Preparation and characterization of nano-particle LiFePO4 and LiFePO4/C by spray-drying and post-annealing method

Pure, nano-sized LiFePO₄ and LiFePO₄/C cathode materials are synthesized by spray-drying and post-annealing method. The influence of the sintering temperature and carbon coating on the structure, particle size, morphology and electrochemical performance of LiFePO₄ cathode material is investigated. The optimum processing conditions are found to be thermal treatment for 10 h at 600 °C. Compared with LiFePO₄, LiFePO₄/C particles are smaller in size due to the inhibition of crystal growth to a great extent by the presence of carbon in the reaction mixture. And that the LiFePO₄/C composite coated with 3.81 wt.% carbon exhibits the best electrode properties with discharge capacities of 139.4, 137.2, 133.5 and 127.3 mAh g⁻¹ at C/5, 1C, 5C and 10C rates, respectively. In addition, it shows excellent cycle stability at different current densities. Even after 50 cycles at the high current density of 10C, a discharge capacity of 117.7 mAh g⁻¹ is obtained (92.4% of its initial value) with only a low capacity fading of 0.15% per cycle.     

Emulsion drying synthesis of olivine LiFePO4/C composite and its electrochemical properties as lithium intercalation material

The electroactive LiFePO₄/C nano-composite has been synthesized by an emulsion drying method. During burning-out the oily emulsion precipitates in an air-limited atmosphere at 300 °C, amorphous or low crystalline carbon was generated along with releasing carbon oxide gases, and trivalent iron as a cheap starting material was immediately reduced to the divalent one at this stage as confirmed by X-ray photoelectron spectroscopy, leading to a low crystalline LiFePO₄/C composite. Heat-treatment of the low crystalline LiFePO₄/C in an Ar atmosphere resulted in a well-ordered olivine structure, as refined by Rietveld refinement of the X-ray diffraction pattern. From secondary electron microscopic and scanning transmission electron microscopic observations with the corresponding elemental mapping images of iron and phosphorous, it was found that the LiFePO₄ powders are modified by fine carbon. The in situ formation of the nano-sized carbon during crystallization of LiFePO₄ brought about two advantages: (i) an optimized particle size of LiFePO₄, and (ii) a uniform distribution of fine carbon in the product. These effects of the fine carbon on LiFePO₄/C composite led to high capacity retention upon cycling at 25 and 50 °C and high rate capability, resulting from a great enhancement of electric conductivity as high as 10⁻⁴ S cm⁻¹. That is, the obtained capacity was higher than 90 mAh (g-phosphate)⁻¹ by applying a higher current density of about 1000 mA g⁻¹ (11 C) at 50 °C.     

Process investigation, electrochemical characterization and optimization of LiFePO4/C composite from mechanical activation using sucrose as carbon source

LiFePO₄/C composite was synthesized by mechanical activation using sucrose as carbon source. High-energy ball milling facilitated phase formation during thermal treatment. TG-DSC and TPR experiments demonstrated sucrose was converted to CH_x intermediate before completely decomposed to carbon. Ball milling time, calcination temperature and dwelling time all had significant impact on the discharge capacity and rate performance of the resulted power. The optimal process parameters are high-energy ball milling for 2-4 h followed by thermal treatment at 700 °C for 20 h. The product showed a capacity of 174 mAh/g at 0.1C rate and around 117 mAh/g at 20C rate with the capacity fade less than 10% after 50 cycles. Too low calcination temperature or insufficient calcination time, however, could result in the residual of CH_x in the electrode and led to a decrease of electrode performance.     

Synthesis and characterization of LiFePO4/(Ag + C) composite cathodes with nano-carbon webs

LiFePO₄/(Ag + C) composite cathodes with a new type of nano-sized carbon webs were synthesized by two methods of an aqueous co-precipitation and a sol-gel process, respectively. Simultaneous thermogravimetric-differential thermal analysis indicates that the crystallization temperature of LiFePO₄ is about 455-466 °C, which is close to the pyrolysis temperature of polypropylene, 460 °C. The silver and carbon co-modifying does not affect the olivine structure of LiFePO₄ but improves its kinetics in terms of discharge capacity and rate capability. Discharge capacities were improved from 153.4 mA h g^− 1 of LiFePO₄/C to 160.5 mA h g^− 1and 162.1 mA h g^− 1 for LiFePO₄/(Ag + C) cathodes synthesized by the co-precipitation and sol-gel methods, respectively. The possible reasons for the small difference in discharge capacity of two LiFePO₄/(Ag + C) cathodes were discussed. AC impedance measurements show that the Ag + C co-modification decreases the charge transfer resistance of LiFePO₄/(Ag + C) cathodes.     

