A New Insight into the Capacity Decay Mechanism of Ni-Rich Layered Oxide Cathode for Lithium-Ion Batteries

In Situ Constructing Ultrastable Mechanical Integrity of Single-Crystalline LiNi0.9 Co0.05 Mn0.05 O2 Cathode by Interior and Exterior Decoration Strategy

Planar gliding along with anisotropic lattice strain of single-crystalline nickel-rich cathodes (SCNRC) at highly delithiated states will induce severe delamination cracking that seriously deteriorates LIBs' cyclability. To address these issues, a novel lattice-matched MgTiO3 (MTO) layer, which exhibits same lattice structure as Ni-rich cathodes, is rationally constructed on single-crystalline LiNi0.9 Co0.05 Mn0.05 O2 (SC90) for ultrastable mechanical integrity. Intensive in/ex situ characterizations combined with theoretical calculations and finite element analysis suggest that the uniform MTO coating layer prevents direct contact between SC90 and organic electrolytes and enables rapid Li-ion diffusion with depressed Li-deficiency, thereby stabilizing the interfacial structure and accommodating the mechanical stress of SC90. More importantly, a superstructure is simultaneously formed in SC90, which can effectively alleviate the anisotropic lattice changes and decrease cation mobility during successive high-voltage de/intercalation processes. Therefore, the as-acquired MTO-modified SC90 cathode displays desirable capacity retention and high-voltage stability. When paired with commercial graphite anodes, the pouch-type cells with the MTO-modified SC90 can deliver a high capacity of 175.2 mAh g-1 with 89.8% capacity retention after 500 cycles. This lattice-matching coating strategy demonstrate a highly effective pathway to maintain the structural and interfacial stability in electrode materials, which can be a pioneering breakthrough in commercialization of Ni-rich cathodes.

Direct Regenerating Cathode Materials from Spent Lithium-Ion Batteries

Recycling cathode materials from spent lithium-ion batteries (LIBs) is critical to a sustainable society as it will relief valuable but scarce recourse crises and reduce environment burdens simultaneously. Different from conventional hydrometallurgical and pyrometallurgical recycling methods, direct regeneration relies on non-destructive cathode-to-cathode mode, and therefore, more time and energy-saving along with an increased economic return and reduced CO2 footprint. This review retrospects the history of direct regeneration and discusses state-of-the-art development. The reported methods, including high-temperature solid-state, hydrothermal/ionothermal, molten salt thermochemistry, and electrochemical method, are comparatively introduced, targeting at illustrating their underlying regeneration mechanism and applicability. Further, representative repairing and upcycling studies on wide-applied cathodes, including LiCoO2 (LCO), ternary oxides, LiFePO4 (LFP), and LiMn2 O4 (LMO), are presented, with an emphasis on milestone cases. Despite these achievements, there remain several critical issues that shall be addressed before the commercialization of the mentioned direct regeneration methods.

Building Negative-Thermal-Expansion Protective Layers on the Grain Boundary of Ni-rich Cathodes Enables Safe and Durable High Voltage Lithium-Ion Batteries

Ni-rich layered oxide cathode materials demonstrate high energy densities for Li-ion batteries, but the electrochemically driven thermal runaway and mechanical degradation remain their long-standing challenges in practical applications. Herein, it presents a novel ZrV2 O7  (ZVO) coating with negative thermal expansion properties along the secondary particles and primary particle grain boundaries (GBs), to simultaneously enhance the structural and thermal stability of LiNi0.8 Co0.1 Mn0.1 O2 (NCM811). It unveils that, such an architecture can significantly enhance the electronic conductivity, suppress the microcracks of GBs, alleviate the layered to spinel/rock-salt phase transformation, and meanwhile relieve the lattice oxygen loss by increasing the oxygen vacancy formation energy increased (1.43 vs 1.90 eV). Consequently, the ZVO-coated NCM811 material demonstrates a remarkable cyclability with 86.5% capacity retention after 100 cycles, and an outstanding rate performance of 30 C under a high-voltage of 4.6 V, outperforming the state-of-the-art literature. More importantly, the Li+ transportation can be readily blocked at 120 °C by the negative-thermal-expansion ZVO coating, thus avoiding the high-temperature thermal runaway.

How sintering temperature affects the electrochemical performance of ultra-high nickel (Ni > 0.9) cathode material

