Eunryeol
Lee‡
a,
Dae-Hyung
Lee‡
ab,
Stéphanie
Bessette
c,
Sang-Wook
Park
ab,
Nicolas
Brodusch
c,
Gregory
Lazaris
c,
Hojoon
Kim
ab,
Rahul
Malik
d,
Raynald
Gauvin
c,
Dong-Hwa
Seo
*ab and
Jinhyuk
Lee
*c
aSchool of Energy and Chemical Engineering, Ulsan National Institute of Science and Technology (UNIST), 50 UNIST-Gil, Ulsan 44919, Republic of Korea
bDepartment of Materials Science and Engineering, Korea Advanced Institute of Science and Technology (KAIST), 291 Daehak-ro, Daejeon 34141, Republic of Korea. E-mail: dseo@kaist.ac.kr
cDepartment of Mining and Materials Engineering, McGill University, Montreal, QC H3A 0C5, Canada. E-mail: jinhyuk.lee@mcgill.ca
dOffice of Energy Research and Development, Natural Resources Canada, Ottawa, ON, Canada
First published on 27th March 2024
The global transition to electric vehicles and large-scale energy storage systems requires cost-effective and abundant alternatives to commercial Co/Ni-based cathodes (e.g., LiNi0.6Mn0.2Co0.2O2) for Li-ion batteries (LIBs). Manganese-based disordered rock-salts (Mn-DRXs) can outperform conventional cathodes at lower cost, achieving >900 W h kg-AM−1 (per active material, AM), but such performance has been demonstrated exclusively in cell constructions far removed from commercial viability, namely with diluted electrode films (∼70 wt%-AM) containing excessive carbon and binder. Herein, our work involves a comprehensive study to attain AM-concentrated Mn-DRX cathodes (>95 wt%-AM), covering from inherent material properties to the microstructure of electrodes, to address the formidable challenges in Mn-DRX research. We reveal that Mn-DRXs’ failures in AM-concentrated electrodes originate from their extremely low electrical conductivity (10−10–10−8 S cm−1) and the collapse of the electrical network with volume change over cycling. These failure modes are resolved through electrical percolation engineering and enhancement of electrode mechanical properties, allowing our demonstration of nearly all-AM Mn-DRX cathodes (∼96 wt%-AM) and the highest application-level energy density (∼1050 W h kg-cathode−1) reported to date. This work further unveils the trade-off role of Mn-content on Mn-DRXs’ electrical conductivity and volume change, providing guidelines for material design to advance Co/Ni-free LIBs’ technology readiness.
Broader contextThe quest for lower $ per kWh in Li-ion batteries (LIBs) hinges on the advancement of high-energy cathodes that sidestep supply-constrained elements like Co and Ni. Mn-based disordered rock-salts (Mn-DRXs) emerge as promising contenders, boasting exceptional energy densities (>900 W h kg−1 of active material, AM) and leveraging Mn, an abundant and sustainable resource. Despite their potential, Mn-DRXs have primarily been explored in cathode films with diluted AM content (∼70 wt%-AM), laden with a substantial amount of carbon (15–30 wt%) and binder (5–10 wt%). This configuration diminishes electrode/cell-level energy density and obscures issues in practical cathode films featuring high AM content and loading. This study delves into critical failure mechanisms in Mn-DRX cathodes with elevated AM concentration and tackles these challenges head-on to showcase nearly all-AM Mn-DRX cathodes with the highest application-level energy density (>95 wt%-AM, >1000 W h kg-cathode−1), propelling the advancement of Ni- and Co-free LIBs. |
By delivering higher energy density (>900 W h kg-AM−1 per active material, AM) than the layered oxides (∼770 W h kg-AM−1) with the affordability of LiFePO4 (a cheap albeit low energy-density cathode, ∼580 W h kg-AM−1),5 Mn-based cation-disordered rock-salts (Mn-DRXs, e.g., Li2MnO2F,6 Li2Mn1/2Ti1/2O2F,7 and Li1.68Mn1.60O3.7F0.38) made of cheaper metals (Mn, Ti, etc.) than Ni and Co (Fig. 1(a)) are one of only a handful of Co/Ni-free cathode materials with one of the lowest projected cost per energy-stored ($ per W h),9 that can shift the current cathode market-share. However, these materials’ promising performance has been demonstrated in highly diluted