Scalable Synthesis of Single Crystal Ni-Rich Cathodes for Advanced Lithium-Ion Batteries

Abstract

Long-range electrical vehicles require high energy density lithium-ion batteries that utilize stable, high-energy cathode materials. Among various cathodes, Ni-rich NMC cathodes with a layered structure, knows for their high capacity, high voltage, and cost-effectiveness, stand out as one of the most promising cathodes. Traditional polycrystalline Ni-rich NMC encounter issues such as pulverization, gas generation and moisture sensitivity, limiting their widespread use in EV batteries on large scale. The single crystal format of Ni-rich cathode can effectively eliminate and mitigate these issues. However, synthesizing of high-performance single crystal Ni rich NMC, especially when Ni ≥0.8, presents a significant challenge.We’ve explored an innovative phase separation approach for direct synthesis of high-performance single crystal NMC811. The comprehensive investigation into the reaction mechanism of single crystal growth was conducted to understand the relationship between synthesis, morphology, and performance in growing single crystal NMC811. The enhanced performance of these materials was realized through the precise morphological and structural control of precursors and has been confirmed in practical 2Ah pouch cells. The developed approach is readily adaptable to current industry manufacturing processes and provides valuable new insights that can be broadly applied to cost-efficient large-scale synthesis of single crystals and various advanced battery materials technologies.