WO2014051089A1 - ニッケルコバルト複合水酸化物とその製造方法および製造装置、非水系電解質二次電池用正極活物質とその製造方法、および非水系電解質二次電池 - Google Patents
ニッケルコバルト複合水酸化物とその製造方法および製造装置、非水系電解質二次電池用正極活物質とその製造方法、および非水系電解質二次電池 Download PDFInfo
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- H01M10/05—Accumulators with non-aqueous electrolyte
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- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/36—Selection of substances as active materials, active masses, active liquids
- H01M4/48—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides
- H01M4/52—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron
- H01M4/525—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
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- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M2004/026—Electrodes composed of, or comprising, active material characterised by the polarity
- H01M2004/028—Positive electrodes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
Definitions
- the present invention relates to a nickel cobalt composite hydroxide, a production method thereof, and a production apparatus.
- the present invention also provides a positive electrode active material for a non-aqueous electrolyte secondary battery using the nickel-cobalt composite hydroxide as a raw material, a method for producing the same, and a positive electrode active material for the non-aqueous electrolyte secondary battery as a positive electrode material.
- the present invention relates to a non-aqueous electrolyte secondary battery to be used.
- Lithium ion secondary batteries which are non-aqueous electrolyte secondary batteries, are frequently used to satisfy such requirements.
- As a positive electrode active material of a lithium ion secondary battery lithium cobalt composite oxide (LiCoO 2 ) that is relatively easy to synthesize is mainly used.
- the raw material for the lithium cobalt composite oxide includes rare and expensive cobalt compounds. For this reason, the unit price per capacity of a lithium ion secondary battery using lithium cobalt composite oxide as a positive electrode material has reached about four times that of a nickel metal hydride battery. Due to this high cost, the use of lithium ion batteries is currently quite limited. Therefore, reducing the cost of the positive electrode active material and making it possible to provide a cheaper lithium-ion secondary battery has a great significance for reducing the weight and size of portable electronic devices that are currently popular. .
- LiMn 2 O 4 Lithium-manganese composite oxide (LiMn 2 O 4 ) using manganese, which is cheaper than cobalt, and lithium-nickel composite oxide using nickel ( LiNiO 2 ) has been studied.
- lithium manganese composite oxide is a material that is excellent in thermal stability and safety in addition to being inexpensive as the raw material manganese.
- the theoretical capacity is only about half that of the lithium cobalt composite oxide, there is a drawback that it is difficult to meet the demand for higher capacity of the lithium ion secondary battery that is increasing year by year.
- a temperature of 45 ° C. or higher there is a drawback that self-discharge is intense and the charge / discharge life is also reduced.
- lithium-nickel composite oxides are inexpensive and stable as well as manganese, and moreover have a higher capacity than lithium-cobalt composite oxides. This is expected, and research and development is actively underway.
- the lithium ion secondary battery using a lithium nickel composite oxide composed only of lithium and nickel as a positive electrode active material has a problem that the cycle characteristics are inferior compared to the case of using a lithium cobalt composite oxide. is there. This is because the lithium-nickel composite oxide changes its crystal structure (phase transition) between hexagonal crystal and monoclinic crystal as lithium is desorbed, and the reversibility of the change is poor. For this reason, it is considered that the sites where lithium can be desorbed and inserted are gradually lost while the charge / discharge reaction is repeated.
- a reaction crystallization method As a method that enables uniform dispersion of cobalt, there is a reaction crystallization method.
- a nickel salt aqueous solution, a cobalt salt aqueous solution and a caustic alkaline aqueous solution are continuously supplied into a reaction vessel whose pH value and temperature are adjusted while controlling the concentration and flow rate.
- a continuous crystallization method is described in which the product is collected from the reaction aqueous solution overflowing from the reaction vessel to control the characteristics of the resulting nickel cobalt composite hydroxide.
- the stability of the crystal structure of the nickel-cobalt composite hydroxide is improved, and phase transfer accompanying charge / discharge is suppressed.
- the number of crystal grain boundaries that cause the destruction of the particle structure is extremely reduced, and the particles can be prevented from being refined or dropped off, so that a positive electrode active material having good cycle characteristics can be obtained.
- the batch method is more advantageous than the continuous crystallization method, but the batch method has a disadvantage that it is inferior in productivity to the continuous crystallization method.
- the batch method if it is attempted to obtain large particles of 10 ⁇ m or more by the batch method, it is necessary to increase the amount of raw material to be supplied. For this purpose, a large reaction tank must be used, and productivity is increased. It will be inferior.
- Japanese Patent Application Laid-Open No. 10-265225 and Japanese Patent Application Laid-Open No. 2003-86182 disclose a technique for collecting particles collected by continuous crystallization while classifying them.
- the reaction tank is constituted by a main body and a separation device integrally provided below the main body, and the particles grown in the main body and having increased specific gravity are separated by a separation device provided on the lower side of the main body.
