阅读说明：本技术 通过表面涂层稳定钛酸锂氧化物(lto)的方法 (Method for stabilizing Lithium Titanate Oxide (LTO) by surface coating ) 是由 鹿鹏 M.P.巴洛格 吁志强 刘海晶 D.B.哈达 于 2017-03-13 设计创作，主要内容包括：预处理包含钛酸锂氧化物(LTO)的电活性材料的方法包括使电活性材料的表面与预处理组合物接触。在一个变体中,所述预处理组合物包含选自以下的锂氟盐的盐：六氟磷酸锂(LiPF<Sub>6</Sub>)、四氟硼酸锂(LiBF<Sub>4</Sub>)及其组合,和溶剂。在另一个变体中,所述预处理组合物包含有机磷化合物。以这种方式,在电活性材料表面上形成了保护性表面涂层。所述保护性表面涂层包含氟、氧、磷或硼,以及任选的元素例如碳、氢、和列出的金属,以及它们的组合。(A method of pretreating an electroactive material comprising a Lithium Titanate Oxide (LTO) comprises contacting a surface of the electroactive material with a pretreatment composition. In one variation, the pretreatment composition comprises a salt of a lithium fluoride salt selected from the group consisting of: lithium hexafluorophosphate (LiPF) 6 ) Lithium tetrafluoroborate (LiBF) 4 ) And combinations thereof, and solvents. In another variation, the pretreatment composition comprises an organophosphorus compound. In this manner, a protective surface coating is formed on the surface of the electroactive material. The protective surface coating comprises fluorine, oxygen, phosphorus or boron, and optional elements such as carbon, hydrogen, and the listed metals, and combinations thereof.)

1. A method of making an electroactive material for an electrochemical cell, the method comprising:

pre-treating a surface comprising Li by contacting the surface of an electroactive material with a pre-treatment composition_(4+x)Ti₅O₁₂(LTO) to form a protective surface coating on a surface of the electroactive material, wherein 0 ≦ x ≦ 3, wherein the pretreatment composition comprises a lithium fluoride salt selected from lithium hexafluorophosphate (LiPF) and a solvent₆) Lithium tetrafluoroborate (LiBF)₄) And combinations thereof, wherein the protective surface coating comprises fluorine, oxygen, and at least one element selected from the group consisting of: phosphorus, boron, and combinations thereof.

2. The method of claim 1, wherein the protective surface coating comprises a composition consisting of P_xO_yF_zA first compound represented by M_aP_xO_yF_zThe second compound represented by (a), or a combination of the first compound and the second compound, wherein 0 when P in the formula is normalized such that x =1, is< y ≤ 4，0 < z ≤ 6，0 <a is less than or equal to 3, and M_aSelected from the following elements: lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), barium (Ba), titanium (Ti), aluminum (Al), and combinations thereof.

3. The method of claim 2, wherein the protective surface coating comprises a composition consisting of P_xO_yF_zThe first compound represented, comprising fluorine (F) in an amount of greater than or equal to about 19 wt% to less than or equal to about 67 wt%.

4. The method of claim 2, wherein the protective surface coating comprises a coating consisting of M_aP_xO_yF_zThe second compound of (a), comprising fluorine (F) in an amount of greater than or equal to about 6 wt% to less than or equal to about 59 wt%.

5. The method of claim 2, wherein the protective surface coating further comprises titanium Tetrafluoride (TiF)₄)。

6. The method of claim 1, wherein the protective surface coating comprises a coating consisting of B_xO_yF_zA compound of formula (I) wherein when B in the formula is normalized to 1 and x equals about 1,0<y is less than or equal to 4 and 0<z ≤ 4。

7. The method of claim 6, wherein the protective surface coating further comprises titanium Tetrafluoride (TiF)₄)。

8. The method of claim 1, wherein the lithium fluoride salt is present in the pretreatment composition at greater than or equal to about 0.1 wt% to less than or equal to about 15 wt%.

9. The method of claim 1, wherein pre-treatment to form the protective surface coating occurs in the absence of any applied electrical potential or current.

10. The method of claim 1, wherein the electroactive material is in the form of a plurality of LTO particles and the pretreating comprises mixing the plurality of LTO particles with a pretreatment composition, wherein the plurality of LTO particles are used to form a negative electrode after a protective coating is formed on the surface.

11. The method of claim 1, wherein the LTO is contained in a pre-fabricated electrode layer and the pre-treating comprises applying the pre-treatment composition onto at least one exposed surface of the pre-fabricated electrode layer.

12. A method of making an electroactive material for an electrochemical cell, the method comprising:

pre-treating a surface comprising Li by contacting the surface of an electroactive material with a pre-treatment composition_(4+x)Ti₅O₁₂(LTO) to form a protective surface coating on said surface, wherein 0 ≦ x ≦ 3, wherein said pretreatment composition comprises a metal oxide selected from the group consisting of M_aP_xO_yF_zC_nH_mAn organic phosphorus compound represented by (I), wherein when x =1, 0. ltoreq. a.ltoreq.3, 0< y ≤ 4，0 <z is less than or equal to 6, n is more than or equal to 0 and less than or equal to 20, M is more than or equal to 0 and less than or equal to 42, and M_aSelected from the following elements: lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), barium (Ba), titanium (Ti), aluminum (Al), and combinations thereof, wherein the protective surface coating comprises fluorine, oxygen, phosphorus, carbon, and hydrogen.

13. The method of claim 12, wherein the organophosphorus compound is selected from: perfluorinated phosphonic acids, methallyl phosphates, alkyl fluorophosphates, phosphorylated poly (methyl methacrylate) (PMMA), phosphonated polyimides, (aminomethyl) phosphonic acids, lithium metaphosphate, adenosine diphosphate, phospholipids, and combinations thereof.

14. The method of claim 12, wherein the organophosphorus compound consists of P_xO_yF_zC_nH_mRepresents, wherein when x =1, 0< y ≤ 4，0 <z ≦ 6, 0 ≦ n ≦ 20, 0 ≦ m ≦ 42, and fluorine (F) is included in greater than or equal to about 4 wt% to less than or equal to about 50 wt%.

15. The method of claim 12, wherein the organophosphorus compound is present in the pretreatment composition in the range of greater than or equal to about 0.1 wt% to less than or equal to about 15 wt%.

16. The method of claim 12, wherein the pre-treatment to form the protective surface coating is performed in the absence of any applied electrical potential.

17. The method of claim 12, wherein the protective surface coating comprises a coating consisting of M_aP_xO_yF_zC_nH_mAn organophosphorus compound represented by (i) a formula (I) to form a protective surface coating on the surface, wherein when x =1, 0. ltoreq. a.ltoreq.3, 0< y ≤ 4，0<z is less than or equal to 6, n is more than or equal to 0 and less than or equal to 20, M is more than or equal to 0 and less than or equal to 42, and M_aSelected from the following elements: lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), barium (Ba), titanium (Ti), aluminum (Al), and combinations thereof.

18. The method of claim 12, wherein the electroactive material:

(i) in the form of a plurality of LTO particles and the pre-treatment comprises mixing the plurality of LTO particles with the pre-treatment composition, wherein the plurality of LTO particles is used to form a negative electrode after a protective coating is formed on the surface; or

(ii) Contained in a pre-formed electrode layer and said pre-treatment comprises applying said pre-treatment composition onto at least one exposed surface of the pre-formed electrode layer.

19. An electroactive material for an electrochemical cell, comprising:

Li_(4+x)Ti₅O₁₂wherein x is more than or equal to 0 and less than or equal to 3 (LTO); and

a protective top coating formed thereon, the protective top coating comprising a metal oxide consisting of M_aP_xO_yF_zC_nH_mThe compounds are represented to form a protective surface coating on a surface, wherein when x =1, 0 ≦ a ≦ 3,0< y ≤ 4，0 <z is less than or equal to 6, n is more than or equal to 0 and less than or equal to 20, M is more than or equal to 0 and less than or equal to 42, and M_aSelected from the following elements: lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca) and barium(Ba), titanium (Ti), aluminum (Al), and combinations thereof.

