity retention for x = 0.5 composition, making this as the optimal high‐energy high‐power material. The mechanisms involved in the symbiotic relationship of the spinel and layered Li‐rich components in the above composites are discussed.     

Understanding the Rate Capability of High‐Energy‐Density Li‐Rich Layered Li1.2Ni0.15Co0.1Mn0.55O2 Cathode Materials

The high‐energy‐density, Li‐rich layered materials, i.e., xLiMO₂(1‐x)Li₂MnO₃, are promising candidate cathode materials for electric energy storage in plug‐in hybrid electric vehicles (PHEVs) and electric vehicles (EVs). The relatively low rate capability is one of the major problems that need to be resolved for these materials. To gain insight into the key factors that limit the rate capability, in situ X‐ray absorption spectroscopy (XAS) and X‐ray diffraction (XRD) studies of the cathode material, Li_1.2Ni_0.15Co_0.1Mn_0.55O₂ [0.5Li(Ni_0.375Co_0.25 Mn_0.375)O₂·0.5Li₂MnO₃], are carried out. The partial capacity contributed by different structural components and transition metal elements is elucidated and correlated with local structure changes. The characteristic reaction kinetics for each element are identified using a novel time‐resolved XAS technique. Direct experimental evidence is obtained showing that Mn sites have much poorer reaction kinetics both before and after the initial activation of Li₂MnO₃, compared to Ni and Co. These results indicate that Li₂MnO₃ may be the key component that limits the rate capability of Li‐rich layered materials and provide guidance for designing Li‐rich layered materials with the desired balance of energy density and rate capability for different applications.     

Countering Voltage Decay and Capacity Fading of Lithium‐Rich Cathode Material at 60 °C by Hybrid Surface Protection Layers

Li‐rich layered metal oxides have attracted much attention for their high energy density but still endure severe capacity fading and voltage decay during cycling, especially at elevated temperature. Here, facile surface treatment of Li_1.17Ni_0.17Co_0.17Mn_0.5O₂ (0.4Li₂MnO₃·0.6LiNi_1/3Co_1/3Mn_1/3O₂) spherical cathode material is designed to address these drawbacks by hybrid surface protection layers composed of Mg²⁺ pillar and Li‐Mg‐PO₄ layer. As a result, the surface coated Li‐rich cathode material exhibits much enhanced cycling stability at 60 °C, maintaining 72.6% capacity retention (180 mAh g^?1) between 3.0 and 4.7 V after 250 cycles. More importantly, 88.7% average discharge voltage retention can be obtained after the rigorous cycle test. The strategy developed here with novel hydrid surface protection effect can provide a vital approach to inhibit the undesired side reactions and structural deterioration of Li‐rich cathode materials and may also be useful for other layered oxides to increase their cycling stability at elevated temperature.     

Ni‐Rich/Co‐Poor Layered Cathode for Automotive Li‐Ion Batteries: Promises and Challenges

To pursue a higher energy density (>300 Wh kg^?1 at the cell level) and a lower cost (<$125 kWh^?1 expected at 2022) of Li‐ion batteries for making electric vehicles (EVs) long range and cost‐competitive with internal combustion engine vehicles, developing Ni‐rich/Co‐poor layered cathode (LiNi_1?x?yCo_xMn_yO₂, x+y ≤ 0.2) is currently one of the most promising strategies because high Ni content is beneficial to high capacity (>200 mAh g^?1) while low Co content is favorable to minimize battery cost. Unfortunately, Ni‐rich cathodes suffer from limited structure stability and electrode/electrolyte interface stability in the charged state, leading to electrode degradation and poor cycling performance. To address these problems, various strategies have been employed such as doping, structural optimization design (e.g., core–shell structure, concentration‐gradient structure, etc.), and surface coating. In this review, five key aspects of Ni‐rich/Co‐poor layered cathode materials are explored: energy density, fast charge capability, service life including cycling life and calendar life, cost and element resources, and safety. This enables a comprehensive analysis of current research advances and challenges from the perspective of both academy and industry to help facilitate practical applications for EVs in the future.     

A New P2‐Type Layered Oxide Cathode with Extremely High Energy Density for Sodium‐Ion Batteries

Herein, a new P2‐type layered oxide is proposed as an outstanding intercalation cathode material for high energy density sodium‐ion batteries (SIBs). On the basis of the stoichiometry of sodium and transition metals, the P2‐type Na_0.55[Ni_0.1Fe_0.1Mn_0.8]O₂ cathode is synthesized without impurities phase by partially substituting Ni and Fe into the Mn sites. The partial substitution results in a smoothing of the electrochemical charge/discharge profiles and thus greatly improves the battery performance. The P2‐type Na_0.55[Ni_0.1Fe_0.1Mn_0.8]O₂ cathode delivers an extremely high discharge capacity of 221.5 mAh g^?1 with a high average potential of ≈2.9 V (vs Na/Na⁺) for SIBs. In addition, the fast Na‐ion transport in the P2‐type Na_0.55[Ni_0.1Fe_0.1Mn_0.8]O₂ cathode structure enables good power capability with an extremely high current density of 2400 mA g^?1 (full charge/discharge in 12 min) and long‐term cycling stability with ≈80% capacity retention after 500 cycles at 600 mA g^?1. A combination of electrochemical profiles, in operando synchrotron X‐ray diffraction analysis, and first‐principles calculations are used to understand the overall Na storage mechanism of P2‐type Na_0.55[Ni_0.1Fe_0.1Mn_0.8]O₂.     

