Layer cathode methods of manufacturing and materials for Li-ion rechargeable batteries

1. A method for forming an electrode material made of substituted lithium nickel-manganese oxides, comprising the steps of:

producing compositions of Li 1+x Ni α Mn β A γ O 2 wherein A is chosen from the group consisting of Mg, Zn, Al, Co, Ga, B, Zr, and Ti, and further wherein x is between about 0 and 0.2, α is between about 0.1 and 0.5, β between about 0.4 and 0.6, and γ between about 0 and about 0.1 through a electrode forming process chosen from the group consisting of a solid-state reaction method, an aqueous solution method, and a sol-gel method;

further wherein the solid-state reaction method comprises the steps of:

mixing amounts of lithium hydroxide (or lithium carbonate), (Ni,Mn)-hydroxide, and A-hydroxide or A oxide (wherein A is chosen from the group consisting of Mg, Zn, Al, Co, Ga, B, Zr, and Ti) in acetone using zirconia balls for about 12-24 hours to form a mixed powder;

calcining the mixed powder at about 450˜550° C. for about 12-30 hours in air;

calcining the mixed powder at about 900-1100° C. for about 10-24 hours either in an air or an nitrogen/oxygen atmosphere; and

rapidly quenching the calcined powders into liquid nitrogen.

2. The method of claim 1 , wherein x is between about 0 and 0.2, α is between about 0.2 and 0.5, and β is between about 0.5 and 0.6.

3. The method of claim 1 , wherein A is Mg and further wherein x is between about 0 and 0.2, α is between about 0.1 and 0.5, β between about 0.4 and 0.6, and γ is between about 0.01 and about 0.1.

4. The method of claim 1 , wherein A is Al and further wherein x is between about 0 and 0.2, α is between about 0.15 and 0.5, β is between about 0.45 and 0.6, and γ is between about 0.01 and about 0.1.

5. The method of claim 1 , wherein A is Co and further wherein x is between about 0 and 0.2, α is between about 0.15 and 0.5, β is between about 0.45 and 0.6, and γ is between about 0.01 and about 0.1.

6. The method of claim 1 , wherein A is Ti and further wherein x is between about 0 and 0.2, α is between about 0.2 and 0.5, the β is between about 0.4 and 0.6, and γ is between about 0.01 and about 0.1.

7. An electronic device comprising an electrode comprised of the electrode material produced by the method of claim 1 and wherein the electrode is a cathode comprising a mixture of about 80 weight percent of the electrode material, about 10 weight percent carbon, and about 10 weight percent polyvinylidene difluoride as a binder.

8. A method for forming an electrode material made of substituted lithium nickel-manganese oxides, comprising the steps of:

producing compositions of Li 1+x Ni α Mn β A γ O 2 wherein A is chosen from the group consisting of Mg, Zn, Al, Co, Ga, B, Zr, and Ti, and further wherein x is between about 0 and 0.2, α is between about 0.1 and 0.5, β between about 0.4 and 0.6, and γ between about 0 and about 0.1 through a electrode forming process chosen from the group consisting of a solid-state reaction method, an aqueous solution method, and a sol-gel method;

further wherein the aqueous solution method comprises the steps of:

dissolving appropriate amounts of lithium hydroxide, nickel hydroxide, and A-hydroxide or A-nitrate (wherein A is chosen from the group consisting of Mg, Zn, Al, Co, and Ga) in water;

adding an aqueous solution of manganese acetate to form a mixed solution;

refluxing the mixed solution in a round bottom flask attached with a condenser at about 80° C. for about 12-24 hours;

evaporating the mixed solution in a rotary vacuum evaporator;

eliminating the organic contents in the mixed solution at about 400° C. for about 2 hours;

calcining the resulting powder at about 900-1100° C. for about 10-24 hours in either an air or an nitrogen/oxygen atmosphere; and

rapidly quenching the calcined powders into liquid nitrogen.

