Synthesis of LiFePO4/carbon composite from nano-FePO4 by a novel stearic acid assisted rheological phase method

LiFePO₄/carbon composite was synthesized at 600 °C for 4 h in an Ar atmosphere by a stearic acid assisted rheological phase method using amorphous nano-FePO₄ as the iron source. XRD, SEM and TEM observations show that the LiFePO₄/carbon composite has good crystallinity, ultrafine and well-dispersed particles of 60–150 nm size and in situ carbon coated on the surface of LiFePO₄ crystallites. The synthesized LiFePO₄/carbon composite shows a high discharge capacity of 160 mAh g⁻¹ and 155 mAh g⁻¹ at rates of 0.5 C and 1 C, respectively. Even at a high current density of 30 C, the material still presents a discharge capacity of 93 mAh g⁻¹ and exhibits an excellent cycling performance.     

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.     

Electrochemical performance of Li3V2(PO4)3/C cathode material using a novel carbon source

Polyethylene glycol (PEG, mean molecular weight of 10,000) has been used to prepare a Li₃V₂(PO₄)₃/C cathode material by a simple solid-state reaction. The Raman spectra shows that the coating carbon has a good structure with a low I_D/I_G ratio. The images of SEM and TEM show that the carbon is dispersed between the Li₃V₂(PO₄)₃ particles, which improves the electrical contact between the corresponding particles. The electronic conductivity of Li₃V₂(PO₄)₃/C composite is 7.0 × 10⁻¹ S/cm, increased by seven orders of magnitude compared with the pristine Li₃V₂(PO₄)₃ (2.3 × 10⁻⁸ S/cm). At a low discharge rate of 0.28C, the sample presents a high discharge capacity of 131.2 mAh/g, almost achieving the theoretical capacity (132 mAh/g) for the reversible cycling of two lithium. After 500 cycles, the discharge capacity is 123.9 mAh/g with only 5.6% fading of the initial specific capacity. The Li₃V₂(PO₄)₃/C material also exhibits an excellent rate capability with high discharge capacities of 115.2 mAh/g at 1C and 106.4 mAh/g at 5C.     

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 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.     

An effective and simple way to synthesize LiFePO4/C composite

The cathode material is synthesized from FeC₂O₄·2H₂O and LiH₂PO₄ by a solid-state reaction using citric acid as a carbon source. The electric conductivity of the synthesized LiFePO₄ has been raised by eight orders of magnitude from 10⁻⁹ S cm⁻¹. The LiFePO₄/C composite shows a greatly enhanced rate performance and the cyclic stability at room temperature. It delivers an initial discharge capacity of 128 mAh g⁻¹ at 4C, which is retained as high as 92% after 1000 cycles. In addition, the tested low temperature character is attractive. At −20 °C, the composite exhibits a discharge capacity of 110 mAh g⁻¹ at 0.1C. The homogenous morphology, the porous surface, the small particles inside and the conductive carbon observed contribute much to obtain the favorable electrochemical performance.     

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.     

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.     

The structure and electrochemical performance of LiFeBO3 as a novel Li-battery cathode material

LiFeBO₃ cathode material has been synthesized successfully by solid-state reaction using Li₂CO₃, H₃BO₃ and FeC₂O₄·2H₂O as starting materials. The crystal structure has been determined by the X-ray diffraction. Electrochemical tests show that an initial discharge capacity of about 125.8 mAh/g can be obtained at the discharge current density of 5 mA/g. When the discharge current density is increased to 50 mA/g, the specific capacity of 88.6 mAh/g can still be held. In order to further improve the electrochemical properties, the carbon-coated LiFeBO₃, C-LiFeBO₃, are also prepared. The amount of carbon coated on LiFeBO₃ particles was determined to be around 5% by TG analysis. In comparison with the pure LiFeBO₃, a higher discharge capacity, 158.3 mAh/g at 5 mA/g and 122.9 mAh/g at 50 mA/g, was obtained for C-LiFeBO₃. Based on its low cost and reasonable electrochemical properties obtained in this work, LiFeBO₃ may be an attractive cathode for lithium-ion batteries.     

Design and synthesis of high-rate micron-sized, spherical LiFePO4/C composites containing clusters of nano/microspheres

A micron-sized LiFePO₄/C composite with a spherical morphology was reduced carbothermally from precursor particles prepared by ball milling-assisted spray-drying. The specific capacity of the electrode at a 10 C (1700 mA/g) rate was 110 mAh/g and a high voltage plateau was achieved. The high-rate performance of the composite electrode was due to its unique spherical structure, comprising clusters of nano- or sub-micron-sized spherical particles. This morphology increases the effective conductive surface area, reduces the charge-transfer reaction resistance and improves the diffusion of lithium ions.     