cathode films with large amounts of carbon black (15–30 wt%, CB) and binder (5–10 wt%, such as polyvinylidene fluoride, PVDF),7–15 acting as the conductive additive and glue. Testing AM in a diluted film conceals problems evident in practical films and cells with minimized CB/binder content (e.g., ∼2 wt% CB, ∼2 wt% binder), problems that persist and limit materials’ usage in practical LIBs even if AM-level problems are solved.7,9,10,16–18 Moreover, diluting an electrode limits the practical energy density gain at the electrode or cell level (W h kg-electrode/cell−1, W h l-electrode/cell−1) (Fig. 1(b)). For instance, Li1.68Mn1.60O3.7F0.3 could deliver nearly 1100 W h kg-AM−1 but only in a 70 wt%-AM film (AM is only ∼70 wt% of the electrode),8 resulting in cathode energy density of ∼770 W h kg-cathode−1, a marginal improvement over commercial Ni/Co-based layered cathodes (∼740 W h kg-cathode−1, ∼770 W h kg-AM−1) cycling with a small amount of CB and binder.9
Herein, we investigate the behavior of Mn-DRXs in an AM-concentrated cathode using experiments and computational modeling. The materials’ low electrical conductivity and volume-change-driven electrode disintegration (electrochemical fatigue) limit Mn-DRXs’ capacity and accelerate the capacity fading in an AM-concentrated cathode made with CB as the conductive additive. However, we demonstrate that replacing CB with multiwalled carbon nanotubes (MWCNT) and changing the binder type enable nearly all-AM Mn-DRX cathodes (to 96 wt% AM) that achieve >1050 W h kg-cathode−1, by enhancing the electrical percolation and mechanical properties of the composite electrode. Moreover, we reveal the counteracting role of Mn-content in Mn-DRXs for the electrical conductivity and volume change during cycling to provide further guidelines toward optimized all-AM Mn-DRX cathodes for high-performance Co/Ni-free LIBs.
Mn-DRXs have been exclusively cycled in diluted electrodes with excessive conductive additives and binder.7,9,10,20 To examine their behavior in an AM-concentrated electrode, we prepared LMOF and LMTO films with different electrode compositions by using CB and PVDF as the conductive additives and binder: 70:20:10 (AM:CB:PVDF, by wt%), 80:10:10, and 90:5:5. Increasing the AM content in the electrode decreases the electrode thickness upon achieving a similarly loaded (i.e., mg-cathode cm−2) electrode for a higher density (∼3.96 kg l−1) of LMOF (or any Mn-DRX) than CB (∼1.8 kg l−1) (Fig. S2, ESI†), which would appear beneficial if one only considers transport distance of Li+ or electrons. Fig. 2(a)–(c) show LMOF's voltage profiles in the 70:20:10, 80:10:10, and 90:5:5 films (25 mA g-AM−1, 1.5–4.8 V, room temperature). The mass loading of these electrodes was consistently maintained at ∼5 mg-cathode cm−2. In the 70:20:10 film, LMOF delivers 370 mA h g-AM−1 upon 1st discharging, and its capacity decreases to 327 and 268 mA h g-AM−1 after 5 and 25 cycles. Meanwhile, the LMOF 80:10:10 electrode delivers 335, 239, and 38 mA h g-AM−1 in the 1st, 5th, and 25th cycle, showing smaller capacity and drastically faster capacity fading. Also, LMOF in the 90:5:5 film achieves only 77, 39, and 23 mA h g-AM−1 in the 1st, 5th, and 25th cycle. Finally, LMOF's capacity at a higher rate of 250 mA g-AM−1 also decreases significantly without electrode dilution, demonstrating 325 mA h g-AM−1 in the 70:20:10 film but no capacity at all in the 90:5:5 film (Fig. S3, ESI†). Note that the achieved capacity and its retention of these LMOF:CB:PVDF electrodes are sensitive to the calendering (electrode roll pressing) process and become significantly worse without it (Fig. S4, ESI†), which is necessary for intimate contact between AM, CB, and PVDF particles and reduced electrode porosity.21