- a system is disclosed that classifies by collecting undeveloped particles back to the main body by upward flow in the separator while recovering through the system.
- JP-A-9-270258 Japanese Patent Laid-Open No. 10-265225 JP 2003-86182 A
- an object of the present invention is to provide a nickel cobalt composite hydroxide having a sharp particle size distribution. Another object of the present invention is to provide a method and an apparatus for producing such a nickel cobalt composite hydroxide by a continuous crystallization method advantageous for production on an industrial scale. Furthermore, the present invention provides a non-aqueous electrolyte secondary battery having excellent cycle characteristics by synthesizing a positive electrode active material using the nickel cobalt composite hydroxide as a precursor and using the positive electrode active material as a positive electrode. With the goal.
- the present inventors have made extensive studies on a nickel-cobalt composite hydroxide used as a precursor of a positive electrode active material for a non-aqueous electrolyte secondary battery and a method for producing the same.
- an aqueous solution containing nickel and cobalt, an aqueous solution containing an ammonium ion supplier, and an aqueous caustic solution are continuously supplied with stirring, and the nickel-cobalt composite produced by the crystallization reaction from this reaction vessel.
- a slurry containing hydroxide is extracted, separated into a large particle size portion and a small particle size portion by classification, and the small particle size portion is continuously refluxed to the reaction vessel, so that particles having a uniform particle size can be efficiently obtained.
- the inventors have found that it can be manufactured and have completed the present invention.
- the nickel-cobalt composite hydroxide of the present invention have the general formula: Ni 1-xy Co x M y (OH) 2 (although, 0.05 ⁇ x ⁇ 0.50,0 ⁇ y ⁇ 0.10,0 0.05 ⁇ x + y ⁇ 0.50, where M is a nickel cobalt composite hydroxide represented by at least one metal element selected from Al, Mg, Mn, Ti, Fe, Cu, Zn, and Ga) , The relationship of (D50 ⁇ D10) /D50 ⁇ 0.30 and (D90 ⁇ D50) /D50 ⁇ 0.30 is established between D10, D50 and D90 of the nickel cobalt composite hydroxide. To do.
- the nickel cobalt composite hydroxide preferably has a tap density of 2.0 g / cm 3 or more.
- the average particle diameter of the nickel cobalt composite hydroxide is preferably in the range of 10 ⁇ m to 30 ⁇ m.
- an aqueous solution containing nickel and cobalt, an aqueous solution containing an ammonium ion supplier, and a caustic aqueous solution are continuously supplied to the reaction vessel and reacted.
- a refluxing step of continuously refluxing the small particle diameter portion to the reaction vessel In the reaction step of obtaining nickel-cobalt composite hydroxide, the separation step of continuously extracting the slurry containing the nickel-cobalt composite hydroxide from the reaction vessel and separating it into a large particle size portion and a small particle size portion by classification And a refluxing step of continuously refluxing the small particle diameter portion to the reaction vessel.
- the separation step it is preferable to use a wet separation device utilizing centrifugal force.
- M is at least one metal element selected from Al, Mg, Mn, Ti, Fe, Cu, Zn, and Ga), It is preferable to further provide.
- An apparatus for producing a nickel-cobalt composite hydroxide of the present invention comprises a reaction vessel, an aqueous solution containing nickel and cobalt, an aqueous solution containing an ammonium ion supplier, and an aqueous caustic solution, respectively.
- the positive electrode active material for a non-aqueous electrolyte secondary battery of the present invention have the general formula: Li 1 + u Ni 1- xy Co x M y O 2 ( however, 0 ⁇ u ⁇ 0.30,0.05 ⁇ x ⁇ 0 .50, 0 ⁇ y ⁇ 0.10, 0.05 ⁇ x + y ⁇ 0.50, M is at least one metal element selected from Al, Mg, Mn, Ti, Fe, Cu, Zn, and Ga) And is composed of a hexagonal lithium nickel cobalt composite oxide having a layered structure, and (D50 ⁇ D10) /D50 ⁇ 0.30 between D10, D50 and D90 of the lithium nickel cobalt composite oxide, and The relationship of (D90 ⁇ D50) /D50 ⁇ 0.30 is established.
- the tap density of the positive electrode active material for a non-aqueous electrolyte secondary battery is preferably 2.0 g / cm 3 or more.
- the average particle diameter of the positive electrode active material for a non-aqueous electrolyte secondary battery is preferably in the range of 10 ⁇ m to 30 ⁇ m.
- the method for producing a positive electrode active material for a non-aqueous electrolyte secondary battery according to the present invention includes the nickel cobalt composite hydroxide or the nickel cobalt composite hydroxide in an oxidizing atmosphere at a temperature of 300 ° C. to 700 ° C.