Continuous synthesis of lithium iron phosphate (LiFePO4) nanoparticles in supercritical water: Effect of mixing tee

Continuous supercritical hydrothermal synthesis of olivine (LiFePO₄) nanoparticles was carried out using mixing tees of three different geometries; a 90° tee (a conventional Swagelok^® T-union), a 50° tee, and a swirling tee. The effects of mixing tee geometry and flow rates on the properties of the synthesized LiFePO₄, including particle size, surface area, crystalline structure, morphology, and electrochemical performance, were examined. It was found that, when the flow rate increased, the particle size decreased; however, the discharge capacity of the particles synthesized at the high flow rate was lower due to the enhanced formation of Fe³⁺ impurities. The use of a swirling tee led to smaller-sized LiFePO₄ particles with fewer impurities. As a result, a higher discharge capacity was observed with particles synthesized with a swirling tee when compared with discharge capacities of those synthesized using the 90° and 50° tees. After carbon coating, the order of initial discharge capacity of LiFePO₄ at a current density of 17 mA/g (0.1C) and at 25 °C was swirling tee (149 mAh/g) > 50° tee (141 mAh/g) > 90° tee (135 mAh/g). The carbon-coated LiFePO₄ synthesized using the swirling tee delivered 85 mAh/g at 20C-rate and at 55 °C.     

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 bare and Ta-substituted Nb2O5 nanostructures

In this work, bare and Ta-substituted Nb₂O₅ nanofibers are prepared by electrospinning followed by sintering at temperatures in the 800–1100 °C range for 1 h in air. Obtained bare and Ta-substituted Nb₂O₅ polymorphs are characterized by X-ray diffraction, scanning electron microscopy, density measurement, and Brunauer, Emmett and Teller surface area. Electrochemical properties are evaluated by cyclic voltammetry and galvanostatic techniques. Cycling performance of Nb₂O₅ structures prepared at temperature 800 °C, 900 °C, and 1100 °C shows following discharge capacity at the end of 10th cycle: 123, 140, and 164 (±3) mAh g⁻¹, respectively, in the voltage range 1.2–3.0 V and at current rate of 150 mA g⁻¹ (1.5 C rate). Heat treated composite electrode based on M-Nb₂O₅ (1100 °C) in argon atmosphere at 220 °C, shows an improved discharge capacity of 192 (±3) mAh g⁻¹ at the end of 10th cycle. The discharge capacity of Ta-substituted Nb₂O₅ prepared at 900 °C and 1100 °C showed a reversible capacity of 150, 202 (±3) mAh g⁻¹, respectively, in the voltage range 1.2–3.0 V and at current rate of 150 mA g⁻¹. Anodic electrochemical properties of M-Nb₂O₅ deliver a reversible capacity of 382 (±5) mAh g⁻¹ at the end of 25th cycle and Ta-substituted Nb₂O₅ prepared at 900 °C, 1000 °C and 1100 °C shows a reversible capacity of 205, 130 and 200 (±3) mAh g⁻¹ (at 25th cycle) in the range, 0.005–2.6 V, at current rate of 100 mA g⁻¹.     

Effect of CeO2-coating on the electrochemical performances of LiFePO4/C cathode material

The effect of CeO₂ coating on LiFePO₄/C cathode material has been investigated. The crystalline structure and morphology of the synthesized powders have been characterized by XRD, SEM, TEM and their electrochemical performances both at room temperature and low temperature are evaluated by CV, EIS and galvanostatic charge/discharge tests. It is found that, nano-CeO₂ particles distribute on the surface of LiFePO₄ without destroying the crystal structure of the bulk material. The CeO₂-coated LiFePO₄/C cathode material shows improved lithium insertion/extraction capacity and electrode kinetics, especially at high rates and low temperature. At −20 °C, the CeO₂-coated material delivers discharge capacity of 99.7 mAh/g at 0.1C rate and the capacity retention of 98.6% is obtained after 30 cycles at various charge/discharge rates. The results indicate that the surface treatment should be an effective way to improve the comprehensive properties of the cathode materials for lithium ion batteries.     