Fig. 2 The electrochemical properties of LMOF and LMTO (under different electrode compositions) and their electrical conductivities. (a)–(c) The voltage profiles and the capacity retention of LMOF when cycled at 25 mA g-AM−1 between 1.5–4.8 V in (a) a 70:20:10 (AM:CB:PVDF, by weight), (b) 80:10:10, and (c) 90:5:5 electrode film. (d)–(f) The Nyquist plots of LMOF/Li-metal half-cells before cycle (black) and after 10 cycles (red) at 25 mA g-AM−1 between 1.5–4.8 V in a (d) 70:20:10, (e) 80:10:10, and (f) 90:5:5 film (short dash: experimental values, line: fitted values): cathode/electrolyte and solid/electrolyte interfacial resistance (Rfilm), charge-transfer resistance of cathode (Rct(cathode)) or anode (Rct(anode)), and Warburg resistance. Z-Fitting details are explained in Methods and Fig. S5 (ESI†). The ‘≈’ notation represents the dominant resistance in the mixed contribution of various resistances, supported by DRT analysis in Fig. S6 and S7 (ESI†). (g) The first cycle voltage profiles and the capacity retention of LMTO when cycled at 20 mA g-AM−1 between 1.5–4.8 V in a 70:20:10, 80:10:10, and 90:5:5 film. The DC polarization test results of (h) LMOF and (i) LMTO for electrical conductivity measurements: insets show the image of LMOF and LMTO pellets used in this test. |
LMOF's poorer performance in the AM-concentrated electrodes arises from significantly increased charge-transfer resistance.22,23Fig. 2(d)–(f) show the Nyquist plots of LMOF/Li-metal half-cells before cycling and after 10 cycles (1.5–4.8 V, 25 mA g-AM−1) with the 70:20:10, 80:10:10, and 90:5:5 LMOF:CB:PVDF electrodes. With the 70:20:10 electrode, the (depressed) semi-circle in the high- and medium-frequency range, corresponding to the sum of charge-transfer resistances of the cathode and anode (Rct(cathode) & Rct(anode)) and electrode/electrolyte film resistances (Rfilm from cathode/electrolyte interface, CEI, and solid–electrolyte interface, SEI) has ∼55 Ω diameter before cycling and slightly increases to ∼920 Ω after 10 cycles dominantly by the Rct(cathode) changes. We provide more detailed interpretations of the results in the ESI† by using the distribution of relaxation times (DRT) measurement (Fig. S6 and S7, ESI†). Before cycling, the LMOF/Li cell using the 80:10:10 LMOF film also shows a small diameter of ∼75 Ω at the same frequency range, which increases to nearly ∼10000 Ω after 10 cycles (vs. ∼920 Ω in the 70:20:10 case), primarily due to the substantially greater LMOF charge-transfer degradation, elucidating the origin of LMOF's smaller capacity and accelerated capacity loss in the 80:10:10 film (Fig. 2(b)). For the 90:5:5 film, the resistance already starts much higher at ∼1600 Ω and reaches ∼9200 Ω after 10 cycles (Fig. 2(f)). In the ESI,† we present Nyquist plots of these LMOF/Li cells obtained at different states of charge, illustrating the consistent trend of significantly higher resistances from the LMOF film with a higher AM content (Fig. S8, ESI†). LMTO exhibits similar behavior to LMOF. LMTO's capacity decreases from ∼250 mA h g-AM−1 to ∼170 and 0 mA h g-AM−1 as the electrode composition changes from 70:20:10 to 80:10:10 and 90:5:5, indicating even severer performance degradation in a concentrated film than LMOF (Fig. 2(g)). Also, LMTO's capacity retention declines drastically with higher AM content.
Using the DC polarization method, we evaluated the electrical conductivity of LMOF and LMTO pellets as low AM conductivities can limit the charge-transfer reaction in a concentrated film with low CB content (Fig. 2(h) and (i)). Our numbers here serve as reference points instead of the most accurate values, as the electrical conductivity can be measured slightly differently by the measurement method and particle microstructure (Fig. S9, ESI†). We measured ∼5.76 × 10−8 S cm−1 for LMOF and ∼1.51 × 10−10 S cm−1 for LMTO, noticeably smaller values than conventional layered oxides like LiNi0.8Mn0.1Co0.1O2 (∼1.1 × 10−3 S cm−1, Fig. S10, ESI†) and even lower for LMTO than LiFePO4 (∼5 × 10−8 S cm−1) notorious for its poor electrical conductivity.24 In particular, LMTO has ∼380 times lower conductivity than LMOF, consistent with the lighter color of LMTO than LMOF (insets in Fig. 2(h) and (i)), explaining why LMTO's performance depends more on the CB content than LMOF.