20. A lithium-ion electrochemical cell comprising the electroactive material of claim 19 as a negative electrode, and further comprising:

a positive electrode;

a spacer; and

comprising lithium hexafluorophosphate (LiPF)₆) Lithium tetrafluoroborate (LiBF)₄) And combinations thereof.

Disclosure of Invention

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

In certain variations, the present disclosure relates to methods of making electroactive materials for electrochemical cells. The method optionally includes pre-treating the composition to contain Li_(4+x)Ti₅O₁₂(LTO) wherein 0X is less than or equal to 3. The pretreatment can include contacting a surface of the electroactive material with a pretreatment composition. The pretreatment composition comprises a salt of a lithium fluoride salt (lithium fluoride salt) selected from the group consisting of: lithium hexafluorophosphate (LiPF)₆) Lithium tetrafluoroborate (LiBF)₄) And combinations thereof. The pretreatment composition may further comprise a solvent. The pretreatment thereby forms a protective surface coating on the surface of the electroactive material. The protective surface coating comprises fluorine, oxygen and at least one element selected from the group consisting of: phosphorus, boron, and combinations thereof.

In one aspect, the protective surface coating comprises a composition consisting of P_xO_yF_zA first compound represented by M_aP_xO_yF_zThe second compound of (a), or a combination of the first compound and the second compound. In the first compound and the second compound, 0 is used when P in the formula is normalized to 1 so that x is equal to about 1< y ≤ 4，0 < z ≤ 6，0 <a is less than or equal to 3, and M_aSelected from the following elements: lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), barium (Ba), titanium (Ti), aluminum (Al), and combinations thereof.

In one aspect, comprising the reaction of P_xO_yF_zA first compound represented by M_aP_xO_yF_zThe protective surface coating of the second compound, or combination of first and second compounds, of (a) further comprises titanium Tetrafluoride (TiF)₄)。

In one aspect, the protective surface coating comprises a composition consisting of P_xO_yF_zThe first compound represented, comprising fluorine (F) in an amount of greater than or equal to about 19 wt% to less than or equal to about 67 wt%.

In one aspect, the protective surface coating comprises a composition consisting of M_aP_xO_yF_zThe second compound of (a), comprising fluorine (F) in an amount of greater than or equal to about 6 wt% to less than or equal to about 59 wt%.

In one aspect, the protective surface coating comprises a coating of a metal selected from the group consisting of B_xO_yF_zThe compounds represented, when B is normalized to 1 and x equals about 1,0<y is less than or equal to 4 and 0<z ≤ 4。

In one aspect, comprises a compound represented by B_xO_yF_zThe protective surface coating of the compound of (a) further comprises titanium Tetrafluoride (TiF)₄)。

In one aspect, the lithium fluoride salt is present in the pretreatment composition at greater than or equal to about 0.1 wt.% to less than or equal to about 15 wt.%.

In one aspect, the pretreatment is performed in the absence of any applied electrical potential or current to form the protective surface coating.

In one aspect, the electroactive material may be in the form of a plurality of LTO particles. The pretreatment may include mixing the plurality of LTO particles with a pretreatment composition. After the protective coating is formed on the surface, the plurality of LTO particles is used to form a negative electrode.

In one aspect, the LTO is contained in a prefabricated electrode layer. The pre-treatment comprises applying a pre-treatment composition onto at least one exposed surface of the pre-fabricated electrode layer. A protective coating is formed on the exposed surface of the LTO in the pre-formed electrode layer.

In another variation, the present disclosure relates to a method of making an electroactive material for an electrochemical cell. The method includes pre-treating a surface comprising Li by contacting the surface of an electroactive material with a pre-treatment composition_(4+x)Ti₅O₁₂(LTO), wherein 0. ltoreq. x. ltoreq.3. The pretreatment composition comprises a mixture of M_aP_xO_yF_zC_nH_mAn organophosphorus compound represented by (I), wherein when x is equal to about 1, 0. ltoreq. a.ltoreq.3, 0< y ≤ 4，0 <z is less than or equal to 6, n is more than or equal to 0 and less than or equal to 20, M is more than or equal to 0 and less than or equal to 42, and M_aSelected from the following elements: lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), barium (Ba), titanium (Ti), aluminum (Al), and combinations thereof, to form a protective surface coating on the surface. The protective surface coating comprises fluorine, oxygen, phosphorus, carbon, and hydrogen.

In one aspect, the organophosphorus compound is selected from: perfluorinated phosphonic acids, methallyl phosphates, alkyl fluorophosphates, phosphorylated poly (methyl methacrylate) (PMMA), phosphonated polyimides, (aminomethyl) phosphonic acids, lithium metaphosphate, adenosine diphosphate, phospholipids, and combinations thereof.

In one aspect, the protective surface coating consists of P_xO_yF_zC_nH_mMeaning that when P is normalized to 1 such that x equals about 1, where 0< y ≤ 4，0 < z ≤ 6，0 <n is less than or equal to 20 and m is less than or equal to 42 and is more than or equal to 0.

In one aspect, the organophosphorus compound consists of P comprising fluorine (F) in an amount of greater than or equal to about 4 wt% to less than or equal to about 50 wt%_xO_yF_zC_nH_mAnd (4) showing.

In one aspect, the organophosphorus compound is present in the pretreatment composition in an amount greater than or equal to about 0.1 wt% to less than or equal to about 15 wt%.

In one aspect, the pretreatment is performed in the absence of any applied electrical potential to form the protective surface coating.

In one aspect, the electroactive material:

(i) in the form of a plurality of LTO particles. The pre-treatment comprises mixing the plurality of LTO particles with a pre-treatment composition. The protective coating is formed on the surface and the plurality of LTO particles are used to form a negative electrode; or

(ii) Contained in a prefabricated electrode layer. The pre-treatment comprises applying a pre-treatment composition onto at least one exposed surface of the pre-fabricated electrode layer.

In certain other variations, the present disclosure relates to an electroactive material for an electrochemical cell comprising Li_(4+x)Ti₅O₁₂Wherein 0. ltoreq. x.ltoreq.3 (LTO), and a protective surface coating formed thereon. The protective surface coating comprises a metal oxide coating consisting of M_aP_xO_yF_zC_nH_mA compound of formula (I) wherein x is equal to or greater thanWhen 1 is about, 0. ltoreq. a.ltoreq.3, 0< y ≤ 4，0 <z is less than or equal to 6, n is more than or equal to 0 and less than or equal to 20, M is more than or equal to 0 and less than or equal to 42, and M_aSelected from the following elements: lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), barium (Ba), titanium (Ti), aluminum (Al), and combinations thereof.

In one aspect, a lithium-ion electrochemical cell includes the electroactive material as a negative electrode, and further includes a positive electrode, a separator, and a lithium hexafluorophosphate (LiPF) containing material₆) Lithium tetrafluoroborate (LiBF)₄) And combinations thereof.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Drawings

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1 is a schematic diagram of an exemplary electrochemical storage cell for illustrative purposes;

fig. 2 is a schematic diagram showing a simplified batch process for pre-treating a plurality of Lithium Titanate Oxide (LTO) containing electroactive material particles with a protective coating, according to certain aspects of the present disclosure;

fig. 3 is a schematic diagram showing a simplified continuous process for pretreating a plurality of electroactive material particles comprising Lithium Titanate Oxide (LTO) in a continuous flow reactor to have a protective coating, according to certain aspects of the present disclosure;

fig. 4 is a schematic diagram showing a simplified process for pre-treating a pre-fabricated electrode having an electroactive material comprising Lithium Titanate Oxide (LTO) with a protective coating, according to certain aspects of the present disclosure; and

fig. 5 is a schematic diagram showing a plurality of Lithium Titanate Oxide (LTO) -containing electroactive material particles having a multilayer protective coating applied in accordance with certain aspects of the present disclosure.

Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.