An optimized Ni doped LiFePO4/C nanocomposite with excellent rate performance

Both Ni doping and carbon coating are adopted to synthesize a nano-sized LiFePO₄ cathode material through a simple solid-state reaction. It is found that the Ni²⁺ has been successfully doped into LiFePO₄ without affecting the phospho-olivine structure from the XRD result. The images of SEM and TEM show that the size of particles is distributed in the range of 20-60 nm, and all the particles are coated with carbon completely. The results of XPS show the valence state of Fe and Ni in the LiFePO₄. The electronic conductivity of the material is as high as 2.1 × 10⁻¹ S cm⁻¹, which should be ascribed to the coefficient of the conductive carbon network and Ni doping. As a cathode material for lithium-ion batteries, the Ni doped LiFePO₄/C nanocomposite delivers a discharge capacity of 170 mAh g⁻¹ at 0.2 C, approaching the theoretical value. Moreover, the material shows excellent high-rate charge and discharge capability and long-term cyclability. At the high rates of 10 and 15 C, this material exhibits high capacities of 150 and 130 mAh g⁻¹, retaining 95% after 5500 cycles and 93% after 7200 cycles, respectively. Therefore, the as-prepared material is capable of such large-scale applications as electric vehicles and plug-in hybrid electric vehicles.     

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.     

Improving the rate performance of LiFePO4 by Fe-site doping

LiFePO₄ doped by bivalent cation in Fe-sites show improved rate performance and cyclic stability. Under 10 C rate at room temperature, the capacities of LiFe_0.9M_0.1PO₄ (M = Ni, Co, Mg) maintain at 81.7, 90.4 and 88.7 mAh/g, respectively, in comparison with 53.7 mAh/g for undoped LiFePO₄ and 54.8 mAh/g for carbon-coated LiFePO₄ (LiFePO₄/C). The capacity retention is 95% after 100 cycles for doped samples while this value is only 70% for LiFePO₄ and LiFePO₄/C. Such a significant improvement in electrochemical performance should be partially related to the enhanced electronic conductivities (from 2.2 × 10⁻⁹ to <2.5 × 10⁻⁷ S cm⁻¹) and probably the mobility of Li⁺ ions in the doped samples.     

Aqueous processing based novel composite electrode for Li-ion batteries using an environmentally benign binder

Along with the high energy density and safer battery materials, easy and environment benign electrode processing is also one of the major concerns for the battery manufacturing industries. Therefore, herein, water-based electrode processing is used which reduces manufacturing cost and makes easy and cost-effective recycling of discarded batteries. In addition, the increasing use of Li-ion batteries from portable electronics to electric vehicles has imposed a threat to the environment due to hazardous materials used. The present study also focuses on the replacement of polyvinylidene difluoride (PVDF) non-conducting binder dissolves in toxic solvent N-methyl 2-pyrrolidone with water-soluble poly (3,4-ethylene dioxythiophene): poly (styrene sulfonate) (PEDOT:PSS) conducting binder. The entire study is performed on the synergistic effect of PEDOT:PSS with multi-walled carbon nanotubes (MWCNTs or MC) and carbon black (CB) on Li-ion battery performance using LiFePO₄ cathode active material. The discharge capacities were found 144 mAh g⁻¹ and 160 mAh g⁻¹ at 0.1C for composite electrodes LFP/CB-9P and LFP/MC-9P, respectively having 9 wt% PEDOT:PSS. Whereas the composite electrodes LFP/CB-10PV and LFP/MC-10PV having 10 wt% PVDF binder show only capacities 117 mAh g⁻¹ and 134 mAh g⁻¹, respectively. The composite electrode LFP/MC-9P shows the highest capacities up to 20C rate and maximum retention capacity of 84% at 5C after 500 cycles among all samples studied. Whereas electrodes prepared with PVDF binder could not perform well at more than 5C current rate, capacity retention is also found nearly 0% after 500 cycles. Therefore, superior results of PEDOT:PSS and MWCNTs with LiFePO₄ propose an environmentally benign composite electrode of next generation Li-ion batteries for electric vehicles.     

Synthesis of LiFePO4/C cathode material from ferric oxide and organic lithium salts

LiFePO₄/C cathode material has been simply synthesized via a modified in situ solid-state reaction route using the raw materials of Fe₂O₃, NH₄H₂PO₄, Li₂C₂O₄ and lithium polyacrylate (PAALi). The sintering temperature of LiFePO₄/C precursor is studied by thermo-gravimetric (TG)/differential thermal analysis (DTA). The physical properties of LiFePO₄/C are then investigated through analysis using by X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscope (TEM) and the electrochemical properties are investigated by electrochemical impedance spectra (EIS), cyclic voltammogram (CV) and constant current charge/discharge test. The LiFePO₄/C composite with the particle size of ∼200 nm shows better discharge capacity (156.4 mAh g⁻¹) than bare LiFePO₄ (52.3 mAh g⁻¹) at 0.2 C due to the improved electronic conductivity which is demonstrated by EIS. The as-prepared LiFePO₄/C through this method also shows excellent high-rate characteristic and cycle performance. The initial discharge capacity of the sample is 120.5 mAh g⁻¹ and the capacity retention rate is 100.6% after 50 cycles at 5 C rate. The results prove that the using of organic lithium salts can obtain a high performance LiFePO₄/C composite.     

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.