Note that in addition to the poor electrical conductivity of the AM particles limiting electron transfer, suppressed Li+ transport along the electrode pores may also contribute to increased charge-transfer resistance by reducing the number of Li+–e− recombination sites at the electrode/electrolyte interface. However, our use of the typical carbonate electrolyte (1 M LiPF6 in EC:DMC = 1:1) with low viscosity and relatively thin electrodes (30–40 μm, Fig. S2, ESI†) for the impedance tests facilitates electrolyte soaking into the electrode to mitigate the Li+ accessibility problem. Consequently, the observed increase in charge-transfer resistance and lower capacities in the electrode with a smaller CB content (higher AM content) are most likely attributed to the poor electrical conductivity of the AM. This is also supported by our galvanostatic intermittent titration technique (GITT) test, demonstrating that the difference in the overpotential of charging the LMOF:CB:PVDF electrodes with varying ratios is predominantly attributed to non-Warburg-related resistances, rather than Li-transport-related Warburg resistances (Fig. S11, ESI†).
While low AM's electrical conductivities paired with limited CB percolation explain smaller capacities of LMOF and LMTO in an AM-concentrated electrode, we find their faster capacity loss in the concentrated electrode mainly stems from electrode disintegration during cycling (i.e., electrochemical fatigue), degrading the AM/CB and CB/CB contacts more significantly in the AM-concentrated film (thus damaging the electrical percolation in the electrode) and allowing CEI layers to form. Fig. 3(d)–(f) are SEM images of the cross-section of the 80:10:10 LMOF electrode before cycling and after 5 and 20 cycles (1.5–4.8 V, 25 mA g-AM−1), respectively. The white, gray, and black regions correspond to LMOF, CB/PVDF, and pores. Intimate contacts are seen between LMOF and CB/PVDF in the electrode before cycling (Fig. 3(d)), but many pores appear (already) after 5 cycles that loosen the LMOF/CB and CB/CB contacts (Fig. 3(e)). After 20 cycles, significant pore accumulation occurs in the electrode on certain regions (Fig. 3(f)). Also, we observe crack-generation and propagation upon cycling (Fig. 3(d)–(f), bottom images), making the 20-cycled 80:10:10 electrode highly fragile (Fig. S12, ESI†). Note that electrode porosity or cracks may develop by electrolyte soaking to the electrode alone,27 but our electrolyte soaking test suggests that this should not be the main cause of the electrode disintegration during our cycling tests (Fig. S13, ESI†).
Electrode disintegration via electrochemical fatigue is commonly observed in layered oxide cathodes due to stress and strain built within the electrode, induced by the AM's 2–3% volume change upon cycling.28,29 However, volume change can reach nearly 10% for some Mn-DRXs. In particular, LMOF exhibits nearly ∼8.4% volume change during cycling according to our XRD analysis (Fig. S14–S16, ESI†), consistent with the number (∼8.3%) from Ceder et al.:8 note that volume change analysis of Mn-DRXs based on XRD may not be most accurate due to broad XRD peaks from the Mn-DRXs’ pulverized particle morphology and structure amorphization upon mixed Mn- and O-redox processes during cycling, leaving a certain degree of arbitrariness in XRD refinement. Yet, lattice parameters and thus volume are among the most reliable information from XRD analysis, and we report these volume change numbers (%) as particle-ensemble-averaged reference numbers, not as the most precise values, obtaining which deserves dedicated research. When the electrode is diluted, AM volume change has a mitigated effect on AM performance and electrode integrity. Excessive CB and binder buffer the stress, provide strong adhesion between components, maintain electrical percolation even if some AM/CB or CB/CB contacts are lost, and slow down the CEI resistance growth during cycling, but these benefits disappear in AM-concentrated electrodes. This explains our observation of (i) large cracks for the 80:10:10 LMOF electrode after cycling (Fig. 3(f) and Fig. S17, ESI†) but not for the 70:20:10 electrode (Fig. S17, ESI†) and (ii) the faster capacity loss from non-Warburg-related (e.g., charge-transfer) resistances with smaller CB/PVDF content (Fig. 2).