Detailed Description

The exemplary embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those skilled in the art. Numerous specific details are set forth such as examples of specific compositions, components, devices, and methods to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, none of which should be construed to limit the scope of the disclosure. In some exemplary embodiments, well-known methods, well-known device structures, and well-known techniques have not been described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, elements, components, steps, integers, operations, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. While the open-ended term "comprising" should be understood as a non-limiting term used to describe and claim the various embodiments described herein, in certain aspects the term is instead understood to be a more limiting and limiting term such as "consisting of … …" or "consisting essentially of … …". Thus, for any given embodiment that recites a composition, material, component, element, feature, integer, operation, and/or process step, the disclosure also specifically includes embodiments that consist of, or consist essentially of, such recited composition, material, component, element, feature, integer, operation, and/or process step. In the case of "consisting of … …, alternative embodiments exclude any additional compositions, materials, components, elements, features, integers, operations, and/or process steps, and in the case of" consisting essentially of … …, "exclude from such embodiments any additional compositions, materials, components, elements, features, integers, operations, and/or process steps that substantially affect the basic and novel characteristics, but may include in such embodiments any compositions, materials, components, elements, features, integers, operations, and/or process steps that do not substantially affect the basic and novel characteristics.

Any method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be used, unless otherwise stated.

When a component, element, or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it may be directly on, engaged, connected, or coupled to the other element, or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being directly on another element or layer, "directly engaged", "directly connected", or "directly coupled" to the other element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" vs "directly between", "adjacent" vs "directly adjacent", etc.). As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various steps, elements, components, regions, layers and/or sections, these steps, elements, components, regions, layers and/or sections should not be limited by these terms unless otherwise specified. These terms may be only used to distinguish one step, element, component, region, layer or section from another step, element, component, region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first step, element, component, region, layer or section discussed below could be termed a second step, element, component, region, layer or section without departing from the teachings of the example embodiments.

For ease of description, spatially and temporally relative terms, such as "before", "after", "inside", "outside", "below", "lower", "upper", "lower", and the like, may be used herein to describe one element or feature's relationship to another element or feature as illustrated in the figures. Spatially and temporally relative terms may be intended to encompass different orientations of the device or system in use or operation in addition to the orientation depicted in the figures.

Throughout this disclosure, numerical values represent approximate measurements or range limits to include embodiments that deviate slightly from the given value and that generally have the listed values, as well as embodiments that have exactly the listed values. Other than in the examples provided at the end of the detailed description, all numerical values of parameters (such as amounts or conditions) in this specification (including the appended claims) are to be understood as being modified in all instances by the term "about", whether or not "about" actually appears before the numerical value. By "about" is meant that the numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by "about" is not otherwise understood in the art with this ordinary meaning, then "about" as used herein at least refers to variations that may result from ordinary methods of measuring and using such parameters. For example, "about" may encompass variations of less than or equal to 5%, optionally less than or equal to 4%, optionally less than or equal to 3%, optionally less than or equal to 2%, optionally less than or equal to 1%, optionally less than or equal to 0.5%, and in certain aspects optionally less than or equal to 0.1%.

In addition, the disclosure of a range includes all values within the full range and further sub-ranges, including the endpoints and sub-ranges given for these ranges.

As used herein, the terms "composition" and "material" are used interchangeably to refer broadly to a substance that contains at least a preferred compound, but may also contain additional substances or compounds (including impurities).

Exemplary embodiments will now be described more fully with reference to the accompanying drawings.

An exemplary schematic of a lithium ion battery 20 is shown in fig. 1. The lithium ion battery 20 includes a negative electrode 22, a positive electrode 24, and a separator 30 (e.g., a microporous polymer separator) disposed between the two electrodes 22, 24. The separator 26 contains an electrolyte 30, which may also be present in the negative electrode 22 and the positive electrode 24. The negative electrode current collector 32 may be located at or near the negative electrode 22 and the positive electrode current collector 34 may be located at or near the positive electrode 24. The negative electrode current collector 32 and the positive electrode current collector 34 collect and move free electrons to and from the external circuit 40, respectively. An interruptible external circuit 40 and load 42 connect the negative electrode 22 (through its current collector 32) and the positive electrode 24 (through its current collector 34). The negative electrode 22, the positive electrode 24, and the separator 26 may each further comprise an electrolyte 30 capable of conducting lithium ions. Separator 26 acts as both an electrical insulator and a mechanical support by being sandwiched between negative electrode 22 and positive electrode 24 to prevent physical contact and thus short circuit. In addition to providing a physical barrier between the two electrodes 22, 24, the separator 26 may also provide a path of minimal resistance for the internal passage of lithium ions (and associated anions) to facilitate operation of the lithium ion battery 20.

When the negative electrode 22 contains a relatively large amount of intercalated lithium, the lithium ion battery 20 may generate an electric current during discharge via a reversible electrochemical reaction that occurs when the external circuit 40 is closed (to connect the negative electrode 22 and the positive electrode 34). The difference in chemical potential between the positive electrode 24 and the negative electrode 22 drives electrons generated at the negative electrode 22 by oxidation of the intercalated lithium toward the positive electrode 24 through an external circuit 40. Lithium ions, which are also generated at the negative electrode, are transferred to the positive electrode 24 through the electrolyte 30 and the separator 26. The electrons flow through the external circuit 40 and the lithium ions migrate through the separator 26 in the electrolyte 30 to form intercalated lithium at the positive electrode 24. The current through the external circuit 40 can be harnessed and directed through the load device 42 until the intercalated lithium in the negative electrode 22 is depleted and the capacity of the lithium ion battery 20 is reduced.

The lithium ion battery 20 can be charged or recharged at any time by connecting an external power source to the lithium ion battery 20 to reverse the electrochemical reactions that occur during battery discharge. The connection of an external power source to the lithium ion battery 20 forces non-spontaneous oxidation of the lithium intercalated at the positive electrode 24 to produce electrons and lithium ions. The electrons, which flow back to the negative electrode 22 through the external circuit 40, and the lithium ions, which are carried by the electrolyte 30 through the separator 26 back to the negative electrode 22, recombine at the negative electrode 22 and replenish it with intercalated lithium for consumption during the next battery discharge cycle. The external power source that may be used to charge the lithium ion battery 20 may vary depending on the size, configuration, and particular end use of the lithium ion battery 20. Some notable exemplary external power sources include, but are not limited to, AC wall sockets and motor vehicle alternators. In many lithium ion battery configurations, the negative current collector 32, the negative electrode 22, the separator 26, the positive electrode 24, and the positive current collector 34 are each prepared as relatively thin layers (e.g., a thickness of a few microns or 1 millimeter or less) and assembled in layers connected in an electrically parallel arrangement to provide a suitable energy package.

In addition, the lithium ion battery 20 may include various other components known to those skilled in the art, although not described herein. For example, the lithium ion battery 20 may include a housing, gaskets, end caps, and any other conventional components or materials that may be located within the battery 20, including between or around the negative electrode 22, the positive electrode 24, and/or the separator 26 (as non-limiting examples). As described above, the size and shape of the lithium ion battery 20 may vary depending on the particular application for which it is intended. For example, battery powered automobiles and handheld consumer electronic devices are two examples of different sizes, capacities, and power output specifications that the lithium ion battery 20 will most likely be designed to. The lithium ion battery 20 may also be connected in series or parallel with other similar lithium ion cells or batteries to produce greater voltage output and power density if desired by the load device 42.

Thus, the lithium ion battery 20 is capable of generating an electrical current to a load device 42 (which may be operatively connected to the external electrical circuit 40). The load device 42 may be wholly or partially powered by current through the external circuit 40 when the lithium ion battery 20 is discharged. While load device 42 may be any number of known electrically driven devices, some specific examples of power consuming load devices include motors for hybrid or all-electric vehicles, laptops, tablets, mobile phones, and cordless power tools or appliances, as non-limiting examples. The load device 42 may also be a power generation device that charges the lithium ion battery 20 to store energy.