Synthesis and characterization of high-density LiFePO4/C composites as cathode materials for lithium-ion batteries

To achieve a high-energy-density lithium electrode, high-density LiFePO₄/C composite cathode material for a lithium-ion battery was synthesized using self-produced high-density FePO₄ as a precursor, glucose as a C source, and Li₂CO₃ as a Li source, in a pipe furnace under an atmosphere of 5% H₂-95% N₂. The structure of the synthesized material was analyzed and characterized by X-ray diffraction (XRD) and scanning electron microscope (SEM). The electrochemical properties of the synthesized LiFePO₄/carbon composite were investigated by cyclic voltammetry (CV) and the charge/discharge process. The tap-density of the synthesized LiFePO₄/carbon composite powder with a carbon content of 7% reached 1.80 g m⁻³. The charge/discharge tests show that the cathode material has initial charge/discharge capacities of 190.5 and 167.0 mAh g⁻¹, respectively, with a volume capacity of 300.6 mAh cm⁻³, at a 0.1C rate. At a rate of 5C, the LiFePO₄/carbon composite shows a high discharge capacity of 98.3 mAh g⁻¹ and a volume capacity of 176.94 mAh cm⁻³.     

In situ construction of carbon nano-interconnects between the LiFePO4 grains using ultra low-cost asphalt

LiFePO₄/C composite cathode materials with carbon nano-interconnect structures were synthesized by one-step solid state reaction using low-cost asphalt as both carbon source and reducing agent. Based on the thermogravimetry, differential scanning calorimetry, transmission electron microscopy and high-resolution transmission electron microscopy, a growth model was proposed to illustrate the formation of the carbon nano-interconnect between the LiFePO₄ grains. The LiFePO₄/C composite shows enhanced discharge capacity (150 mAh g⁻¹) with excellent capacity retention compared with the bare LiFePO₄ (41 mAh g⁻¹) due to the electronically conductive nanoscale networking provided by the asphalt-based carbon. The results prove that the asphalt is a perfect carbon source and reduction agent for cost-effective production of high performance LiFePO₄/C composite.     

Enhanced electrochemical performance of carbon nanospheres-LiFePO4 composite by PEG based sol-gel synthesis

The carbon nanospheres-LiFePO₄ (CNSs-LiFePO₄) composite has been synthesized by PEG (polyethylene glycol, mean molecular weight of 30,000) based sol-gel route. Highly conductive CNSs (30-40 nm) were adopted to improve the electronic conductivity of LiFePO₄. PEG was used to promote the dispersion of CNSs with the surface functionalization of CNSs, which could facilitate the coating of CNSs on the surface of the LiFePO₄ particles. The sample was characterized by X-ray diffraction, field emission scanning electron microscopy, transmission electron microscopy, and Raman scattering. Electrochemical performance of the CNSs-LiFePO₄ composite was characterized by the charge-discharge test and electrochemical impedance spectra measurement. The results indicated that LiFePO₄ particles were well coated with the conductive CNSs to overcome the intrinsic low electronic conductivity problem of LiFePO₄. The CNSs-LiFePO₄ composite delivered an enhanced rate capability (146, 128 and 113 mAh g⁻¹ at 0.1 C, 1 C and 5 C rate). The PEG based sol-gel route enables LiFePO₄ networked with CNSs, which offered a higher electrochemical performance.     

Rechargeable Li/LiFePO4 cells using N-methyl-N-butyl pyrrolidinium bis(trifluoromethane sulfonyl)imide-LiTFSI electrolyte incorporating polymer additives