- the non-aqueous electrolyte secondary battery of the present invention includes a positive electrode, a negative electrode, a separator, and a non-aqueous electrolyte, and the positive electrode active material for the non-aqueous electrolyte secondary battery is used as the positive electrode material of the positive electrode. It is characterized by that.
- a nickel cobalt composite hydroxide having a very sharp particle size distribution can be obtained. For this reason, the cycle characteristic of the non-aqueous electrolyte secondary battery using the positive electrode active material obtained by using this nickel cobalt composite hydroxide as a precursor can be improved.
- the raw material to be input can be used without waste, not only the cost can be reduced, but also the production efficiency can be improved, so that its industrial significance is very large.
- FIG. 1 is a graph showing the particle size distributions of the nickel cobalt composite hydroxide obtained by the production method of the present invention and the nickel cobalt composite hydroxide obtained by the conventional production method.
- FIG. 2 is a flowchart schematically showing the production process of the nickel cobalt composite hydroxide according to the present invention.
- FIG. 3 is a conceptual diagram showing an apparatus for producing a nickel-cobalt composite hydroxide of the present invention.
- FIG. 4 is a schematic cross-sectional view of a 2032 type coin type battery used for battery evaluation.
- the average particle size, crystal shape, and the like can be adjusted by controlling the conditions for producing the nickel-cobalt composite hydroxide.
- the average particle size is mainly 10 ⁇ m.
- An example of producing a substantially spherical nickel-cobalt composite hydroxide in the range of ⁇ 30 ⁇ m will be described.
- Nickel-cobalt composite hydroxide and production method thereof (1) Nickel-cobalt composite hydroxide
- the nickel-cobalt composite hydroxide of the present invention (hereinafter referred to as “composite hydroxide”) has a general formula: Ni 1-xy Co x M y (OH) 2 (where 0.05 ⁇ x ⁇ 0.50, 0 ⁇ y ⁇ 0.10, 0.05 ⁇ x + y ⁇ 0.50, M represents Al, Mg, Mn, Ti, Fe, At least one metal element selected from Cu, Zn, and Ga), and (D50 ⁇ D10) / D50 ⁇ between D10, D50, and D90 of the composite hydroxide. 0.30 and (D90 ⁇ D50) /D50 ⁇ 0.30 is established. That is, the composite hydroxide of the present invention is characterized by having a very sharp particle size distribution.
- the value x indicating the amount of cobalt (Co) added is 0.05 to 0.50, preferably 0.10 to 0.50, and more preferably 0.10 to 0.30. If the value of x is less than 0.05, the effect of adding Co cannot be sufficiently obtained. On the other hand, when the value of x exceeds 0.50, the raw material cost increases.
- the value of y indicating the amount of additive element M added is 0 to 0.10, preferably 0.01 to 0.09, more preferably 0.02 to 0.08. If the value of y exceeds 0.10, the charge / discharge capacity is reduced.
- the additive element M is selected from aluminum (Al), magnesium (Mg), manganese (Mn), titanium (Ti), iron (Fe), copper (Cu), zinc (Zn), and gallium (Ga). Although at least one kind of metal element can be used, it is preferable to use aluminum and / or magnesium from the viewpoint of cost and battery characteristics.
- the total amount of cobalt and additive element M is 0.05 to 0.50, preferably 0.05 to 0.40, and more preferably 0.05 to 0.25.
- the total amount of cobalt and additive element M is less than 0.05, the effect of adding cobalt and additive element M cannot be obtained.
- the total amount of cobalt and additive element M exceeds 0.50, not only the raw material cost increases, but also the charge / discharge capacity decreases, and the merit of the nickel (Ni) -based positive electrode active material is reduced. It will be damaged.
- the composite hydroxide of the present invention is characterized in that a relationship of (D50 ⁇ D10) /D50 ⁇ 0.30 and (D90 ⁇ D50) /D50 ⁇ 0.30 is established between D10, D50 and D90.
- D10, D50, and D90 mean particle sizes corresponding to 10%, 50%, and 90% of integrated values of the particle size distribution, respectively.
- the method for obtaining D10, D50, and D90 is not particularly limited, and for example, it can be obtained from the volume integrated value measured with a laser diffraction / scattering particle size analyzer.
- the particle size distribution of the composite hydroxide is extremely sharp. Therefore, a secondary battery using a positive electrode active material obtained using this composite hydroxide as a precursor is used. In this case, the cycle characteristics can be sufficiently improved. Specifically, it is possible to set the capacity maintenance rate, which is an index of the cycle characteristics of the nonaqueous electrolyte secondary battery, to 97.5% or more. On the other hand, when either one of (D50-D10) / D50 and (D90-D50) / D50 exceeds 0.30, the uniformity of the particle size deteriorates, and this nickel-cobalt composite hydroxide is reduced.