Fig. 4(a) and (b) show the EDS maps and SEM images of the 90:5:5 electrode made with LMOF, MWCNT, and PVDF before and after 5 cycles (1.5–4.8 V, 25 mA g-AM−1). The blue area in the EDS map is from MWCNT and PVDF. Unlike the case of CB (Fig. 3(c)), we observe percolating MWCNT/PVDF throughout the 90:5:5 electrode, which facilitates electron transport and improves the electrode's mechanical strength. In turn, the LMOF electrodes with MWCNT show remarkably high capacities and energy density of >360 mA h g-AM−1 and ∼1090 W h kg-AM−1 (∼4330 W h l-AM−1: calculated based on the theoretical crystal density of LMOF, 3.96 kg l−1) even as the AM content increases to 96 wt% (Fig. 4(c)) without any noticeable difference in the capacity retention (∼65%) over 30 cycles (1.5–4.8 V, 25 mA g-AM−1), strikingly better than the 80:10(CB):10 LMOF electrode showing <50 mA h g-AM−1 (∼11% retention) after 25 cycles (Fig. 2(b)). This improved capacity retention with MWCNT (vs. CB) is due to much-suppressed impedance growth upon cycling (Fig. S22, ESI†). Also, with MWCNT, the rate capability of even the 96 wt%-AM LMOF electrode in Fig. S23 (ESI†) is impressive, delivering 244 mA h g-AM−1 and 194 mA h g-AM−1 at 2 A g-AM−1 and 4 A g-AM−1, respectively. Note that the as-made LMOF(90):MWCNT(5):PVDF(5) and LMOF(96):MWCNT(2):PVDF(2) electrodes discussed above have the electrode porosity of 13.53% and 16.65%, respectively, and their loading density was ∼5 mg-cathode cm−2 (Fig. S24, ESI†). Many electrode-processing factors, such as calendering, loading (mg cm−2), electrode thickness, and the amount of residual basic Li species (e.g., LiOH, Li2CO3 generated upon air exposure or non-fully reacted Li precursors), can further affect the cycling performance, which is discussed in the ESI†(Fig. S2, S4, and S25, S26).21,32–34 Of note, we find that the MWCNT-based electrode's performance is much less sensitive to the calendering process than the CB-based electrode (Fig. S4, ESI†). Finally, MWCNT's morphology influences the enhancement in performance (Fig. S27, ESI†). MWCNTs with lower tap density appear more effective than those with higher tap density, facilitating intimate mixing between the AM and carbon and resulting in a larger AM/carbon contact area during electrode preparation. These morphology effects observed with different carbons, such as MWCNT and graphene, warrant dedicated studies in the future.
We still observe some pore generation for the 90:5(MWCNT):5 LMOF electrode (1.5–4.8 V, 25 mA g-AM−1, after 5 cycles) during cycling, seen as white regions in the EDS map or black areas in the SEM image (Fig. 4(a) and (b)). Such residual porosity increase may constitute remaining capacity fading along with LMOF's AM-level problems. Meanwhile, unlike the highly fragile 80:10(CB):10 LMOF electrode after 20 cycles, the 92:4(MWCNT):4 electrode does not display such fragility, indicating improved mechanical property even with less binder (Fig. S12, ESI†). The cross-sectional SEM analysis (Fig. S28, ESI†) confirms the improved mechanical properties of the MWCNT-based electrode, in which crack-generation and pore-propagation are barely seen even in the 96:2(MWCNT):2 electrode after 20 cycles, likely because the vine-like MWCNT entangles with other components to hold them together, as in CNT metal matrix composites.35,36 Moreover, our electrode peeling test shows ∼70% higher load needed to peel off the 96:2(MWCNT):2 electrode than the 96:2(CB):2 electrode, confirming improved electrode mechanical properties with MWCNT (Fig. S26, ESI†).
We also applied MWCNT to LMTO and Li1.25Mn0.75O1.33F0.67 (LLF,37 full DRX, Fig. S29, ESI†). Even the 96:2(MWCNT):2 LMTO electrode delivers ∼220 mA h g-AM−1 (∼673 W h kg-AM−1, ∼2560 W h l-AM−1) with similar capacity retention as the 70:20(MWCNT):10 and 90:5(MWCNT):5 electrodes (1.5–4.8 V, 20 mA g-AM−1), contrary to the 90:5(CB):5 electrode showing zero capacity (Fig. 4(d) and 2(g)). Meanwhile, the 1st-discharge-capacity reduction with higher AM content (less MWCNT) is more pronounced for LMTO than LMOF, considering that LMOF's capacity reduction is ∼7% in the 70:20(MWCNT):10 and 96:2(MWCNT):2 electrodes but ∼14% for LMTO (Fig. S30, ESI†). This trend correlates well with the ∼380 times poorer electrical conductivity of LMTO than LMOF, making its capacity more sensitive to the carbon amount (here MWCNT). In this regard, LMTO's rate capability in the MWCNT electrode also depends more on the MWCNT amount than LMOF (Fig. S23, ESI†).
