Method for synthesis of carbon-coated redox materials with controlled size
First Claim
1. A method for the synthesis of compounds of formula C—
- LixM1−
yM′
y(XO4)n, wherein C represents carbon cross-linked with the compound LixM1−
yM′
y(XO4)n in which x, y and n are numbers such as 0≦
x≦
2.0≦
y ≦
0.6, and 1≦
n≦
1.5, M is a transition metal or a mixture of transition metals from the first line of the periodic table, M′
is an element with fixed valency selected among Mg2+, Ca2+, Al3+, Zn2+ or a combination of these same elements and X is chosen from among S, P and Si, by bringing into equilibrium, in the required proportions, a mixture (preferably intimate and/or homogeneous) comprising at least;
a) a source of M, at least one part of the said transition metal or metals that constitutes M being in an oxidation state greater or less than that of the metal in the final compound LixM1−
yM′
y(XO4)n;
b) a source of an element M′
;
c) a compound that is a source of lithium; and
d) possibly a compound that is a source of X, e) a source of carbon, called carbon conductor the sources of the elements M, M′
, Li and X may be introduced or not, in whole or in part, in at least one step, in the form of compounds having more than one source element, and the synthesis being carried out by thermodynamic or kinetic reaction and bringing into equilibrium, in the required proportions, the mixture of the source compounds (also called precursors) a) to d), with a gaseous atmosphere, in such a way as to cause an oxidation state of the transition metal to the desired valency (preferably, this valency is equal to two for iron, manganese, cobalt and nickel, and three or four for titanium and vanadium) for the forming of LixM1−
yM′
y(XO4)n, by controlling the composition of the said gaseous atmosphere, the temperature of the synthesis reaction step. and the amount of the source compound c) relative to the other source compounds a), b) and d);
a method comprising at least one pyrolysis step of the source compound e) such as to obtain a compound whose electronic conductivity, measured on a sample of powder compressed at a pressure greater than or equal to 3000, preferably 3750 Kg.cm−
2, is greater than 10−
8 S.cm−
1.
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Abstract
A method for the synthesis of compounds of the formula C—LixM1−yM′y(XO4)n, where C represents carbon cross-linked with the compound LixM1−yM′y(XO4)n, in which x, y and n are numbers such as 0≦x≦2, 0≦y≦0.6, and 1≦n≦1.5, M is a transition metal or a mixture of transition metals from the first period of the periodic table, M′ is an element with fixed valency selected among Mg2+, Ca2+, Al3+, Zn2+ or a combination of these same elements and X is chosen among S, P and Si, by bringing into equilibrium, in the required proportions, the mixture of precursors, with a gaseous atmosphere, the synthesis taking place by reaction and bringing into equilibrium, in the required proportions, the mixture of the precursors, the procedure comprising at least one pyrolysis step of the carbon source compound in such a way as to obtain a compound in which the electronic conductivity measured on a sample of powder compressed at a pressure of 3750 Kg.cm−2 is greater than 10−8 S.cm−1. The materials obtained have excellent electrical conductivity, as well a very improved chemical activity.
-
Citations
139 Claims
-
1. A method for the synthesis of compounds of formula C—
- LixM1−
yM′
y(XO4)n, wherein C represents carbon cross-linked with the compound LixM1−
yM′
y(XO4)n in which x, y and n are numbers such as 0≦
x≦
2.0≦
y ≦
0.6, and 1≦
n≦
1.5, M is a transition metal or a mixture of transition metals from the first line of the periodic table, M′
is an element with fixed valency selected among Mg2+, Ca2+, Al3+, Zn2+ or a combination of these same elements and X is chosen from among S, P and Si,by bringing into equilibrium, in the required proportions, a mixture (preferably intimate and/or homogeneous) comprising at least;
a) a source of M, at least one part of the said transition metal or metals that constitutes M being in an oxidation state greater or less than that of the metal in the final compound LixM1−
yM′
y(XO4)n;
b) a source of an element M′
;
c) a compound that is a source of lithium; and
d) possibly a compound that is a source of X, e) a source of carbon, called carbon conductor the sources of the elements M, M′
, Li and X may be introduced or not, in whole or in part, in at least one step, in the form of compounds having more than one source element, andthe synthesis being carried out by thermodynamic or kinetic reaction and bringing into equilibrium, in the required proportions, the mixture of the source compounds (also called precursors) a) to d), with a gaseous atmosphere, in such a way as to cause an oxidation state of the transition metal to the desired valency (preferably, this valency is equal to two for iron, manganese, cobalt and nickel, and three or four for titanium and vanadium) for the forming of LixM1−
