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Amidst the rapid expansion of the electric vehicle industry, the need for alternative battery technologies that balance economic viability with sustainability has never been more critical. Here, we report that common lithium salts of Li2CO3 and Li2SO4 are transformed into cathode active mass in Li-ion batteries by ball milling to form a composite with Cu2S. The optimal composite cathode comprising Li2CO3, Li2SO4, and Cu2S, with a practical active mass loading of 12.5-13.0 mg/cm2, demonstrates a reversible capacity of 247 mAh/g based on the total mass of Cu2S and the lithium salts, a specific energy of 716 Wh/kg, and a stable cycle life. This cathode chemistry rivals layered oxide cathodes of Li-ion batteries in energy density but at substantially reduced cost and ecological footprint. Mechanistic investigations reveal that in the composite Li2CO3 serves as the primary active mass, Li2SO4 enhances kinetic properties and reversibility, and Cu2S stabilizes the resulting anionic radicals for reversibility as a binding agent. Our findings pave the way for directly using precursor lithium salts as cathodes for Li-ion batteries to meet the ever-increasing market demands sustainably. 

Ni-rich layered oxides as high-capacity battery cathodes suffer from degradation at high voltages. We utilize a dry surface modification method, mechanofusion (MF), to achieve enhanced battery stability. The simplicity, high yield, and flexibility make it cost-effective and highly attractive for processing at the industrial scale. The underlying mechanisms responsible for performance improvement are unveiled by a systematic study combining multiple probes, e.g., 3D nano-tomography, spectroscopic imaging, in situ synchrotron diffraction, and finite element analysis (FEA). MF affects the bulk crystallography by introducing partially disordered structure, microstrain, and local lattice variation. Furthermore, the crack initiation and propagation pattern during delithiation are regulated and the overall mechanical fracture is reduced after such surface coating. We validate that MF can alter the bulk charging pathways. Such a synergic effect between surface modification and bulk charge distribution is fundamentally important for designing next-generation battery cathode materials. 

Abstract Single-crystalline nickel-rich cathodes are a rising candidate with great potential for high-energy lithium-ion batteries due to their superior structural and chemical robustness in comparison with polycrystalline counterparts. Within the single-crystalline cathode materials, the lattice strain and defects have significant impacts on the intercalation chemistry and, therefore, play a key role in determining the macroscopic electrochemical performance. Guided by our predictive theoretical model, we have systematically evaluated the effectiveness of regaining lost capacity by modulating the lattice deformation via an energy-efficient thermal treatment at different chemical states. We demonstrate that the lattice structure recoverability is highly dependent on both the cathode composition and the state of charge, providing clues to relieving the fatigued cathode crystal for sustainable lithium-ion batteries. 

Active particles in composite electrodes initially show asynchronous activity that evolves toward synchronous behavior. 

Charge heterogeneity is a prevalent feature in many electrochemical systems. In a commercial cathode of Li-ion batteries, the composite is hierarchically structured across multiple length scales including the sub-micron single-crystal primary-particle domains up to the macroscopic particle ensembles. The redox kinetics of charge transfer and mass transport strongly couples with mechanical stresses. This interplay catalyzes substantial heterogeneity in the charge (re)distribution, stresses, and mechanical damage in the composite electrode during charging and discharging. We assess the heterogeneous electrochemistry and mechanics in a LiNi_xMn_yCo_zO₂(NMC) cathode using a fully coupled electro-chemo-mechanics model at the cell level. A microstructure-resolved model is constructed based on the synchrotron X-ray tomography data. We calculate the stress field in the composite and then quantitatively evaluate the kinetics of surface charge transfer and Li transport biased by mechanical stresses. We further model the cyclic behavior of the cell. The repetitive deformation of the active particles and the weakening of the interfacial strength cause gradual increase of the interfacial debonding. The mechanical damage impedes electron transfer, incurs more charge heterogeneity, and results in the capacity degradation in batteries over cycles.