Any suitable electrolyte 30 (whether in solid form or in solution) capable of conducting lithium ions between the negative electrode 22 and the positive electrode 24 may be used in the lithium ion battery 20. In certain aspects, the electrolyte solution may be a non-aqueous liquid electrolyte solution comprising a lithium salt dissolved in an organic solvent or mixture of organic solvents. Many conventional non-aqueous liquid electrolyte 30 solutions may be used in the lithium ion battery 20. A non-limiting list of lithium salts that can be dissolved in an organic solvent to form a non-aqueous liquid electrolyte solution includes LiPF₆、LiClO₄、LiAlCl₄、LiI、LiBr、LiSCN、LiBF₄、LiB(C₆H₅)₄、LiAsF₆、LiCF₃SO₃、LiN(CF₃SO₂)₂And combinations thereof. These and other similar lithium salts may be dissolved in various organic solvents, including, but not limited to, various alkyl carbonates, such as cyclic carbonates (ethylene carbonate (EC), Propylene Carbonate (PC), Butylene Carbonate (BC)), acyclic carbonates (dimethyl carbonate (DMC), diethyl carbonate (DEC), ethylmethyl carbonate (EMC)), aliphatic carboxylic acid esters (methyl formate, methyl acetate, methyl propionate), γ -lactones (γ -butyrolactone, γ -valerolactone), chain structural ethers (1, 2-dimethoxyethane, 1, 2-diethoxyethane, ethoxymethoxyethane), cyclic ethers (tetrahydrofuran, 2-methyltetrahydrofuran), and mixtures thereof.

In one embodiment, the separator 30 may comprise a microporous polymer separator comprising a polyolefin. The polyolefin may be a homopolymer (derived from a single monomer component) or a heteropolymer (derived from more than one monomer component), which may be linear or branched. If the heteropolymer is derived from two monomeric components, the polyolefin may exhibit any copolymer chain arrangement, including those of block copolymers or random copolymers. Similarly, if the polyolefin is a heteropolymer derived from more than two monomeric components, it may likewise be a block copolymer or a random copolymer. In certain aspects, the polyolefin may be Polyethylene (PE), polypropylene (PP), or a blend of PE and PP.

When the separator 30 is a microporous polymeric separator, it may be a single layer or a multilayer laminate, which may be made by either a dry or wet process. For example, in one embodiment, a single layer of the polyolefin may form the entire microporous polymeric separator 30. In other aspects, the separator 30 may be a fibrous membrane having a large number of pores through opposing surfaces and may have a thickness of, for example, less than 1 millimeter. However, as another example, multiple separate layers of similar or dissimilar polyolefins may be assembled to form the microporous polymeric separator 30. The microporous polymeric separator 30 may comprise other polymers in addition to the polyolefin, such as, but not limited to, polyethylene terephthalate (PET), polyvinylidene fluoride (PVDF), and/or polyamide. The polyolefin layer and any other optional polymer layers may be further included as fibrous layers in the microporous polymer separator 30 to help provide the microporous polymer separator 30 with the appropriate structural and porosity characteristics. Various conventionally available polymers and commercial products for forming the separator 30 are contemplated, as well as numerous manufacturing methods that may be used to manufacture such microporous polymeric separators 30.

The positive electrode 24 may be formed of any lithium-based active material capable of sufficient lithium intercalation and deintercalation while serving as the positive terminal of the lithium ion battery 20. Positive electrode 24 may include a polymeric binder material to structurally strengthen the lithium-based active material. One exemplary common type of known material that may be used to form positive electrode 24 is a layered lithium transition metal oxide. For example, in various embodiments, positive electrode 24 can comprise at least one spinel, such as lithium manganese oxide (Li)_(1+x)Mn_(2-x)O₄) Where 0. ltoreq. x.ltoreq.1, where x is usually less than 0.15, including LiMn₂O₄Lithium manganese nickel oxide (LiMn)_(2-x)Ni_xO₄) Where 0. ltoreq. x.ltoreq.1, e.g. LiMn_1.5Ni_0.5O₄Lithium cobalt oxide (LiCoO)₂) Lithium manganese oxide (LiMn)₂O₄) Lithium nickel oxide (LiNiO)₂) Lithium nickel manganese cobalt oxide (Li (Ni)_xMn_yCo_z)O₂) Wherein x is more than or equal to 0 and less than or equal to 1, y is more than or equal to 0 and less than or equal to 1, z is more than or equal to 0 and less than or equal to 1, and x + y + z =1, lithium nickel cobalt metal oxide LiNi_(1-x-y)Co_xM_yO₂(wherein 0)<x<1，y<1, and M may be Al, Mn, etc.), lithium-transition metal oxides or mixed oxides, lithium iron phosphate, or lithium iron polyanionic oxides such as lithium iron phosphate (LiFePO)₄) Or lithium iron fluorophosphate (Li)₂FePO₄F) In that respect Various other known lithium-based active materials may also be used. As a non-limiting example, an alternative material may include lithium nickel oxide (LiNiO)₂) Lithium aluminum manganese oxide (Li)_xAl_yMn_(1-y)O₂) And lithium vanadium oxide (LiV)₂O₅). In certain variations, positive electrode 24 comprises at least one of: spinels, e.g. lithium manganese oxide (Li)_(1+x)Mn_(2-x)O₄) Lithium manganese nickel oxide (LiMn)_(2-x)Ni_xO₄) Where 0. ltoreq. x.ltoreq.1, lithium manganese nickel cobalt oxides (e.g. LiMn)_1/3Ni_1/3Co_1/3O₂) Or lithium iron phosphate (LiFePO)₆). Such active materials may be mixed with at least one polymeric binder, for example by slurry casting the active material with a binder such as polyvinylidene fluoride (PVDF), Ethylene Propylene Diene Monomer (EPDM) rubber, or carboxymethylcellulose (CMC). The positive current collector 34 may be formed of aluminum or any other suitable conductive material known to those skilled in the art.

In various aspects, the negative electrode 22 includes an electroactive material as a lithium host material capable of serving as a negative terminal of a lithium ion battery. The negative electrode 22 may also include another electrically conductive material, and one or more polymeric binder materials to structurally hold the lithium host material together. For example, in one embodiment, the negative electrode 22 may be formed from Lithium Titanate Oxide (LTO) particles mixed in at least one of polyvinylidene fluoride (PVDF), Nitrile Butadiene Rubber (NBR), Styrene Butadiene Rubber (SBR) binder, or carboxymethylcellulose (CMC), as non-limiting examples, as will be described in more detail below. The negative electrode current collector 32 may be formed of copper or any other suitable conductive material known to those skilled in the art.

In various aspects of the present disclosure, the negative electrode 22 includes Li-containing modified according to certain principles of the present teachings₄Ti₅O₁₂(LTO) active material. The LTO is capable of sufficiently performing lithium intercalation or alloying and deintercalation or alloy disintegration while serving as a negative electrode terminal of the lithium ion battery 20. When LTO is intercalated or alloyed with lithium ions, it is made of Li₄Ti₅O₁₂Conversion to Li_{4+ x}Ti₅O₁₂Wherein x is 0. ltoreq. x.ltoreq.3 (wherein LTO in fully intercalated or alloyed form is Li)₇Ti₅O₁₂). As previously mentioned, LTO is particularly useful as the negative electrode 22 active material because it has excellent electrochemical performance and, in addition, little or no volume change after lithium insertion. Therefore, it is considered to be a zero strain material providing excellent long-term stability.

Therefore, LTO is a promising lithium battery electrode material due to its excellent cycling stability, current efficiency, rate capability. Furthermore, LTO can be designed as a nanostructured material to achieve higher packing density and very high rated capacity. However, as previously mentioned, one potential drawback to using LTO as the negative electrode 22 is that it appears that over time, at relatively high temperatures and under certain charging conditions, LTO may generate significant amounts of gas within the electrochemical cell. Such gas generation over time is undesirable since lithium ion batteries are typically hermetically sealed. The main component of the gas generated by LTO in a lithium ion battery is hydrogen (H)₂) Its production seems to increase with temperature and state of charge (S-OC). LTO and typical cathode active materials (e.g., Li)_(1+x)Mn_(2-x)O₄) Does not contain a hydrogen source per se and therefore does not generate hydrogen per se. Furthermore, although the lithium electrolyte has a source of hydrogen (e.g., from a non-aqueous solvent such as alkyl carbonate), the electrolyte is at ambient temperatureAre generally stable in degrees. The gas generation problem appears to be proprietary to the use of LTO or similar materials as the negative electrode active material, while altering the cathode active material does not mitigate the generation of gas.

While not limiting the present teachings to any particular theory, in theory, components in the electrolyte solution may decompose and form species that react with the active metal oxide (LTO) to form hydrogen gas and other undesirable byproducts. For example, when the electrolyte comprises lithium hexafluorophosphate (LiPF)₆) It can be dissociated into LiF and PF at a high voltage (e.g., about 2.6V versus Li)₅。PF₅Is a strong lewis acid that reacts with and consumes lithium ions in the electrochemical cell. In addition, HF may be generated by undesirable reactions between certain electrolytes and the active hydroxide in LTO. This causes the LTO to react with the electrolyte and consume lithium, undesirably reducing the battery capacity.