yM′
y(XO4)n, by controlling the composition of the said gaseous atmosphere, the temperature of the synthesis reaction step. and the amount of the source compound c) relative to the other source compounds a), b) and d);
a method comprising at least one pyrolysis step of the source compound e) such as to obtain a compound whose electronic conductivity, measured on a sample of powder compressed at a pressure greater than or equal to 3000, preferably 3750 Kg.cm−
2, is greater than 10−
8 S.cm−
1. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 57, 63, 67, 68)
- LixM1−
-
56. Material made of particles having a core and/or a coating and/or a cross-linking, the said core comprising at least one compound of the formula C—
- LixM1−
yM′
yXO4)n, in which C represents carbon cross-linked to the compound LixM1−
yM′
y(XO4)n, x, y and n are numbers such as 0≦
x≦
2, 0≦
y≦
0.6, and 1≦
n≦
1.5, M is a transition metal or a mixture of transition metals from the first line of the periodic table, M′
is an element with fixed valence chosen from among Mg2+, Ca2+, Al3+, Zn2+ and X is chosen from among S, P and Si, the said materials having a conductivity greater than 10−
8 Scm−
1, on a sample of powder compacted at 3750 Kg.cm−
2 and of which the granulometry of the said constituent particles of the material is preferably comprised between 0.05 and 15 micrometers, preferably between 0.1 and 10 micrometers. - View Dependent Claims (58, 59, 60, 61, 62, 64, 65, 66)
- LixM1−
-
70. The method according to claim 69, wherein the synthesis reaction between the precursors a) to d) is carried out simultaneously with the pyrolysis reaction of precursor e).
-
71. The method according to claim 69, wherein the pyrolysis reaction is carried out in a second step, consecutive to the synthesis reaction between precursors a) to d) in a reducing or neutral gaseous atmosphere.
-
72. The method according to claim 69, wherein a compound of formula C—
- LixM1−
yM′
y(XO4)n is obtained in the form of a particle wherein the size and shape of the particle of compound C—
LixM1−
yM′
y(XO4)n is essentially determined by the size and the shape of a intimate or homogeneous mixture of precursors a) to d) used for the synthesis reaction. - View Dependent Claims (73, 74)
- LixM1−
-
75. The method according to claim 69, wherein the amount carbon conductor is sufficient to coat at least a part of the surface of the particle of the compound of formula LixM1−
- yM′
y(XO4)n with carbon. - View Dependent Claims (76, 77)
- yM′
-
78. The method according to claim 69, wherein the amount of carbon conductor in the reaction medium is sufficient to bond particles of compound LixM1−
- yM′
y(XO4)n to each other and to constitute agglomerates with sizes between 1 and 20 microns. - View Dependent Claims (79)
- yM′
-
80. The method according to claim 69, wherein a final form of the compound C—
- LixM1−
yM′
y(XO4)n is determined by a form given to the mixture of precursors a) to d) before synthesis. - View Dependent Claims (81, 82)
- LixM1−
- 83. The method according to claim 69, wherein the organic substance that is the source of the carbon conductor is selected from the group consisting of polymers and oligomers containing a carbon skeleton, simple carbohydrates and polymers, and aromatic hydrocarbons.
-
84. A method according to claim 69, wherein the source of carbon conductor source comprises, in the same compound or in a mixture that constitutes the source of carbon conductor, oxygen and hydrogen that are bound chemically and from which pyrolysis locally releases carbon monoxide, carbon dioxide, or hydrogen and water vapor to create locally a reducing atmosphere required for synthesis of a compound of formula LixM1−
- yM′
y(XO4)n.
- yM′
-
85. The method according to claim 69, wherein the source of carbon conductor comprises a block copolymer comprising at least one carbon source segment that can be pyrolyzed and a segment that is soluble in water and organic solvents to allow distribution, through the compound LixM1−
- yM′
y(XO4)n or precursors a) to d).
- yM′
-
87. The method according to claim 69, wherein precursors a) to d) are in the form of powder or at least partially compressed in the form of pastilles, prior to the synthesis so as to increase points of contact between reagents and to increase the density of the compound of formula C—
- LixM1−
yM′
y(XO4)n while allowing the reaction with the gaseous atmosphere.
