Long-term cyclability of LiFePO4/carbon composite cathode material for lithium-ion battery applications

A simple high-energy ball milling combined with spray-drying method has been developed to synthesize LiFePO₄/carbon composite. This material delivers an improved tap density of 1.3 g/cm³ and a high electronic conductivity of 10⁻² to 10⁻³ S/cm. The electrochemical performance, which is especially notable for its high-rate performance, is excellent. The discharge capacities are as high as 109 mAh/g at the current density of 1100 mA/g (about 6.5C rate) and 94 mAh/g at the current density of 1900 mA/g (about 11C rate). At the high current density of 1700 mA/g (10C rate), it exhibits a long-term cyclability, retaining over 92% of its original discharge capacity beyond 2400 cycles. Therefore, the as-prepared LiFePO₄/carbon composite cathode material is capable of such large-scale applications as hybrid and plug-in hybrid electric vehicles.     

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.     

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 nano-sized LiFePO4/C synthesized by an ultrasonic-assisted co-precipitation method

A simple and effective method, the ultrasonic-assisted co-precipitation method, was employed to synthesize nano-sized LiFePO₄/C. A glucose solution was used as the carbon source to produce in situ carbon to improve the conductivity of LiFePO₄. Ultrasonic irradiation was adopted to control the size and homogenize the LiFePO₄/C particles. The sample was characterized by X-ray powder diffraction, field-emission scanning electron microscopy (FE-SEM), transmission electron microscopy (TEM) and high-resolution transmission electron microscopy (HRTEM). FE-SEM and TEM show that the as-prepared sample has a reduced particle size with a uniform size distribution, which is around 50 nm. A uniform amorphous carbon layer with a thickness of about 4-6 nm on the particle surface was observed, as shown in the HRTEM image. The electrochemical performance was demonstrated by the charge-discharge test and electrochemical impedance spectra measurements. The results indicate that the nano-sized LiFePO₄/C presents enhanced discharge capacities (159, 147 and 135 mAh g⁻¹ at 0.1, 0.5 and 2 C-rate, respectively) and stable cycling performance. This study offers a simple method to design and synthesis nano-sized cathode materials for lithium-ion batteries.     

Synthesis of FePO4·2H2O nanoplates and their usage for fabricating superior high-rate performance LiFePO4

Monoclinic phase FePO₄·2H₂O nanoplates are synthesized very easily in a waterbath and are lithiated to LiFePO₄/C nanoparticles by a simple rheological phase method. The thickness of the nanoplates can be tuned simply by changing the concentrations of the reactants. The LiFePO₄/C nanoparticles lithiated from the thin FePO₄·2H₂O nanoplates, with the sizes about 50 nm and the carbon coating layer at the surface 1–2 nm, show excellent high-rate performance and long-term cyclability as the cathode for lithium ion batteries, delivering discharge capacities of more than 150, 120, 110, 100, and 75 mAh g⁻¹ at rates of 5 C, 10 C, 15 C, 20 C and 30 C, respectively.     

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.     

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.     

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%.     

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.     

Synthesis and electrochemical properties of LiAl0.05Mn1.95O4 by the ultrasonic assisted rheological phase method

Pure-phase and well-crystallized spinel LiAl_0.05Mn_1.95O₄ powders were successfully synthesized by a simple ultrasonic assisted rheological phase (UARP) method. The structure and morphology properties of this as-prepared powder compared with the pristine LiMn₂O₄ and LiAl_0.05Mn_1.95O₄ obtained from the solid-state reaction (SSR) method were investigated by powder X-ray diffraction (XRD) and scanning electron microscopy (SEM). The electrochemical properties focused on the LiAl_0.05Mn_1.95O₄ by this new method have also been investigated in detail. According to these tests results, it is obviously to see that the newly prepared sample delivers a relatively high initial discharge capacity of 111.6 mAh g⁻¹, presents excellent rate capability and reversibility, and shows good cycling stability with capacity retention of 90.6% after 70 cycles. Meanwhile, the electrochemical impedance spectroscopy (EIS) investigations were employed to study the electrochemical process of Li⁺ ions with the synthesized LiAl_0.05Mn_1.95O₄ electrode in detail.     

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.     