To solve these problems, a secondary battery incorporating an LTO negative electrode may be subjected to an aging process in advance, which includes heating the secondary battery for a predetermined period of time to improve capacity retention and reduce gas formation. For example, in one exemplary thermal aging process, a battery having LTO electrodes may be aged at about 70 ℃ for one week at 100% state of charge (SOC)/applied potential. However, such thermally driven aging can undesirably reduce the initial battery capacity by about 10% or more by consuming active lithium in the battery.

In various aspects, the present disclosure provides methods of making electroactive materials for electrochemical cells. The method includes pre-treating a surface comprising Li by contacting the surface of an electroactive material with a pre-treatment composition_(4+x)Ti₅O₁₂(LTO) wherein x is 0. ltoreq. x.ltoreq.3. The pretreatment composition thereby forms a protective surface coating on the surface of the electroactive material. In this manner, the pre-treated LTO with protective coating may be subsequently added to a lithium-ion electrochemical cell while maintaining high capacity and minimal reactivity with the electrolyte to reduce or inhibit the formation of any gases during use.

In one variation, a method of manufacturing an electroactive material for an electrochemical cell is provided. The method includes pre-treating a surface comprising Li by contacting the surface of an electroactive material with a pre-treatment composition_(4+x)Ti₅O₁₂(LTO) wherein x is 0. ltoreq. x.ltoreq.3. The pretreatment composition may comprise a lithium fluoride salt. In certain aspects, the lithium fluoride salt may be selected from: lithium hexafluorophosphate (LiPF)₆) Lithium tetrafluoroborate (LiBF)₄) And combinations thereof. In certain variations, the pretreatment composition may comprise a solvent. In certain variations, the solvent is a non-aqueous solvent. The solvent may include alkyl carbonates such as cyclic carbonates (ethylene carbonate (EC), Propylene Carbonate (PC), Butylene Carbonate (BC)) and/or acyclic carbonates (dimethyl carbonate (DMC), diethyl carbonate (DEC), Ethyl Methyl Carbonate (EMC)).

In certain variations, an electroactive material comprising LTO may have an oxide coated layer, which may use an oxide (e.g., silicon dioxide (SiO)₂) Or silicon oxide (SiO)_x) Coated LTO as an active material that can form a protective coating (e.g., comprising P) by reaction with a pretreatment composition_xO_yF_z) Without consuming the LTO active material.

Forming a protective surface coating on one or more exposed surface areas of the electroactive material after contact with the one or more exposed surface areas of the electroactive material. In certain aspects, one or more components of the lithium fluoride salt react with the LTO to form the protective surface coating. The protective coating may be multiple layers, or may be a single layer. In certain aspects, the protective coating may be a hybrid coating having a plurality of layers with different compositions. For example, while not limiting the disclosure to any particular theory, it is believed that when LiPF is present₆The following reactions represented by equations 1 and 2 below occur to form the protective coating in such variants.

LiPF₆ → LiF + PF₅ (reaction formula 1)

12PF₅ + Li₄Ti₅O₁₂ → 12POF₃ + 5TiF₄ + 4LiF (reaction type 2)

In addition, LiBF is present therein₄In variations of (a), it is believed that the following reactions represented by equations 3 and 4 below occur to form the protective coating.

LiBF₄ → LiF + BF₃ (reaction formula 3)

12BF₃ + Li₄Ti₅O₁₂ → 12BOF + 5TiF₄ + 4LiF (reaction type 4)

Thus, the protective surface coating may comprise fluorine, oxygen and at least one element selected from the group consisting of: phosphorus, boron, and combinations thereof. The protective coating may also comprise titanium.

In certain aspects, the protective surface coating comprises a composition consisting of M_aP_xO_yF_zA compound of formula (la) wherein 0 when P in the formula is normalized to 1 such that x equals about 1(x =1)< y ≤ 4，0 < z ≤ 6，0 ≤ a ≤ 3。M_aSelected from the following elements: lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), barium (Ba), titanium (Ti), aluminum (Al), and combinations thereof.

In one variation, the protective surface coating comprises a composition consisting of P_xO_yF_zA compound of formula (la) wherein 0 when P in the formula is normalized to 1 such that x equals about 1(x =1)< y ≤ 4，0 <z is less than or equal to 6. It should be noted that no metal M is present in the compound_aThus a = 0 in the above equation. In certain variants, comprising P_xO_yF_zThe protective top coat of the compounds represented comprises fluorine (F) in an amount of greater than or equal to about 19 wt% to less than or equal to about 67 wt%. In a variant, the protective coating may also comprise titanium Tetrafluoride (TiF)₄)。

In another variation, the protective surface coating comprises a polymeric material consisting of M_aP_xO_yF_zA compound of formula (la) wherein when P in the formula is normalized to 1 such that x equals about 1(x =1), 0 is present therein< y ≤ 4，0 < z ≤ 6，0 < a ≤ 3。M_aSelected from the following elements: lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), barium (Ba), titanium (Ti), aluminum (Al), and combinations thereof. Such compounds are salts of fluorophosphoric acid. In certain variants, comprising a structural formula consisting of M_aP_xO_yF_zThe protective surface coating of the compounds represented comprises fluorine (F) in an amount of greater than or equal to about 6 wt% to less than or equal to about 59 wt%. In a variant, such a protective coating may also comprise titanium Tetrafluoride (TiF)₄)。

In certain aspects, the protective surface coating comprises a composition consisting of P_xO_yF_zA first compound represented by M_aP_xO_yF_zThe second compound, or combination of the first compound and the second compound, is expressed such that when P is normalized to 1 such that x equals about 1(x =1), then 0 ≦ a ≦ 3,0< y ≤ 4，0 <z is less than or equal to 6, and M_aSelected from the following elements: lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), barium (Ba), titanium (Ti), aluminum (Al), and combinations thereof.

In another variant, the protective surface coating comprises a polymer consisting of B_xO_yF_zA compound of formula (la) wherein when B is normalized to 1 and x equals about 1(x =1), 0 is present therein<y is less than or equal to 4 and 0<z is less than or equal to 4. The compound may further comprise M selected from the group consisting of_a: lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), barium (Ba), titanium (Ti), aluminum (Al), and combinations thereof. In such a variation, the protective coating may further comprise titanium Tetrafluoride (TiF)₄)。

It should be noted that oxides, such as silicon oxides, coated on the surface of LTO particles are also reactive with certain species and form P_xO_yF_zWithout consuming the LTO and thus, when present, may contribute to the reaction and formation of the protective coating.

In various aspects, the protective surface coating is a thin layer applied to one or more pre-selected surface areas of an electroactive material comprising lithium titanate that provides sufficient coverage of the exposed surface areas of the LTO to minimize adsorption and/or reaction of solvents and other hydrogen source species in the battery cell while minimizing electrical impedance at the surface of the electroactive material. The protective surface coating can cover greater than or equal to about 70%, optionally greater than or equal to about 75%, optionally greater than or equal to about 80%, optionally greater than or equal to about 85%, optionally greater than or equal to about 90%, optionally greater than or equal to about 95%, optionally greater than or equal to about 97%, optionally greater than or equal to about 98%, optionally greater than or equal to about 99%, and in certain variations, optionally greater than or equal to about 99.5% of the exposed surface area of the electroactive material.

The thickness of the top coat may be considered to be the surface area of the LTO that has reacted with the precursor of the top coat to form a different chemical composition. In certain variations, the total thickness of the surface coating (including the multiple layers) on the electroactive material is greater than or equal to about 1 nm to less than or equal to about 1 micrometer (μm), optionally greater than or equal to about 3 nm to less than or equal to about 75 micrometers (μm), and in certain aspects, optionally greater than or equal to about 5 nm to less than or equal to about 50 micrometers (μm).