High Voltage Operation of Ni‐Rich NMC Cathodes Enabled by Stable Electrode/Electrolyte Interphases

The lithium (Li) metal battery (LMB) is one of the most promising candidates for next‐generation energy storage systems. However, it is still a significant challenge to operate LMBs with high voltage cathodes under high rate conditions. In this work, an LMB using a nickel‐rich layered cathode of LiNi_0.76Mn_0.14Co_0.10O₂ (NMC76) and an optimized electrolyte [0.6 m lithium bis(trifluoromethanesulfonyl)imide + 0.4 m lithium bis(oxalato)borate + 0.05 m LiPF₆ dissolved in ethylene carbonate and ethyl methyl carbonate (4:6 by weight)] demonstrates excellent stability at a high charge cutoff voltage of 4.5 V. Remarkably, these Li||NMC76 cells can deliver a high discharge capacity of >220 mA h g^?1 (846 W h kg^?1) and retain more than 80% capacity after 1000 cycles at high charge/discharge current rates of 2C/2C (1C = 200 mA g^?1). This excellent electrochemical performance can be attributed to the greatly enhanced structural/interfacial stability of both the Ni‐rich NMC76 cathode material and the Li metal anode using the optimized electrolyte.     

Ameliorating the Interfacial Problems of Cathode and Solid‐State Electrolytes by Interface Modification of Functional Polymers

Solid‐state Li secondary batteries may become high energy density storage devices for the next generation of electric vehicles, depending on the compatibility of electrode materials and suitable solid electrolytes. Specifically, it is a great challenge to obtain a stable interface between these solid electrolytes and cathodes. Herein, this issue can be effectively addressed by constructing a poly(acrylonitrile‐co‐butadiene) coated layer onto the surface of LiNi_0.6Mn_0.2Co_0.2O₂ cathode materials. The polymer layer plays a vital role in working as a protective shell to retard side reaction and ameliorate the contact of the solid–solid interface during the cycling process. In the resultant solid‐state batteries, both rate capacity (99 mA h g^?1 at 3 C) and cycling stability (75% capacity retention after 400 cycles) are improved after coating. This impressive performance highlights the great importance of layer modification in the cathode and inspires the development of solid‐state batteries toward practical applications.     

Cooling Induced Surface Reconstruction during Synthesis of High‐Ni Layered Oxides

Transition metal layered oxides have been the dominant cathodes in lithium‐ion batteries, and among them, high‐Ni ones (LiNi_xMn_yCo_zO₂; x ≥ 0.7) with greatly boosted capacity and reduced cost are of particular interest for large‐scale applications. The high Ni loading, on the other hand, raises the critical issues of surface instability and poor rate performance. The rational design of synthesis leading to layered LiNi_0.7Mn_0.15Co_0.15O₂ with greatly enhanced rate capability is demonstrated, by implementing a quenching process alternative to the general slow cooling. In situ synchrotron X‐ray diffraction, coupled with surface analysis, is applied to studies of the synthesis process, revealing cooling‐induced surface reconstruction involving Li₂CO₃ accumulation, formation of a Li‐deficient layer and Ni reduction at the particle surface. The reconstruction process occurs predominantly at high temperatures (above 350 °C) and is highly cooling‐rate dependent, implying that surface reconstruction can be suppressed through synthetic control, i.e., quenching to improve the surface stability and rate performance of the synthesized materials. These findings may provide guidance to rational synthesis of high‐Ni cathode materials.     

Compositionally Graded Cathode Material with Long‐Term Cycling Stability for Electric Vehicles Application

Al is introduced into a compositionally graded cathode with average composition of Li[Ni_0.61Co_0.12Mn_0.27]O₂ (FCG61) whose Ni and Mn concentrations are designed to vary continuously within the cathode particle. The Al‐substituted full concentration gradient (Al‐FCG61) cathode is tested for 3000 cycles in a full‐cell, mainly to gauge its viability for daily charge/discharge cycles during the service life of electric vehicles (≈10 years). The Al‐substitution enables the Al‐FCG61 cathode to maintain 84% of its initial capacity even after 3000 cycles. It is demonstrated that the Al‐substitution strengthens the grain boundaries, substantiated by the mechanical strength data, thereby delaying the nucleation of microcracks at the phase boundaries which is shown to be the main reason for the cathode failure during long‐term cycling. It also shows that the Al‐substitution decreases the cation mixing and suppresses the deleterious formation of the secondary phase that likely initiates the microcracks. Unlike an NCA cathode, whose depth of discharge (DOD) must be limited to 60% for long‐term cycling, the proposed Al‐FCG61 cathode is cycled at 100% DOD for 3000 cycles to fully utilize its available capacity for maximum energy density and subsequent reduction in cost of the battery.