We have incorporated polymer additives such as poly(ethylene glycol) dimethyl ether (PEGDME) and tetra(ethylene glycol) dimethyl ether (TEGDME) into N-methyl-N-butylpyrrolidinium bis(trifluoromethane sulfonyl)imide (PYR₁₄TFSI)-LiTFSI mixtures. The resulting PYR₁₄TFSI + LiTFSI + polymer additive ternary electrolyte exhibited relatively high ionic conductivity as well as remarkably low viscosity over a wide temperature range compared to the PYR₁₄TFSI + LiTFSI binary electrolytes. The charge/discharge cyclability of Li/LiFePO₄ cells containing the ternary electrolytes was investigated. We found that Li/PYR₁₄TFSI + LiTFSI + PEGDME (or TEGDME)/LiFePO₄ cells containing the two different polymer additives showed very similar discharge capacity behavior, with very stable cyclability at room temperature (RT). Li/PYR₁₄TFSI + LiTFSI + TEGDME/LiFePO₄ cells can deliver about 127 mAh/g of LiFePO₄ (74.7% of theoretical capacity) at 0.054 mA/cm² (0.2C rate) at RT and about 108 mAh/g of LiFePO₄ (63.4% of theoretical capacity) at 0.023 mA/cm² (0.1C rate) at −1 °C for the first discharge. The cell exhibited a capacity fading rate of approximately 0.09-0.15% per cycle over 50 cycles at RT. Consequently, the PYR₁₄TFSI + LiTFSI + polymer additive ternary mixture is a promising electrolyte for cells using lithium metal electrodes such as the Li/LiFePO₄ cell reported here. These cells showed the capability of operating over a significant temperature range (∼0-∼30 °C).     

Electrochemical properties of carbon-mixed LiFePO4 cathode material synthesized by the ceramic granulation method

LiFePO₄/carbon composite cathode material was prepared using polyvinyl alcohol (PVA) as carbon source by pelleting and subsequent pyrolysis in N₂. The samples were characterized by XRD, SEM and TGA. Their electrochemical performance was investigated in terms of charge–discharge cycling behavior. It consists of a single LiFePO₄ phase and amorphous carbon. The special micro-morphology via the process is favorable for electrochemical properties. The discharge capacity of the LiFePO₄/C composite was 145 mAh/g, closer to the theoretical specific capacity of 170 mAh/g at 0.1 C low current density. At 3 C modest current density, the specific capacity was about 80 mAh/g, which can satisfy for transportation applications if having a more planar discharge flat.     

Influence of carbon sources on LiFePO4/C composites synthesized by the high-temperature high-energy ball milling method

Carbon-coated LiFePO₄ composites were synthesized by a new method of high-temperature high-energy ball milling (HTHEBM). Fe₂O₃ and LiH₂PO₄ were used as raw materials. Glucose, sucrose, citric acid and active carbon were used as reducing agents and carbon sources, respectively. In this method, high-energy ball milling and carbon coating worked together and, therefore, fine and homogeneous LiFePO₄/C particles with excellent properties were obtained in a relatively short synthesis time of 9 h. Moreover, the synthesis process could be completely finished at a relatively lower temperature of 600 °C for high-energy ball milling transforming mechanical energy into thermal energy. The results of X-ray diffraction (XRD) analysis, scanning electron microscopy (SEM), transmission electron microscopy (TEM) and electrochemical performance tests indicated that carbon source had an important influence on the properties of LiFePO₄/C composites synthesized by the HTHEBM method. It was proved that the LiFePO₄ composites coated with glucose had the best properties with 1 μm geometric mean diameter and 150.3 mA h g⁻¹ initial discharge capacity at a current rate of 0.1 C. After the 20th cycle test, the reversible capacity was 148 mA h g⁻¹ at 0.1 C, showing a retention ratio to the initial capacity of 98.5%.     

One-step microwave synthesis and characterization of carbon-modified nanocrystalline LiFePO4

The precursors of LiFePO₄ were prepared by a sol-gel method using lithium acetate dihydrate, ferrous sulfate, phosphoric acid, citric acid and polyethylene glycol as raw materials, and then the carbon-modified nanocrystalline LiFePO₄ (LiFePO₄/C) cathode material was synthesized by a one-step microwave method with the domestic microwave oven. The effect of microwave time and carbon content on the performance of the resulting LiFePO₄/C material was investigated. Structural characterization by X-ray diffraction and scanning electron microscopy proved that the olivine phase LiFePO₄ was synthesized and the grain size of the samples was several hundred nanometers. Under the optimal conditions of microwave time and carbon content, the charge-discharge performance indicated that the nanosized LiFePO₄/C had a high electrochemical capacity at 0.2 C (152 mAh g⁻¹) and improved capacity retention; the exchange current density was 1.6977 mA cm⁻². Furthermore, the rate capability was improved effectively after LiFePO₄ was modified with carbon, with 59 mAh g⁻¹ being obtained at 20 C.     