The burgeoning demand for electric vehicles with extended driving ranges has propelled ongoing development efforts for ultra-high nickel (Ni > 0.9) cathode materials. Despite significant ongoing research focused on Ni-rich cathode materials, a more comprehensive foundational understanding of ultra-high nickel cathode materials is essential. In our research, we employed LiNi0.94Co0.06O2 as a model ultra-high nickel cathode material to systematically delve into the interplay between sintering temperature, structural features, and electrochemical behavior. Within a sintering temperature spectrum of 660-720 °C, we discerned that specimens produced at diminished temperatures manifest a reduced initial discharge capacity yet excel in cycling endurance. In stark contrast, their counterparts produced at augmented temperatures behave inversely. Identifying a singular sintering temperature that achieves equilibrium between initial discharge capacity and cycling performance proves elusive. Through X-ray diffraction and high-resolution transmission electron microscopy, it became evident that samples synthesized at lower temperatures exhibit pronounced lithium-nickel mixing and develop a thicker NiO layer on the surface, leading to compromised initial discharge performance and capacity. Utilizing focused ion beam scanning electron microscopy, differential capacity analysis, and in-situ X-ray diffraction, we confirm that samples synthesized at lower temperatures possess smaller particle sizes, enabling them to withstand volumetric expansion stress during cycling, resulting in enhanced cycling performance. In the realm of ultra-high nickel cathode materials, elevating the sintering temperature is a conduit to superior initial discharge efficiency and capacity. Yet, the imperative of preserving diminutive particle dimensions, as a stratagem to bolster cycling performance, stands out as a pivotal research frontier.

Electrochemical Aging Protocol Governed Capacity Losses and Structure Degradations in Layered LiNi0.8 Co0.1 Mn0.1 O2 Oxides

The comparatively poor endurance of Ni-rich cathode materials restricts their application in high-energy lithium-ion batteries. A thorough understanding of the degradation characteristics of such materials under complex electrochemical aging protocols is required to further improve their reliability. In this work, the irreversible capacity losses of LiNi0.8 Mn0.1 Co0.1 O2 under different electrochemical aging protocols are quantitatively evaluated via a well-designed experiment. In addition, it is discovered that the origin of irreversible capacity losses is highly related to electrochemical cycling parameters and can be divided into two types. Type I is heterogeneous degradation caused by low C-rate or high upper cut-off voltage cycling and features abundant capacity loss during H2-H3 phase transition. Such capacity loss is attributed to the irreversible surface phase transition that limits the accessible state of charge during the H2-H3 phase transition stage via the pinning effect. Type II is fast charging/discharging induced homogeneous capacity loss that occurs consistently throughout the whole phase transition time. This degradation pathway shows a distinctive surface crystal structure, which is dominated by a bending layered structure rather than a typical rock-salt phase structure. This work offers detailed insight into the failure mechanism of Ni-rich cathodes and provides guidance on designing long-cycle life, high-reliability electrode materials.

Surface-Stabilized High-Entropy Layered Oxyfluoride Cathode for Lithium-Ion Batteries

High-entropy materials have been demonstrated to improve the structural stability and electrochemical performance of layered cathode materials for lithium-ion batteries (LIBs). However, structural stability at the surface and electrochemical performance of these materials are less than ideal. In this study, we show that fluorine substitution can improve both issues. Here, we report a new high-entropy layered cathode material Li_1.2Ni_0.15Co_0.15Al_0.1Fe_0.15Mn_0.25O_1.7F_0.3 (HEOF1) based on the partial substitution of oxygen with fluorine in previously reported high-entropy layered oxide LiNi_0.2Co_0.2Al_0.2Fe_0.2Mn_0.2O₂. This new compound delivers a discharge capacity of 85.4 mAh g^-1 and a capacity retention of 71.5% after 100 cycles, showing significant improvement from LiNi_0.2Co_0.2Al_0.2Fe_0.2Mn_0.2O₂ (first 57 mAh g^-1 and 9.8% after 50 cycles). This improved electrochemical performance is due to suppression of the surface M₃O₄ phase formation. Although still an early stage study, our results show an approach to stabilize the surface structure and improve the electrochemical performance of high-entropy layered cathode materials.

Construction of Planar Gliding Restriction Buffer and Kinetic Self-Accelerator Stabilizing Single-Crystalline LiNi0.9Co0.05Mn0.05O2 Cathode

The single-crystalline Ni-rich cathode has aroused much attention for extenuating the cycling and safety crises in comparison to the polycrystalline cathode. However, planar gliding and kinetic hindrance hinder its chemo-mechanical properties with cycling, which induce delamination cracking and damage the mechanical integrity in single crystals. Herein, a robust Li_2.64(Sc_0.9Ti_0.1)₂(PO₄)₃ (LSTP) ion/electron conductive network was constructed to decorate single-crystal LiNi_0.9Co_0.05Mn_0.05O₂ (SC90) particles. Via physicochemical characterizations and theoretical calculations, this LSTP coating that evenly grows on the SC90 particle with good lattice matching and strong bonding effectively restricts the anisotropic lattice collapse along the c-axis and the cation mixing activity of SC90, thus suppressing planar gliding and delamination cracking during repeated high-voltage lithiation/delithiation processes. Moreover, such a 3D LSTP network can also facilitate the lithium-ion transport and prevent the electrolyte's corrosion, lightening the kinetic hindrance and triggering the surface phase transformation. Combined with the Li metal anode, the LSTP-modified SC90 cell exhibits a desirable capacity retention of 90.5% at 5 C after 300 cycles and stabilizes the operation at 4.3/4.5 V. Our results provide surface modification engineering to mitigate planar gliding and kinetic hindrance of the single-crystalline ultra-high Ni-rich cathode, which inspires peers to design other layered cathode materials.