In certain aspects, the lithium fluoride salt is present in the pretreatment composition at greater than or equal to about 0.1 wt.% to less than or equal to about 15 wt.%, optionally at greater than or equal to about 0.1 wt.% to less than or equal to about 10 wt.%. The solvent may be present in the pretreatment composition in an amount of greater than or equal to about 85 wt% to less than or equal to about 99.9 wt%, optionally in an amount of greater than or equal to about 90 wt% to less than or equal to about 99.9 wt%. In certain aspects, the pretreatment is performed in the absence of any applied potential (e.g., an externally applied voltage or an externally applied current) to form the protective surface coating.

In one variation shown in fig. 2, the process is carried out as a batch process 50. The electroactive material comprising LTO is in the form of particles 60. The pretreatment method may include introducing the particles 60 into a pretreatment liquid 62. The pretreatment liquid 62 and the particles 60 may be mixed in a vessel 64 and heat may be applied to promote a reaction between the reactive compounds in the pretreatment liquid 62 and the LTO in the particles 60. The reaction may be carried out at a predetermined temperature for a predetermined time. The predetermined reaction time depends on the reaction rate, the concentration of reactive precursors, and the temperature, but may vary from greater than or equal to about 30 minutes to less than or equal to about 72 hours, for example. Suitable temperatures for the pretreatment process can be greater than or equal to about 50 ℃. In certain variations, the temperature may be greater than or equal to about 50 ℃ to less than or equal to about 700 ℃, optionally greater than or equal to about 100 ℃ to less than or equal to about 600 ℃.

It should be noted that in contrast to the aging process performed for LTO active materials fully assembled in an electrochemical cell (e.g., having two electrodes, a separator, and an electrolyte), the present method pretreats the electroactive material outside the electrochemical cell to form a coating. Thus, because there are no temperature sensitive components such as polymeric spacers and polymeric binders, the temperatures that can be used in the pretreatment methods according to the present disclosure can be much higher. Furthermore, the pretreatment process does not reduce the amount of lithium from the electrolyte, which would otherwise occur during the aging process. Thus, the method of the present disclosure does not consume active lithium in the battery and thus does not sacrifice initial capacity.

After forming the protective coating on the exposed surfaces of the particles 60, the particles 60 may be separated from the pretreatment liquid 62 by a separation method, such as filtration using a filter 66. A plurality of coated electroactive material particles 68 are collected. An optional washing step may be performed to remove residual solvent on the surface of the active material, if desired. The pretreatment process can be repeated to build additional or thicker layers on the electroactive material particles, if desired. Various reactor vessels and separation devices known in the art may be used, including free-standing devices, beds, packed beds, screens, dryers, and the like. It should be noted that the exemplary method of fig. 2 is merely a simplified representation and may include various other configurations and components, such as valves, meters, pumps, heat sources, and other devices not shown. The plurality of coated electroactive material particles 68 can then be used in a subsequent electrode formation process.

An electrode may then be fabricated by mixing the electrode active material (e.g., coated LTO powder or particles) into a slurry with a polymeric binder compound, a non-aqueous solvent, an optional plasticizer, and optional conductive particles. The negative electrode may include about 50% to about 90% electroactive material (e.g., LTO particles), about 5% to about 30% conductive material, and the balance binder. Suitable conductive materials include carbon black, graphite, powdered nickel, metal particles, conductive polymers, and combinations and mixtures thereof. Useful binders may include polymeric materials and extractable plasticizers suitable for forming bonded porous composites, such as halogenated hydrocarbon polymers (e.g., poly (vinylidene chloride) and poly ((dichloro-1, 4-phenylene) ethylene), fluorinated polyurethanes, fluorinated epoxides, fluorinated acrylic resins, copolymers of halogenated hydrocarbon polymers, epoxides, ethylene propylene diamine terpolymer (EPDM), polyvinylidene fluoride (PVDF), Hexafluoropropylene (HFP), ethylene acrylic acid copolymer (EAA), ethylene vinyl acetate copolymer (EVA), EAA/EVA copolymer, PVDF/HFP copolymer, and mixtures thereof.

The slurry may be mixed or stirred and then thinly applied to a substrate with the aid of a doctor blade. The substrate may be a removable substrate or alternatively a functional substrate, such as a current collector (e.g., a metal grid or mesh layer) attached to one side of the electrode film. In one variation, heat or radiation may be applied to evaporate the solvent from the electrode film, leaving a solid residue. The electrode film may further be consolidated, wherein heat and pressure are applied to the film to sinter and calendar it. In other variations, the film may be air dried at moderate temperatures to form a self-supporting film. If the substrate is removable, the substrate is then removed from the electrode film, which is then further laminated to a current collector. For either type of substrate, the remaining plasticizer may have to be extracted or removed prior to incorporation into the battery cell.

In another variation shown in fig. 3, the process is carried out as a continuous flow process 70. It should be noted that the exemplary method of fig. 3 is merely a simplified representation and may include various other components, such as valves, meters, pumps, heat sources, and other devices not shown. For the sake of brevity, aspects of the continuous flow process 70 that are identical to the batch process 50 will not be repeated here. The electroactive material comprising LTO is in the form of particles 72. The pretreatment method may include introducing the particles 72 into a pretreatment liquid 74. The pretreatment liquid 74 and particles 72 may be mixed in a vessel 76, such as a continuous flow reactor. The vessel 76 includes at least one inlet 78 for introducing the pretreatment liquid 74 and/or the particles 72. Although not shown, in an alternative design, two different inlets may separately introduce the particles 72 and the pretreatment liquid 74.

The vessel 76 may be continuously stirred or agitated and may have a heat source applied to promote reaction between the reactive compounds in the pretreatment liquid 74 and the LTO in the particles 72. The dimensions and flow rates within the vessel 76 thus provide the particles within the reactor with a suitable residence time to react and form a plurality of coated particles 80. The residence time (. tau.) can be determined by the mass of particles in the reactor(s) ((r))m) Divided by the flow rate in the reactor (q) To determine. The residence time of the reaction depends on the reaction rate, the concentration of reactive precursors, and the temperature, but can vary from greater than or equal to about 10 minutes to less than or equal to about 72 hours, for example.

Suitable temperatures for the pretreatment process can be similar to those described in the case of a batch process, e.g., greater than or equal to about 50 ℃. In certain variations, the temperature may be greater than or equal to about 50 ℃ to less than or equal to about 700 ℃, optionally greater than or equal to about 100 ℃ to less than or equal to about 600 ℃.

After the protective coating is formed on the exposed surfaces of the particles 72, the coated particles 80 may be separated from the pretreatment liquid 74 by a separation method (e.g., filtration) to collect the particles in a reservoir 82. The coated particles 80 are separated from the liquid effluent exiting the vessel 76 via at least one outlet 84. One or more filters may be placed along the solvent flow path in the flow reactor vessel 76 to collect the coated particles 80 after reaction. Although not shown, in an alternative design, two different outlets may be employed to remove and separate the coated particles 80 from the pretreatment liquid 74. A plurality of coated electroactive material particles 80 are collected. An optional washing step may be performed to remove residual solvent on the surface of the active material, if desired. The plurality of coated electroactive material particles 80 may then be used in a subsequent electrode formation process.

In another variation shown in fig. 4, a method 90 pretreats an electroactive material in the form of a plurality of LTO particles 92 contained in a prefabricated electrode layer 94. For simplicity, the aspects of the method 90 that are common to the continuous flow method 70 of FIG. 3 and the batch method 50 of FIG. 2 will not be repeated here. The preformed electrode layer 94 may be formed as described above with the components described above, including electroactive material particles, a polymeric binder compound, and optionally conductive particles. A prefabricated electrode layer 94 is provided on the current collector 96. The preformed electrode layer 94 also contains a plurality of conductive particles 98, such as carbon black particles. The conductive particles 98 and LTO particles 92 may be distributed in a polymer binder 100.

The pretreatment method may include contacting the pre-formed electrode layer 94 containing LTO particles 92 with a pretreatment liquid 102. The pre-treatment liquid 102 may be poured over the pre-formed electrode layer 94. Thus, the pretreatment liquid composition 102 is applied to at least one exposed surface of the electroactive LTO particles 92 in the pre-formed electrode layer 94. Heat may be applied to promote a reaction between the reactive compounds in the pretreatment liquid 102 and the LTO particles 92. The reaction may be carried out at a predetermined temperature for a predetermined time, such as those discussed above in the context of fig. 2. A protective coating is thus formed on the surface of the pre-treated electrode and on any exposed surfaces of the LTO particles 92 within the pre-formed electrode layer 94.