Synthesis of LiFePO4/C by solid-liquid reaction milling method

LiFePO₄/C was synthesized by the method of solid-liquid reaction milling, using FeCl₃·6H₂O, Li₂CO₃ and (NH₄)₂HPO₄ and glucose, which was used as reductant (carbon source). The samples were characterized by X-ray diffraction (XRD), scanning electron microscope (SEM), TG-DTA analysis, infrared absorption carbon-sulfur analysis and electrochemical performance test. The sample synthesized at 680 °C for 8 h showed, at initial discharge, a capacity of 155.8, 153.2, 148.5, 132.7 mAh g^− 1 at 0.2 °C, 0.5 °C, 1 °C and 3 °C rate respectively. The sample also showed an excellent capacity retention as there was no significant capacity fade after 10 cycles.     

Improved electrochemical performance of La0.7Sr0.3MnO3 and carbon co-coated LiFePO4 synthesized by freeze-drying process

Carbon coated LiFePO₄ particles were first synthesized by sol-gel and freeze-drying method. These particles were then coated with La_0.7Sr_0.3MnO₃ nanolayer by a suspension mixing process. The La_0.7Sr_0.3MnO₃ and carbon co-coated LiFePO₄ particles were calcined at 400 °C for 2 h in a reducing atmosphere (5% of hydrogen in nitrogen). Nanolayer structured La_0.7Sr_0.3MnO₃ together with the amorphous carbon layer forms an integrate network arranged on the bare surface of LiFePO₄ as corroborated by high-resolution transmission electron microscopy. X-ray diffraction results proved that the co-coated composite still retained the structure of the LiFePO₄ substrate. The twin coatings can remarkably improve the electrochemical performance at high charge/discharge rates. This improvement may be attributed to the lower charge transfer resistance and higher electronic conductivity resulted from the twin nanolayer coatings compared with the carbon coated LiFePO₄.     

LiFePO4 cathode power with high energy density synthesized by water quenching treatment

A water quenching (WQ) method was developed to synthesize LiFePO₄ and C-LiFePO₄. Our results indicate that this synthesis method ensures improved electrochemical activity and small crystal grain size. The synthetic conditions were optimized using orthogonal experiments. The LiFePO₄ sample prepared at the optimized condition showed a maximum discharge capacity of 149.8 mAh g⁻¹ at a C/10 rate. C-LiFePO₄ with a low carbon content of 0.93% and a high discharge specific capacity of 163.8 mAh g⁻¹ has also been obtained using this method. Water quenching treatment shows outstanding improvement of the electrochemical performance of LiFePO₄.     

Cathodic performance of LiMn1−xMxPO4 (M = Ti, Mg and Zr) annealed in an inert atmosphere

To improve the cathodic performance of olivine-type LiMnPO₄, we investigated the optimal annealing conditions for a composite of carbon with cation doping. Nanocrystalline and the cation-doped LiMn_1−xM_xPO₄ (M = Ti, Mg, Zr and x = 0, 0.01, 0.05 and 0.10) was synthesized in aqueous solution using a planetary ball mill. The synthesis was performed at the fairly low temperature of 350 °C to limit particle size. The obtained samples except for the Zr doped one consisted of uniform and nano-sized particles. The performance of LiMnPO₄ was much improved by an annealing treatment between 500 and 550 °C with carbon in an inert atmosphere. A small amount of metal-rich phosphide (Mn₂P) was detected in the sample annealed at 900 °C. In addition, 1 at.% Mg doping for Fe enhanced the rate capability in our doped samples. The discharge capacity of LiMn_0.99Mg_0.01PO₄/C was 146 mAh/g at 0.1 mA/cm² and 125 mAh/g even at 2.0 mA/cm².     

Synthesis of FePO4·xH2O for fabricating submicrometer structured LiFePO4/C by a co-precipitation method

Amorphous hydrated iron (III) phosphate has been synthesized by a coordinate precipitation method from equimolecular Fe(NO₃)₃ and (NH₄)₂HPO₄ solutions at an elevated temperature. Hydrated iron (III) phosphate samples and the corresponding LiFePO₄/C products were characterized by XRD and SEM. The electrochemical behavior was studied by cyclic voltammetry (CV) and electrochemical impedance spectroscopy (EIS). The LiFePO₄/C fabricated from as-synthesized FePO₄ delivered discharge capacities of 162.5, 147.3, 133.0, 114.7, 97.2, 91.3 and 88.5 mAh g⁻¹ at rates of 0.1C, 0.2C, 0.5C, 1C, 2C, 3C and 4C with satisfactory capacity retention, respectively.     