- LixM1−
-
88. The method according to claim 69, wherein precursors a) to d) are compacted in the presence of carbon conductor.
- 89. The method according to claim 69, wherein the method is carried out continuously in a reactor that promotes the equilibrium of solid powders, agglomerated or not, with the gaseous atmosphere via control of the composition and the circulation of the gaseous atmosphere.
- 91. The method according to claim 69, wherein a reduction is obtained by the action of a reducing gaseous atmosphere able to reduce an oxidation state of a metallic ion of M to the level required for the composition of the compound without reducing the oxidation state of a metallic ion of M to a neutral metallic state.
- 98. The method according to claim 69, wherein the gaseous atmosphere comprises a gas reformed in situ or ex situ.
-
100. The method according to claim 69, wherein thermal processing comprising formation of LixM1−
- yM′
y(XO4)n, reduction, pyrolysis, and, optionally, dehydration of one or more of precursors a) to d)) is carried out by heating to a temperature between 500°
C. and 1100°
C. - View Dependent Claims (101)
- yM′
-
102. The method according to claim 69, wherein dwell time of precursors a) to e) in thermal processing is less than 5 hours.
-
103. The method according to claim 69, wherein the compound LixM1−
- yM′
y(XO4)n, wherein n=1, has an electrochemical capacity greater than 150 mAh/g−
1, measured for specific intensities greater than 10 mA.g−
1.
- yM′
-
104. The method according to claim 69, wherein the source of M is also the source of X, the source of M′
- is also the source of X, the source of lithium is also the source of X, or the source of X is also the source of lithium.
-
105. The method according to claim 69, wherein bringing the mixture of precursors a) to d) into equilibrium is carried out in the form of an intimate or homogeneous mixture of precursors a) to d) and the gaseous atmosphere.
-
106. The method according to claim 69, wherein the transition metal or metals is selected from the group consisting of iron, manganese, cobalt, nickel, vanadium, titanium, chromium, and copper.
- 107. The method according to claim 69, wherein the source of M is in an oxidation state from 3 to 7.
- 109. The method according to claim 69, wherein the compound that is the source of lithium is selected from the group consisting of lithium oxide, lithium hydroxide, lithium carbonate, neutral phosphate Li3PO4, acid phosphate LiH2PO4, lithium orthosilicates, lithium metasilicates, lithium polysilicates, lithium sulfate, lithium oxalate, lithium acetate and mixtures thereof.
-
111. The method according to claim 69, wherein the source of X is selected from the group consisting of sulfuric acid, lithium sulfate, phosphoric acid, phosphoric acid esters, neutral phosphate Li3PO4, acid phosphate LiH2PO4, monoammonium phosphate, diammonium phosphate, trivalent ferric phosphate, manganese and ammonium phosphate (NH4MnPO4), silica, lithium silicates, alkoxysilanes and partial hydrolysis products thereof, and mixtures thereof.
-
113. The method according to claim 69, wherein at least one compound of formula LixM1−
- yM′
y(XO4)n is of the formula LiFePO4;
LiFe1−
sMnsPO4, wherein 0≦
s≦
0.9;
LiFe1−
yMgyPO4 or LiFe1−
yCayPO4, wherein 0≦
y≦
0.3;
LiFe1−
s−
yMnsMgyPO4, wherein 0≦
s≦
1 and 0≦
y≦
0.2;
Li1−
xFeP1−
xSixO4, wherein 0≦
x≦
0.9;
Li1+xFe1−
sMnsP1−
xSixO, wherein 0≦
s≦
1;
Li1+zFe1−
s−
zMnsP1−
zSzO4, wherein 0≦
s≦
1, 0≦
z≦
0.2;
Li1+2qFe1−
s−
qMnsPO4, where 0≦
s≦
1, and 0≦
q≦
0.3;
Li1+rFe1−
8Mns(S1−
rPrO4)1,5, wherein 0≦
r≦
1, 0≦
s,t≦
1;
or Li0,5+uFe1−
tTit(PO4)1,5 wherein 0≦
t≦
1 and 0≦
u≦
1.5.
- yM′
-
114. The method according to claim 69, wherein the compound of formula LixM1−
- yM′
y(XO4)n has an olivine or Nasicon structure.
- yM′
- 115. The method according to claim 69, wherein reaction parameters of the kinetics of reduction by the gaseous atmosphere, are chosen such that the carbon conductor is not consumed during reduction.