Similarly, LLF delivers ∼250 mA h g-AM−1 (∼786 W h kg-AM−1, ∼3000 W h l-AM−1) even in the 96:2(MWCNT):2 electrode (Fig. 4(e)), which is impossible with CB (Fig. S31, ESI†). However, unlike LMOF and LMTO, LLF's capacity retention becomes notably poorer with 94 wt%-AM or 96 wt%-AM (Fig. 4(e)). The relative capacity retention after 30 cycles of the LLF electrode with 96 wt%-AMvs. 70 wt%-AM is only ∼81%, while that of LMOF and LMTO electrodes are ∼100% and ∼98%, respectively (Fig. S30, ESI†). This appears contradictory as LLF (∼1.52 × 10−9 S cm−1) has 10 times higher electrical conductivity than LMTO, but LLF shows a much larger volume change (∼7%) than LMTO (∼4.3%) during cycling to promote the electrode disintegration more significantly. Interestingly, the volume change of LMOF (∼8.4%) is slightly larger than LLF, but the MWCNT-based LMOF electrode exhibits nearly the same capacity retention between the 96 wt%-AM and 70 wt%-AM cases. This difference is most likely due to the much higher electrical conductivity of LMOF than LLF (by ∼38 times) and LMTO (by ∼380 times), enabling LMOF to better carry currents itself (in addition to MWCNT) to maintain electrical conduction in the electrode even with some porosity increase. Thus, for stable capacity in the AM-concentrated electrode, Mn-DRX must be either more electrically conductive, have a small volume change, or be assembled in a highly stable electrode composite matrix such that a given AM-volume change leads to smaller degradation of the electrode and electrical percolation. In this regard, binders with higher adhesive strength, such as styrene–butadiene rubber (SBR)/sodium salt of carboxymethyl cellulose (CMC) and high-molecular-weight PVDF, can further improve the capacity retention of a highly AM-concentrated Mn-DRX electrode by improving the mechanical stability of the composite electrode. For instance, after 50 cycles (1.5–4.8 V, 25 mA g-AM−1), LMOF's capacity retention in the 96:2(MWCNT):2 electrode improves from 47% to 64% as the PVDF5130 binder (that we used to make all electrodes except for this test) is replaced with SBR/CMC binder (Fig. S32, ESI†). Also, this stronger adhesion with SBR/CMC binder leads to a nearly two times higher load needed to peel off the 96:2(MWCNT):2(SBR/CMC) electrode than the 96:2(MWCNT):2(PVDF) electrode (Fig. S26, ESI†).
Using the 92:4(MWCNT):4(PVDF) electrode, we evaluated the performance of Mn-DRX cathodes in a full cell with a graphite anode. (Fig. 4(f)) The Li1.68Mn1.30Ti0.30O3.7F0.3 (T30) and Li1.68Mn1.15Ti0.45O3.7F0.3 (T45), Ti-doped versions of partially ordered LMOF, were used in this test, as they exhibit better capacity/voltage-retention, reduced transition-metal (TM) dissolution, and higher coulombic efficiency than LMOF, rendering them more suitable for the full-cell tests.38 The half-cell performance of T45 in the 92:4(MWCNT):4(PVDF) electrode is shown in the ESI,† demonstrating similar performance across different cathode loading up to ∼17 mg-cathode cm−2 (Fig. S25, ESI†). When cycled in a full cell between 1.0–4.55V (in Fig. 4(f), or 1.0–4.75 V in Fig. S35, ESI†) at 25 mA g-AM−1, T30 and T45 achieve 689 W h kg-cathode−1 (770 W h kg-cathode−1) and 675 W h kg-cathode−1 (737 W h kg-cathode−1), which are comparable to the energy density of the LiNi0.8Co0.1Mn0.1O2 cathode in a full cell (699–732 W h kg-cathode−1, depending on the upper cut-off voltage, Fig. S35, ESI†): the specific capacity and energy density of T30 and T45 reported here are based on the weight of the T30 and T45 after pre-lithiation of the compounds required to achieve a high capacity in a full cell, where (unlike in a half-cell) over-lithiation of the partially ordered (initially Li-vacancy containing) compounds during the first discharging is not possible due to the use of a non-Li-containing graphite anode. Furthermore, 92:4(MWCNT):4 T30 and T45 electrodes show 202 mA h g-AM−1 and 162 mA h g-AM−1 discharge capacity in a full cell with 53% and 70% capacity retention over 200 cycles at a high current of 0.75 A g-AM−1 (∼4C rate, 1.0–4.75 V, Fig. 4(f), bottom), respectively. This corresponds to energy densities of 503 W h kg-cathode−1 (power density of 670 W kg-cathode−1) for T30 and 386 W h kg-cathode−1 (power density of 673 W kg-cathode−1) for T45. In the ESI,† we also show the full-cell performance of other Mn-DRX-MWCNT electrodes (Fig. S36, ESI†).