Preparation and electrochemical properties of LiMn2O4 by the microwave-assisted rheological phase method

Pure-phase and well-crystallized spinel LiMn₂O₄ powders as cathode materials for lithium-ion batteries were successfully synthesized by a new simple microwave-assisted rheological phase method, which was a timesaving and efficient method. The physical properties of the as-synthesized samples compared with the pristine LiMn₂O₄ obtained from the rheological phase method were investigated by thermogravimetry analysis (TGA), X-ray diffraction (XRD) and scanning electronic microscope (SEM). The as-prepared powders were used as positive materials for lithium-ion battery, whose charge/discharge properties and cycle performance were examined in detail. The powders resulting from the microwave-assisted rheological phase method were pure, spinel structure LiMn₂O₄ particles of regular shapes with distribution uniformly, and exhibited promising electrochemical properties for battery. Furthermore, cyclic voltammetry (CV) and electrochemical impedance spectroscopy (EIS) were employed to characterize the reactions of Li-ion insertion into and extraction from LiMn₂O₄ electrode.     

A novel method for preparing LiFePO4 nanorods as a cathode material for lithium-ion power batteries

An effective method for synthesizing a one-dimensional nanostructure to improve the rate performance of LiFePO₄ as the cathode material for Li-ion power batteries is described. The crystal structure, composition, and morphology of the prepared LiFePO₄ were characterized by X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS) and transmission electron microscopy (TEM), respectively. The reaction mechanism of the LiFePO₄ nanorods is discussed herein. Electrodes consisting of the LiFePO₄ nanorods have better rate discharge capacities over a potential range of 2.5-4.2 V (vs. Li⁺/Li). These results are attributed to the shorter distance of electron transport and the fact that ion diffusion in the electrode material is limited by the nanorod radius. Our results indicate that the prepared LiFePO₄ nanorods are promising cathode materials for Li-ion power batteries. This new process for synthesizing nanorod products from nanorod raw material can be extended to the preparation of other one-dimensional materials.     

High power performance of nano-LiFePO4/C cathode material synthesized via lauric acid-assisted solid-state reaction

A nano-LiFePO₄/C composite has been directly synthesized from micrometer-sized Li₂CO₃, NH₄H₂PO₄, and FeC₂O₄·2H₂O by the lauric acid-assisted solid-state reaction method. The SEM and TEM observations demonstrate that the synthesized nano-LiFePO₄/C composite has well-dispersed particles with a size of about 100–200 nm and an in situ carbon layer with thickness of about 2 nm. The prepared nano-LiFePO₄/C composite has superior rate capability, delivering a discharge capacity of 141.2 mAh g⁻¹ at 5 °C, 130.9 mAh g⁻¹ at 10 C, 121.7 mAh g⁻¹ at 20 °C, and 112.4 mAh g⁻¹ at 30 °C. At −20 °C, this cathode material still exhibits good rate capability with a discharge capacity of 91.9 mAh g⁻¹ at 1 °C. The nano-LiFePO₄/C composite also shows excellent cycling ability with good capacity retention, up to 100 cycles at a high current density of 30 °C. Furthermore, the effect of lauric acid in the preparation of nano-LiFePO₄/C composite was investigated by comparing it with that of citric acid. The SEM images reveal that the morphology of the LiFePO₄/C composite transformed from the porous structure to fine particles as the molar ratio of lauric acid/citric acid increased.     

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.     

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.     

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.     

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.     

A PVB-based rheological phase approach to nano-LiFePO4/C composite cathodes

Nano-LiFePO₄/C cathode materials were synthesized by a PVB-based rheological phase method, followed by calcination at 550 °C for 10 h in argon. Simultaneous thermogravimetric-differential scanning calorimetry analysis indicates that the crystallization temperature of LiFePO₄ is about 436 °C. In the process of heat treatment, the decomposition of polyvinylbutyral coats carbon on the synthesized LiFePO₄ particles in situ. The resulting LiFePO₄ powders with fine particle sizes and homogeneous carbon network connection were observed by using scanning electron microscopy and transmission electron microscopy. Electrochemical measurements show that the LiFePO₄/C composite cathode delivers a large discharge capacity of 162.3 mAh·g^− 1 at the 0.1 C rate, and exhibits a favorable capacity cycling maintenance at lower charge and discharge rate such as 0.5 C rate.     

Preparation and characterization of nano-sized LiFePO4 by low heating solid-state coordination method and microwave heating

The precursors of LiFePO₄ were prepared by low heating solid-state coordination method using lithium acetate, ammonium dihydric phosphate, ferrous oxalate and citric acid as raw materials. Olivine phase LiFePO₄ as a cathode material for lithium-ion batteries was successfully synthesized by microwave heating in a few minutes. X-ray diffraction (XRD) and transmission electron microscope (TEM) were used to characterize its structure and morphology. Cyclic voltammetry (CV) and charge-discharge cycling performance were used to characterize its electrochemical properties. The results showed that the grain size of the optimal sample was about 40-50 nm, and the as-prepared particles were homogeneous. The nano-sized LiFePO₄ obtained has a high electrochemical capacity (125 mAh g⁻¹) and stable cycle ability.