Effect of milling method and time on the properties and electrochemical performance of LiFePO4/C composites prepared by ball milling and thermal treatment

Effects of ball milling way and time on the phase formation, particulate morphology, carbon content, and consequent electrode performance of LiFePO₄/C composite, prepared by high-energy ball milling of Li₂CO₃, NH₄H₂PO₄, FeC₂O₄ raw materials with citric acid as organic carbon source followed by thermal treatment, were investigated. Three ball milling ways and five different milling durations varied from 0 to 8 h were compared. LiFePO₄/C composites could be obtained from all synthesis processes. TEM examinations demonstrated LiFePO₄/C from ball milling in acetone resulted in sphere shape grains with a size of ∼60 nm, similar size was observed for LiFePO₄/C from dry ball milling but in a more irregular shape. The ball milling in benzene resulted in a much larger size of ∼250 nm. The LiFePO₄/C composites prepared from dry ball milling and ball milling in acetone showed much better electrochemical performance than that from ball milling in benzene. SEM examinations and BET measurements demonstrated that the high-energy ball milling effectively reduced the grain size. A ball milling for 4 h resulted in the best electrochemical performance, likely due to the proper amount of carbon and proper carbon structure were created.     

Synthesis and characterization of LiFePO4 cathode material dispersed with nano-structured carbon

Carbon-dispersed LiFePO₄ materials were routinely prepared by heating metal-salt-containing pastes of organogels to temperatures at 300 and 700 °C to benefit the intrinsic conductivity, and we ultimately discerned the optimized carbon content, 4.55 wt%. Carbon doping will decrease tap density of prepared cathode material and then bring about electrode preparing difficulty, so we tried different kinds of organogels to make out the densest carbon composite. They were polyacrylamide (PAM), sugar and phenolic resin. The most excellent pyrolyzed PAM paste was found increasingly electrochemical reversible, exhibiting 113.2 mAh/g at C/6 and 95 mAh/g at C/3. And we found a good cycliability of 95 mAh/g at 0.2 mA cm⁻² at room temperature. Seen from atomic force microscopy, this composite was far more different from other pyrolyzed pastes in morphology, which contained judicious designed hiberarchy and highly dispersed nanoparticles. Decreased 2θ in XRD spectra also showed the varied cell parameters, though no exact figures of the varied cell parameters could be given due to a potential existence of an unknown second phase with electrochemical activity.     

Low temperature solid-state synthesis routine and mechanism for Li3V2(PO4)3 using LiF as lithium precursor

Monoclinic lithium vanadium phosphate, Li₃V₂(PO₄)₃, has been successfully synthesized using LiF as lithium source. The one-step reaction with stoichiometric composition and relative lower sintering temperature (700 °C) has been used in our experimental processes. The solid-state reaction mechanism using LiF as lithium precursor has been studied by X-ray diffraction and Fourier transform infrared spectra. The Rietveld refinement results show that in our product sintered at 700 °C no impurity phases of VPO₄, Li₅V(PO₄)₂F₂, or LiVPO₄F can be detected. The solid-state reaction using Li₂CO₃ as Li-precursor has also been carried out for comparison. X-ray diffraction patterns indicate that impurities as Li₃PO₄ can be found in the product using Li₂CO₃ as Li-precursor unless the sintering temperatures are higher than 850 °C. An abrupt particle growth (about 2 μm) has also been observed by scanning electron microscope for the samples sintered at higher temperatures, which can result in a poor cycle performance. The product obtained using LiF as Li-precursor with the uniform flake-like particles and smaller particle size (about 300 nm) exhibits the better performance. At the 50th cycle, the reversible specific capacities for Li₃V₂(PO₄)₃ measured between 3 and 4.8 V at 1C rate are found to approach 147.1 mAh/g (93.8% of initial capacity). The specific capacity of 123.6 mAh/g can even be hold between 3 and 4.8 V at 5C rate.     

Rate performance and structural change of Cr-doped LiFePO4/C during cycling

Structural change of Cr-doped LiFePO₄/C during cycling is investigated using conventional and synchrotron-based in situ X-ray diffraction techniques. The carbon-coated and Cr-doped LiFePO₄ particles are synthesized by a mechanochemical process followed by a one-step heat treatment. The LiFe_0.97Cr_0.03PO₄/C has shown excellent rate performance, delivering the discharge capacity up to 120 mAh/g at 10 C rate. The results suggest that the improvement of the rate performance is attributed to the chromium doping, which facilitates the phase transformation between triphylite and heterosite during cycling, and conductivity improvement by carbon coating. Structural analysis using the synchrotron source also indicates that the doped Cr replaces Fe and/or Li sites in LiFePO₄.