We explore this further and find that Mn-content correlates well with the Mn-DRX's electrical conductivity; thus, keeping the content high would be beneficial. Fig. 5(a) shows the electrical conductivities of Li+–Mn3+–Ti4+–O2− and Li+–Mn3+–Nb5+–O2− pellets: note the trend is more important here than the absolute measured values as they can slightly change with different measurement techniques and particle morphology (Fig. S9, ESI†). As the Li-excess level increases from 10% to 20% and 30%, electrical conductivity decreases from 2.62 × 10−8 S cm−1 to 1.51 × 10−10 S cm−1 and 3.60 × 10−11 S cm−1 for Li+–Mn3+–Ti4+–O2−; and 2.29 × 10−8 S cm−1 to 7.35 × 10−9 S cm−1 and 4.12 × 10−10 S cm−1 for Li+–Mn3+–Nb5+–O2−, thus showing a lower electrical conductivity with higher Li-excess (reduced Mn-content). Interestingly, Li+–Mn3+–Nb5+–O2− exhibits higher conductivities than Li+–Mn3+–Ti4+–O2− when highly Li-excessed, with ∼50 times greater value at the 20% Li-excess level. Ti4+ and Nb5+ are d0 TM species without d electrons, making them not oxidizable upon cathode charging to participate in charging-induced hole polaron conduction (to be discussed below). Also, they barely constitute valence or conduction bands of Mn3+-DRXs (Fig. S45, ESI†), limiting their participation in thermally excited charge-carriers conduction as well. Therefore, such a difference in electrical conductivity is most likely due to a higher Mn-content in Li+–Mn3+–Nb5+–O2− than Li+–Mn3+–Ti4+–O2− at the same Li-excess level. For instance, at 20% Li-excess level, Mn-content is Mn0.6 (Li1.2Mn0.6Nb0.2O2) for Li+–Mn3+–Nb5+–O2−; whereas it is Mn0.4 (Li1.2Mn0.4Ti0.4O2) for Li+–Mn3+–Ti4+–O2−.
This trend is consistent with our theoretical study on electrical conduction in Mn-DRXs using DFT calculations and Monte Carlo (MC) percolation simulation. Electrical conduction can stem from ionic and electronic (electron, hole) transport. Here we consider charging-induced hole transport as the primary conductivity source, as holes are naturally introduced upon charging the cathode. Ionic conduction should be a minor source for our samples. Otherwise, the electrical conductivity would rather increase with higher Li-excess due to improved Li+ diffusion through the 0-TM percolation network.11
As the Fermi level of Mn-DRXs lies within the Mn 3d band in the discharge state, we calculated the hole polaron hopping barrier through connected Mn sites (Fig. 5(b)). For this calculation, we prepared a cation-mixed LiMnO2 model structure containing symmetric edge-shared and corner-shared Mn–Mn octahedra. We find that the hole polaron hopping barrier is lower when the Mn–Mn octahedra are edge-shared (∼190 meV per h+) rather than corner-shared (∼220 meV per h+), implying that hole conduction would be faster in Mn-DRXs if the crystal structure had more edge-shared Mn-octahedra. The corner-shared path may also contribute to the conduction, as the energy gap (30 meV per h+) between the edge-shared and corner-shared Mn–Mn paths is not high.