When the electroactive material is contained in the pre-formed electrode layer, the pre-treatment may further comprise applying a pre-treatment composition to the exposed surface of the electroactive material in the pre-formed electrode layer by: roll coating, dip coating, spraying, physical vapor deposition, sputter deposition, roll-to-roll coating, chemical vapor deposition, atomic layer deposition, plasma deposition, slurry coating by a conventional slot die or comma bar coater, and the like.

Li pretreated in accordance with the present disclosure_(4+x)Ti₅O₁₂Exemplary particles in which 0 ≦ x ≦ 3(LTO) are shown in FIG. 5 as LTO particles 150. Each LTO particle 152 is shown with a coating having a particular configuration and orientation that is believed to form, although the configuration is non-limiting and may be different than shown. A first coating 160 is disposed on exposed surfaces 162 of the LTO particles 152. The first coating 160 may also comprise titanium and fluorine. In one aspect, the first coating 160 may comprise titanium Tetrafluoride (TiF)₄). The second coating 166 is disposed over the first coating 160. The second coating 166 has a different composition than the first coating 160. The second coating 166 may include fluorine, oxygen, and at least one element selected from the group consisting of: phosphorus, boron, and combinations thereof. In one variation, the protective second coating 166 comprises a coating consisting of M_aP_xO_yF_zWherein 0. ltoreq. a.ltoreq.3, 0, when P in the formula is normalized so that x is equal to about 1<y≤4，0<z is less than or equal to 6. In another variation, the second coating 166 comprises a second coating composed of B_xO_yF_zA compound of formula (I) wherein when B is normalized to 1 and x equals about 1,0<y is less than or equal to 4 and 0<z is less than or equal to 4. The second coating 166 can also include P_xO_yF_zAnd B_xO_yF_zCombinations of (a) and (b). In certain aspects, titanium and fluorine (e.g., TiF) are included₄) Is believed to protect the electroactive material comprising LTO against attack by Hydrogen Fluoride (HF). Containing fluorine, oxygen, phosphorus and/or boron (e.g. P)_xO_yF_zAnd/or M_aP_xO_yF_z) The second coating 166 is believed to stabilize the LTO material surface to reduce electrolyte decomposition (when the coated electroactive material is incorporated into an electrochemical cell and placed in contact with the dielectric) and thus reduce gas generation. In this manner, the present disclosure providesThe provided protective coating system protects underlying LTO active materials from HF and PF₅Erosion of (2). The suppression of gas generation by LTO may further improve the safety and life of the lithium ion battery.

In other variations, the present disclosure provides yet another method of making an electroactive material for an electrochemical cell. The method may include pre-treating the Li-containing alloy with a pre-treatment comprising Li_(4+x)Ti₅O₁₂(LTO) wherein x is 0. ltoreq. x.ltoreq.3. The pretreatment includes contacting a surface of the electroactive material with one or more organophosphorus compounds to form a protective surface coating on the surface of the electroactive material. The organophosphorus compound may be represented by M_aP_xO_yF_zC_nH_mRepresentation, where P is normalized such that x is equal to about 1(x =1) and the following also applies: 0< a ≤ 3，0 < y ≤ 4，0 < z ≤ 6，0 <n is not less than 20, M is not less than 0 and not more than 42, and M_aSelected from the following elements: lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), barium (Ba), titanium (Ti), aluminum (Al), and combinations thereof.

In one variant, the organophosphorus compound consists of P_x'O_yF_zC_nH_mWherein 0 is when P in the formula is normalized to 1 such that x 'is equal to about 1(x' =1)< y ≤ 4，0< z ≤ 6，0<n is less than or equal to 20 and m is less than or equal to 42 and more than or equal to 0. It should be noted that no metal M is present in this compound_aTherefore, a = 0 in the immediately above equation. In certain variations, from P_xO_yF_zC_nH_mThe organophosphorus compounds represented by (i) contain fluorine (F) in an amount of greater than or equal to about 4 wt% to less than or equal to about 50 wt%.

In certain aspects, the organophosphorus compound is selected from: perfluorinated phosphonic acids, methallyl phosphates, alkyl fluorophosphates, phosphorylated poly (methyl methacrylate) (PMMA), phosphonated polyimides, (aminomethyl) phosphonic acids, lithium metaphosphate, adenosine diphosphate, phospholipids, and combinations thereof.

In certain aspects, the method can include surface-contacting the electroactive material with a pretreatment compositionThe contact pretreatment contains Li_(4+x)Ti₅O₁₂(LTO) wherein x is 0. ltoreq. x.ltoreq.3 to form a protective surface coating on the surface of the electroactive material. The pretreatment composition may comprise the organophosphorus compound. The pretreatment composition may optionally further comprise a solvent. In certain variations, the solvent is a non-aqueous solvent. The solvent may include a carbonate-based electrolyte solvent, such as an alkyl carbonate, for example, cyclic carbonates (ethylene carbonate (EC), Propylene Carbonate (PC), Butylene Carbonate (BC)) and/or acyclic carbonates (dimethyl carbonate (DMC), diethyl carbonate (DEC), Ethyl Methyl Carbonate (EMC)). When an organophosphate is used, the solvent may also comprise a non-carbonate based solvent or an aqueous solution.

In certain aspects, the organophosphorus compound is present in the pretreatment composition in an amount of greater than or equal to about 0.1 wt% to less than or equal to about 15 wt%, optionally in an amount of greater than or equal to about 0.1 wt% to less than or equal to about 10 wt%. The solvent may be present in the pretreatment composition in an amount of greater than or equal to about 85 wt% to less than or equal to about 99.9 wt%, optionally in an amount of greater than or equal to about 90 wt% to less than or equal to about 99.9 wt%.

In certain aspects, the pretreatment is performed in the absence of any applied potential (e.g., an externally applied voltage or externally applied current) to form the protective surface coating on the surface of the electroactive material. The protective surface coating can cover the same amount of exposed surface area and have the same thickness and other properties as the previously described embodiments.

The protective surface coating thus formed comprises fluorine, oxygen, phosphorus, carbon and hydrogen. The protective surface coating may thus comprise a coating consisting of M_aP_xO_yF_zC_nH_mThe organophosphorus compounds represented, wherein P is normalized such that x is equal to about 1(x =1) and the following also apply: a is more than or equal to 0 and less than or equal to 3 and 0< y ≤ 4，0 <z is less than or equal to 6, n is more than or equal to 0 and less than or equal to 20, M is more than or equal to 0 and less than or equal to 42, and M_aSelected from the following elements: lithium (Li), sodium (Na), potassium (K)Magnesium (Mg), calcium (Ca), barium (Ba), titanium (Ti), aluminum (Al) and combinations thereof.

In one variation, the protective surface coating comprises a composition consisting of P_xO_yF_zC_nH_mA compound of formula (la) wherein 0 when P in the formula is normalized to 1 such that x equals about 1(x =1)< y ≤ 4，0 <z is less than or equal to 6, n is more than or equal to 0 and less than or equal to 20, and m is more than or equal to 0 and less than or equal to 42. It should be noted that no metal M is present in this compound_aTherefore, a = 0 in the immediately above equation. In certain variations, from P_xO_yF_zC_nH_mThe organophosphorus compounds represented by (i) contain fluorine (F) in an amount of greater than or equal to about 4 wt% to less than or equal to about 50 wt%.

In certain variations, the electroactive material: (i) in the form of a plurality of LTO particles and the pre-treatment comprises mixing the plurality of LTO particles with a pre-treatment composition, wherein the plurality of LTO particles is used to form a negative electrode after a protective coating is formed on the surface; or (ii) contained in a pre-fabricated electrode layer and the pre-treatment comprises applying a pre-treatment composition onto at least one exposed surface of the pre-fabricated electrode layer. The pretreatment may be carried out by any of the methods previously described above, wherein a pretreatment composition comprising an organophosphorus is used. When the electroactive material is in particle or powder form, the pretreatment may further comprise applying the organophosphorus compound by: dip coating, physical vapor deposition, sputter deposition, sputtering, chemical and electrochemical techniques, chemical vapor deposition, atomic layer deposition, and plasma deposition.