9. The method of claim 8 , wherein x is between about 0 and 0.2, α is between about 0.2 and 0.5, and β is between about 0.5 and 0.6.

10. The method of claim 8 , wherein A is Mg and further wherein x is between about 0 and 0.2, α is between about 0.1 and 0.5, β between about 0.4 and 0.6, and γ is between about 0.01 and about 0.1.

11. The method of claim 8 , wherein A is Al and further wherein x is between about 0 and 0.2, α is between about 0.15 and 0.5, β is between about 0.45 and 0.6, and γ is between about 0.01 and about 0.1.

12. The method of claim 8 , wherein A is Co and further wherein x is between about 0 and 0.2, α is between about 0.15 and 0.5, β is between about 0.45 and 0.6, and γ is between about 0.01 and about 0.1.

13. The method of claim 8 , wherein A is Ti and further wherein x is between about 0 and 0.2, α is between about 0.2 and 0.5, the β is between about 0.4 and 0.6, and γ is between about 0.01 and about 0.1.

14. An electronic device comprising an electrode comprised of the electrode material produced by the method of claim 8 and wherein the electrode is a cathode comprising a mixture of about 80 weight percent of the electrode material, about 10 weight percent carbon, and about 10 weight percent polyvinylidene difluoride as a binder.

15. A method for forming an electrode material made of substituted lithium nickel-manganese oxides, comprising the steps of:

producing compositions of Li 1+x Ni α Mn β A γ O 2 wherein A is chosen from the group consisting of Mg, Zn, Al, Co, Ga, B, Zr, and Ti, and further wherein x is between about 0 and 0.2, α is between about 0.1 and 0.5, β between about 0.4 and 0.6, and γ between about 0 and about 0.1 through a electrode forming process chosen from the group consisting of a solid-state reaction method, an aqueous solution method, and a sol-gel method;

further wherein the sol-gel method comprises the steps of:

dissolving appropriate amounts of lithium acetate, nickel acetate, manganese acetate, A-acetate or A-nitrate; (wherein A is chosen from the group consisting of Mg, Zn, Al, Co, and Ga) in water;

adding a glycolic/tartaric acid solution for use as a chelating agent;

adjusting the pH of the resulting solution to about 7 to about 8 using ammonium hydroxide;

continuously stirring and heating the solution on a hot plate to form a gel precursor;

decomposing the gel precursor at 450° C. about for about 5 h in air to form a decomposed powder;

calcining the decomposed powders at about 900-1100° C. for about 10-24 hours in either an air or an nitrogen/oxygen atmosphere; and

rapidly quenching the calcined powders into liquid nitrogen.

16. The method of claim 15 , wherein x is between about 0 and 0.2, α is between about 0.2 and 0.5, and β is between about 0.5 and 0.6.

17. The method of claim 15 , wherein A is Mg and further wherein x is between about 0 and 0.2, α is between about 0.1 and 0.5, β between about 0.4 and 0.6, and γ is between about 0.01 and about 0.1.

18. The method of claim 15 , wherein A is Al and further wherein x is between about 0 and 0.2, α is between about 0.15 and 0.5, β is between about 0.45 and 0.6, and γ is between about 0.01 and about 0.1.

19. The method of claim 15 , wherein A is Co and further wherein x is between about 0 and 0.2, α is between about 0.15 and 0.5, β is between about 0.45 and 0.6, and γ is between about 0.01 and about 0.1.

20. The method of claim 15 , wherein A is Ti and further wherein x is between about 0 and 0.2, α is between about 0.2 and 0.5, the β is between about 0.4 and 0.6, and γ is between about 0.01 and about 0.1.

21. An electronic device comprising an electrode comprised of the electrode material produced by the method of claim 15 and wherein the electrode is a cathode comprising a mixture of about 80 weight percent of the electrode material, about 10 weight percent carbon, and about 10 weight percent polyvinylidene difluoride as a binder.