Since hole polaron conduction in Mn-DRX benefits from continuously connected Mn-sites, we studied the percolation property of Mn-sites in the two types of DRX model structures using MC percolation simulation for random cation order and Markov Chain MC (MCMC) percolation simulation considering short-range order (SRO). Fig. 5(c) shows the percolation probability of “edge-shared” Mn-sites in Li+–Mn3+–Ti4+–O2− and the average percolated Mn-content per stoichiometric O2 within the percolation network. Regarding the structure with a random cation order, the percolation probability drastically decreases from 100% to 50%, and 0% as the Li-excess level increases from 10% (Li1.1Mn0.7Ti0.2O2) to 20% (Li1.2Mn0.4Ti0.4O2) and 30% (Li1.3Mn0.1Ti0.6O2). Moreover, the average percolated Mn-content per O2 within the percolation network also significantly decreases with higher Li-excess (lower Mn-content). Adding the “corner-shared” Mn octahedra in the simulation (Fig. 5(d)), the percolation probability remains near 100% for both Li1.1Mn0.7Ti0.2O2 and Li1.2Mn0.4Ti0.4O2. Nevertheless, the fraction of Mn in the percolation network decreases from 98% to 63%, suggesting that many holes on Mn generated upon charging cannot directly participate in the electrical conduction in Li1.2Mn0.4Ti0.4O2 even after accounting for both edge-sharing and corner-sharing Mn–Mn hole hopping, as visualized with representative MC structures in Fig. 5(e). In the same vein, the structure considering SRO shows the equivalent trend (Fig. 5(c) and (d)). The SRO (Mn-clustering; agglomerating Mn ions) in Li+–Mn3+–Ti4+–O2− slightly improves the Mn-percolation probability and accessible Mn-content within the network, showing an ambivalent effect of SRO that was shown to bring a “negative” impact on 0-TM percolation for Li diffusion in Mn-DRXs.19 Overall, these results support our experimental finding that the Mn-content correlates well with the electrical conductivity of Mn-DRXs.
We want to point out that at high states of charge, electron polaron conduction will prevail over hole polaron conduction due to the changes in the majority of charge carriers from holes to electrons. However, our Mn-connectivity analysis remains applicable within the states of charge where Mn3+ and Mn4+ coexist, as both holes and electrons must pass through the connected Mn-sites. One catch is when high states of charge involve O oxidation, which tends to form O–O dimers.9,39 In this case, polaron conduction would become slower, continuously reforming O–O dimers along the conduction pathways. In this regard, limiting the usage of O-redox to avoid O–O dimer formation would improve the electrical conductivity, which also suggests that higher Mn-content (thus higher Mn-redox capacity to use before O-redox) in Mn-DRXs would be beneficial.
Note that along with the cycling-induced polaronic conduction discussed above, thermally-excited conduction-band electrons and valence-band holes may also contribute to electrical conduction (although their contribution will be orders of magnitude smaller due to the large band gap in Mn-DRXs), whose degree depends on the material's band gap, band structure, and temperature. In the ESI,† we additionally discuss this thermally-excited charge-carrier conduction (Fig. S45 and S46, ESI†), showing that Mn-DRXs’ band gap decreases with a higher Mn-content to lead to the same conclusion that increasing Mn content improves the electrical conductivity of Mn-DRXs as the case of the charging-induced hole-polaronic electrical conduction.
Supposing that simultaneously improving the electrical conductivity while limiting the volume change appears impossible, we suggest prioritizing sacrificing intrinsic electrical conductivity and instead minimizing AM volume change since Mn-DRX's poor electrical conductivity can be overcome at the cathode film level by using advanced conductive additives like MWCNT, as demonstrated in this work, or carbon coating of AM. Also, in this way, one does not need to maximize the Mn-content, accompanying minimizing the Li-excess level needed to endow 0-TM percolation for facile Li diffusion in Mn-DRX, which will become progressively more important when cycling large-size Mn-DRX particles for which long-range Li diffusion is critical.44
Finally, addressing the capacity fading observed in Mn-DRX cathodes and improving their performance requires attention to additional material-level issues, such as the JT distortion around Mn3+ ions, which can promote Mn dissolution and aggravate volume changes,38,40 irreversible cation rearrangement in the bulk structure,46 and the degradation of the DRX particle surface due to side reactions with the electrolyte or oxygen loss, both of which can degrade the Li diffusion (Li+ conductivity) in Mn-DRX and cause voltage fading.9 Therefore, alongside electrode-level engineering, it is essential to incorporate additional material-level strategies to effectively mitigate these challenges. Furthermore, while this study primarily addressed electrical percolation engineering within electrodes to enhance electron transfer, additional attention should be given to engineering of the electrode's microstructure (e.g., pore size/distribution, electrode thickness) since it can affect the Li+ ion conduction (beside electrical conduction) within the electrode and the degree of side reactions with the electrolyte, which can affect both the overall capacity and capacity retention of a cathode film by modulating charge- and mass-transfer resistances and their evolution during cycling.
Footnotes |
† Electronic supplementary information (ESI) available. See DOI: https://doi.org/10.1039/d4ee00551a |
‡ These authors contributed equally to this work. |
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