IP Library Granted Patent US 12,249,707
Granted Patent B2
US 12,249,707 · App. 17/886,096 · Granted Mar 11, 2025

Mono-grain cathode materials

Inventors: Hongli Dai (Los Altos, CA); Huiming Wu (San Jose, CA); Dapeng Wang (Cupertino, CA); John David Carter (Bolingbrook, IL); Yan Li (Westmont, IL); Anh D. Vu (Lemont, IL); Xiaoping Wang (Naperville, IL); Christopher S. Johnson (Naperville, IL); Rui Xu (Lemont, IL); Zhenzhen Yang (Westmont, IL); Yanjie Cui (Arlington Heights, IL); James A. Gilbert (Bolingbrook, IL); Arthur Jeremy Kropf (Westmont, IL); Hakim H. Iddir (Hoffman Estates, IL)
Assignee: Apple Inc.
H01M4/505H01M4/0435H01M4/0471H01M4/525H01M2004/028
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Quick Facts
Patent No.
US 12,249,707
App. No.
17/886,096
Granted
Mar 11, 2025
Kind
B2
Abstract

Methods of making such compounds, powders, and cathode active materials are described. The powders are formed of particles with specific properties: a particle size distribution with a D50 ranging from 10 μm to 20 μm, a D10 less than 8 μm, and a D99 of the particles ranges from 25 μm to 35 μm. The final compound is represented by the Formula Li α (Co 1-x-y-z Mn x Me z Al y )O δ , wherein 0.95<α<1.05, x≤1.00, 0<y≤0.04, 0<z≤0.050, and δ≈2.

Claims (18)

1. A method of making the cathode material, comprising:

forming metal oxide precursors and/or hydroxide precursors, wherein the metal oxide precursors and/or hydroxide precursors have a tap density of at least 1.8 g/cc;

calcinating a mixture of the metal oxide precursors and/or hydroxide precursors and lithium carbonate (Li 2 CO 3 ) at a first elevated temperature for a first period of time to produce a first plurality of particles, wherein the particles comprise a compound representing by Formula: Li α (Co 1-x-y-z Mn x Me z Al y )O δ , where 0.95<α<1.05, x≤1.00, 0≤y≤0.04, 0<z≤0.05, and δ≈2, wherein Me is Ni;

milling the first plurality of particles to form a second plurality of milled particles;

coating the second plurality of milled particles with a Al 2 O 3 coating;

annealing the second plurality of milled particles at a second elevated temperature for a second period of time; and

calendering or further milling the annealed second plurality of milled particles to form a third plurality of pressed particles,

wherein a D50 of the metal oxide precursors and/or hydroxide precursors is at least 7 μm.

2. The method of claim 1 , wherein Me is Ni, the Formula is Li α (Co 1-x-y-z Mn x Ni z Al y )O δ .

3. The method of claim 1 , wherein the first period of time is at least 15 hours.

4. The method of claim 1 , wherein the first elevated temperature is at least 950° C.

5. The method of claim 1 , wherein the second period of time is 8 hours.

6. The method of claim 1 , wherein the second elevated temperature is at least 750° C.

7. The method of claim 1 , wherein a delta D50 between the third plurality of pressed particles and the second plurality of milled particles is less than 12%.

8. The method of claim 1 , wherein a delta D99 between the third plurality of pressed particles and the second plurality of milled particles is less than 40%.

9. The method of claim 1 , wherein a D50 of the second plurality of milled particles ranges from 15 μm to 20 μm.

10. The method of claim 1 , wherein a D90 of the second plurality of milled particles ranges from 20 μm to 30 μm, and a D99 of the second plurality of milled particles ranges from 25 μm to 35 μm.

11. The method of claim 1 , wherein a D10 of the second plurality of milled particles is less than 8 μm.

Continuity (3)
Division 16999265 · Aug 21, 2020
Provisional Application 62889927 · Aug 21, 2019
Related Publication 20220399541A1 · Dec 15, 2022
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