-
117. The method according to claim 69, wherein the temperature and duration of the synthesis are chosen as a function of the nature of the transition metal, wherein the temperature is above a minimum temperature at which the gaseous atmosphere is capable of reducing the transition metal or metals to an oxidation state required in the compound LixM1−
- yM′
y(XO4)n and below a temperature leading to a reduction of the transition metal or metals to a metallic state or an oxidation of the carbon resulting from pyrolysis of the organic substance, and wherein the duration is less than a time leading to a reduction of the transition metal or metals to a metallic state or an oxidation of the carbon resulting from pyrolysis of the organic substance.
- yM′
-
118. The method according to claim 69, wherein thermal processing is carried out by heating to a temperature between 500°
- C. and 1100°
C., in the presence of a reducing atmosphere. - View Dependent Claims (119)
- C. and 1100°
-
120. The method according to claim 69, wherein the compound LixM1−
- yM′
y(XO4)n is LiMPO4 and wherein the amount of carbon conductor after pyrolysis is between 0.1% and 10% by mass in comparison to the mass of the compound LiMPO4.
- yM′
-
121. The method according to claim 69, wherein the organic substance that is the source of carbon conductor is dispersed in processing an intimate mixture with precursors a) to d) by solubilization, agitation, mechanical grinding, ultrasound homogenization, optionally in the presence of a liquid, or by spray-drying of a solution, suspension or emulsion of one or more of precursors a) to d).
-
122. The method according to claim 69, wherein the compound of formula LixM1−
- yM′
y(XO4)n is LiFePO4.
- yM′
-
123. The method according to claim 69, wherein a particle is obtained, wherein said particle has a core essentially comprising a compound of the formula LiFePO4, and wherein the particle has an amount of carbon conductor comprised between 0.2 and 5% in comparison to the mass of the particle.
-
124. A material made of particles comprising a core and/or a coating and/or a cross-linking, wherein the core comprises at least one compound of the formula C—
- LixM1−
yM′
y(XO4)n wherein C represents carbon cross-linked with the compound LixM1−
yM′
y(XO4)n, x, y and n are numbers such that 0≦
x≦
2, 0≦
y≦
0.6 and 1≦
n≦
1.5, M is a transition metal or a mixture of transition metals from the first line of the periodic table, M′
is an element with fixed valence selected from the group consisting of Mg2+, Ca2+, Al3+, and Zn2+, and X is S, P or Si, wherein the conductivity of the material is greater than 10−
8 Scm−
1, measured on a sample of powder compacted at 3750 Kg.cm−
2, and wherein the granulometry of the particles of the material is between 0.05 and 15 micrometers. - View Dependent Claims (126, 127, 128, 129, 130, 132, 133, 134, 135, 136, 137, 138, 139)
- LixM1−
-
125. A material comprising a compound of formula C—
- LixM1−
yM′
y(XO4)n obtained by a method according to claim 69, comprising a core and a coating and/or a cross-linking, wherein the conductivity of the material, measured on a sample of powder compacted at 3750 Kg.cm−
2, is greater than 10−
8 S.cm−
1, wherein the amount of carbon conductor of the material is between 0.2 and 5%, and wherein the granulometry of the material is between 0.05 and 15 micrometers.
- LixM1−
-
131. An electrochemical cell comprising at least two electrodes and at least one electrolyte, wherein at least one electrode comprises at least one material made of particles comprising a core and/or a coating and/or a cross-linking, wherein the core comprises at least one compound of the formula C—
- LixM1−
yM′
y(XO4)n wherein C represents carbon cross-linked with the compound LixM1−
yM′
y(XO4)n, x, y and n are numbers such that 0≦
x≦
2, 0≦
y≦
0.6 and 1≦
n≦
1.5, M is a transition metal or a mixture of transition metals from the first line of the periodic table, M′
is an element with fixed valence selected from the group consisting of Mg2+, Ca2+, Al3+, and Zn2+, and X is S, P or Si, wherein the conductivity of the material is greater than 10−
8 Scm−
1, measured on a sample of powder compacted at 3750 Kg.cm 2, wherein the granulometry of the particles of the material is between 0.05 and 15 micrometers, and wherein at least one of the positive electrodes contains one compound obtained by a method according to claim 69, wherein said compound is alone or in a mixture with a double oxide of cobalt and lithium;
or with a complex oxide of the formula LixNi1−
y−
z−
q−
rCoyMgzAlrO2, wherein 0.1≦
x≦
1, 0≦
y, z and r≦
0.3;
or with a complex oxide of the formula LixMn1−
y−
z−
q−
rCoyMgzAlrO2-qFq, wherein 0.05≦
x≦
1 and 0≦
y, z, r, q≦
0.3.
- LixM1−
Specification