When the electroactive material is contained in the pre-formed electrode layer, the pre-treatment may further comprise applying an organophosphorus compound to the exposed surface of the electroactive material in the pre-formed electrode layer by: roll coating, dip coating, spraying, physical vapor deposition, sputter deposition, roll-to-roll coating, chemical vapor deposition, atomic layer deposition, plasma deposition, slurry coating by a conventional slot die or comma bar coater, and the like.

The present disclosure provides compositions comprising Li_(4+x)Ti₅O₁₂Wherein 0 ≦ x ≦ 3(LTO) for electroactive materials for electrochemical cells. Thus, in certain variations, the electroactive material has a protective surface coating formed thereon, which coating may comprise a coating consisting of M_aP_xO_yF_zC_nH_mAnd/or M_aP_xO_yF_zThe compound of (a) wherein when P is normalized to 1 such that x equals about 1(x =1), the following also applies: a is more than or equal to 0 and less than or equal to 3 and 0< y ≤ 4，0 < z ≤ 6，0 < n ≤ 20，0 <M is less than or equal to 42, and M_aSelected from the following elements: lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), barium (Ba), titanium (Ti), aluminum (Al), and combinations thereof.

The protective surface coating may be applied to any surface of the LTO that may be exposed to the electrolyte or solvent within the electrochemical cell to minimize reaction and/or adsorption of undesirable species. The protective surface coating can cover greater than or equal to about 70% of the exposed surface area of the electroactive material. M as described above_aP_xO_yF_zC_nH_mAnd/or M_aP_xO_yF_zThe compounds stabilize the exposed surface of the LTO-containing electroactive material and thus serve to reduce electrolyte decomposition and gas generation. This is used to improve safety and battery life when LTO is used as the negative electrode active material. This is particularly advantageous for improving the service life of a start-stop lithium ion battery.

The battery may have a laminated cell structure comprising an anode layer, a cathode layer, and an electrolyte/separator between the anode layer and the cathode layer. The anode and cathode layers each comprise a current collector. The negative anode current collector may be a copper current collector foil, which may be in the form of an open-cell grid or a thin film. The current collectors may be connected to external current collector tabs (tab).

The present disclosure contemplates a lithium-ion electrochemical cell or battery comprising an electroactive material having a protective surface coating formed thereon, which may comprise a coating of M_aP_xO_yF_zC_nH_mCompound and/or M_aP_xO_yF_zThe compound represented by the formula (I) is as described above. The electrochemical cell also has a positive electrode, a separator, and a lithium hexafluorophosphate (LiPF) containing electrolyte₆) Lithium tetrafluoroborate (LiBF)₄) And combinations thereof. In certain aspects, any electroactive material comprising LTO that is exposed to an electrolyte in an electrochemical cell has a protective surface coating formed thereon.

For example, in certain variations, an electrode film (e.g., an anode film) comprises an electrode active material (e.g., LTO) dispersed in a polymer binder matrix over a current collector. A separator may then be disposed over the negative electrode element, the separator covered with a positive electrode film comprising a composition of finely divided lithium insertion compound in a polymer binder matrix. The positive current collector (e.g., aluminum current collector foil or grid) is assembled. The tabs of the current collector elements form the respective terminals of the battery. The protective bagging material covers the battery and prevents air and moisture infiltration. Into such a pouch, electrolyte is injected into the separator (and may also be absorbed into the positive and/or negative electrodes) suitable for lithium ion transport. In certain aspects, the laminated battery is further hermetically sealed prior to use.

In this manner, the protective surface coating is capable of suppressing greater than or equal to about 50% of gases that would be generated by a comparative electroactive material that includes the same LTO as the LTO on which the protective surface coating is formed but without the protective surface coating. In certain aspects, the topcoat inhibits greater than or equal to about 60%, optionally 65%, optionally 70%, optionally 75%, optionally 80%, optionally 85%, optionally 90%, optionally 95%, optionally 97%, optionally 98%, optionally 99%, optionally 99.5%, optionally 99.7%, optionally 99.8%, optionally 99.9%, and in certain aspects 99.99% of the gas that would be generated by a comparative exposed LTO material that does not have the protective topcoat of the invention but has the same composition and properties.

In certain aspects, it is preferred that electroactive materials, such as comprising LTO, having a protective surface coating for inhibiting gas formation in an electrochemical cell (e.g., a lithium ion battery) produce no or only minimal amounts of gaseous compounds during the life of the battery. For example, in certain aspects, an electrochemical cell or lithium ion battery comprising an electroactive material having a surface coating according to certain variations of the present disclosure is substantially free of gaseous compounds throughout the life of the electrochemical cell or battery. By "substantially free" is meant that the compound is not present to the extent that it cannot be detected, or if present, does not cause undue adverse effects and/or prevents the battery from being used as a whole for its intended purpose. In some aspects, it is preferred that the concentration of gaseous compounds generated in the electrochemical cell when the electrochemical cell or battery is stored over time (over time) is less than about 1,000 parts per million (ppm), optionally less than about 500ppm, optionally less than about 100 ppm, optionally less than about 75 ppm, and in some preferred aspects optionally less than about 50 ppm. In some aspects, it is preferred that, for example, after storage for 100 hours or more, when the gas volume is evaluated under standard temperature and pressure (298K, 1 atm) conditions, the generated gas corresponds to less than or equal to about 0.1% of the sealed cell volume; optionally less than or equal to about 0.05% of the sealed cell volume; and in certain aspects optionally less than or equal to about 0.01% of the volume of the sealed cell under standard temperature and pressure conditions.

In certain aspects, a lithium-ion electrochemical cell incorporating a pretreated electroactive material of the invention having a protective surface coating for inhibiting gas formation, wherein the lithium-ion electrochemical cell is substantially free of gas generation for the standard life of the electrochemical cell, has a rate capacity of greater than or equal to about 0.05C (C/20) and greater than or equal to about 20 coulombs.

In one aspect, the lithium-ion electrochemical cell has an initial charge capacity greater than or equal to about 0.117A · h.

In certain variations, lithium ion batteries incorporating a pretreated electroactive material with a protective surface coating for inhibiting gas formation made according to certain aspects of the present disclosure are substantially free of gaseous species for battery operation for at least 500 hours, optionally greater than or equal to about 1,000 hours, optionally greater than or equal to about 1,500 hours, and in certain aspects greater than or equal to about 2,000 hours or longer. In certain variations, a lithium ion battery incorporating a pretreated electroactive material with a protective surface coating for inhibiting gas formation made according to certain aspects of the present disclosure is substantially free of generated gaseous species for a period of greater than or equal to about 2 years (including storage and active cycle times at ambient conditions), optionally greater than or equal to about 3 years, optionally greater than or equal to about 4 years, optionally greater than or equal to about 5 years, optionally greater than or equal to about 6 years, optionally greater than or equal to about 7 years, optionally greater than or equal to about 8 years, optionally greater than or equal to about 9 years, and in certain aspects optionally greater than or equal to about 10 years.

In other words, in certain aspects, a lithium ion battery or electrochemical cell incorporating a pretreated electroactive material with a protective surface coating for inhibiting gas formation made according to certain aspects of the present disclosure will be substantially free of gaseous species for at least 1,000 deep discharge cycles, optionally greater than or equal to about 2,000 deep discharge cycles, optionally greater than or equal to about 3,000 deep discharge cycles, optionally greater than or equal to about 4,000 deep discharge cycles, and in certain variations, optionally greater than or equal to about 5,000 deep discharge cycles.

Methods according to certain aspects of the present disclosure form a protective coating on the LTO material or LTO electrode that improves battery life and reduces gassing (gassing). The protective coating reduces electrolyte decomposition and gas formation during operation of the LTO battery. In addition, the protective coating increases battery capacity by reducing the loss of recyclable lithium that occurs during battery formation. Passivated LTO with surface protection may thus be used to increase battery capacity and improve battery life, thereby reducing weight and/or increasing vehicle mileage.

The foregoing description of the embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not explicitly shown or described. It can also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.