- the capacity retention rate in the present invention is a non-aqueous electrolyte secondary battery, which is left for a certain period of time, and after the open circuit voltage (OCV) is stabilized, the current density with respect to the positive electrode is 0.5 mA / cm 2.
- Such values of (D50-D10) / D50 and (D90-D50) / D50 can be realized by repeating the reaction step, the separation step, and the reflux step in the production process of the composite hydroxide.
- the composite hydroxide of the present invention preferably has a tap density of 2.0 g / cm 3 or more, more preferably 2.2 g / cm 3 or more, which serves as an index of filling.
- the tap density represents the density after tapping the sample powder collected in the container 100 times based on JIS Z-2504, and can be measured using a shaking specific gravity measuring instrument.
- the tap density of the composite hydroxide is in such a range, the battery characteristics of the non-aqueous electrolyte secondary battery using the lithium composite oxide obtained by using the composite hydroxide as a precursor as the positive electrode active material can be further improved. It can be excellent. On the other hand, when the tap density is less than 2.0 g / cm 3 , the packing density of the positive electrode active material is not sufficient, and the characteristics of the obtained secondary battery may not be sufficiently improved.
- the upper limit of the tap density is not limited, but in the embodiment of the present invention, the upper limit is about 2.4 g / cm 3 .
- the average particle size of the composite hydroxide is preferably in the range of 10 ⁇ m to 30 ⁇ m, more preferably in the range of 13 ⁇ m to 26 ⁇ m, and still more preferably in the range of 15 ⁇ m to 25 ⁇ m.
- the average particle diameter in the present invention means a particle diameter corresponding to an integrated value of particle size distribution of 50%, that is, D50 (median diameter). If the average particle size of the composite hydroxide is in such a range, the battery characteristics of the non-aqueous electrolyte secondary battery using the lithium composite oxide obtained by using the composite hydroxide as a precursor as the positive electrode active material, It can be made better.
- the capacity retention rate is preferably 98.0% or more, more preferably 98.5% or more. be able to.
- the average particle size is less than 10 ⁇ m, the packing density of the positive electrode active material may not be sufficient, and the characteristics of the secondary battery may not be sufficiently improved.
- the average particle size exceeds 30 ⁇ m, the specific surface area of the positive electrode active material becomes small, and similarly, the characteristics of the secondary battery may not be sufficiently improved.
- the method for producing a composite hydroxide of the present invention comprises an aqueous solution containing nickel and cobalt, an aqueous solution containing an ammonium ion supplier, and a caustic alkali. While stirring, the aqueous solution is continuously supplied to the reaction vessel and reacted to obtain a composite hydroxide, and the slurry containing the composite hydroxide is extracted from the reaction vessel and classified into large particles by classification. It is characterized by comprising a separation step for separating the diameter portion and the small particle size portion, and a reflux step for continuously refluxing the small particle size portion obtained by the separation step to the reaction vessel.
- the reaction step comprises an aqueous solution containing nickel and cobalt (hereinafter referred to as “raw material aqueous solution”), an aqueous solution containing an ammonium ion supplier (hereinafter referred to as “ammonium ion supply aqueous solution”), a caustic alkali
- a composite solution represented by the above-described general formula is formed by continuously supplying each aqueous solution to the reaction vessel while stirring to form a reaction aqueous solution composed of these mixed aqueous solutions and causing a crystallization reaction. This is a step of continuously producing hydroxide.
- the caustic aqueous solution is supplied by adjusting the addition amount so that the pH value of the reaction aqueous solution is maintained within a predetermined range.
- the crystal structure and powder characteristics of the resulting composite hydroxide can be controlled by controlling the pH value of the reaction aqueous solution. That is, in such a continuous crystallization method, the nickel concentration, the cobalt concentration, and the concentration of the additive element M in the reaction aqueous solution formed in the reaction vessel are the same as the solubility of the nickel, cobalt, and additive element M in the reaction aqueous solution (saturated solubility). ), The crystallization reaction of the composite hydroxide occurs. By controlling the pH value of the reaction aqueous solution and adjusting the solubility, the crystal structure and powder of the composite hydroxide obtained are adjusted. Body characteristics can be controlled.
- the raw material aqueous solution is simply supplied to a reaction vessel having low solubility, if the difference between the solubility at the pH value and the concentration of the metal component in the raw material aqueous solution is large, it is a fine and irregular composite hydroxide. Will be deposited at once.
- the present invention from the viewpoint of preventing such a situation, by supplying an ammonium ion supply aqueous solution simultaneously with the raw material aqueous solution to the reaction vessel and forming complex ions of nickel, cobalt, and additive element M, respectively, at the same pH value. Even so, the solubility of the metal component is stabilized on the high side.
- the composite hydroxide can be gradually precipitated, and the composite hydroxide can be grown into a substantially spherical shape by repeating the precipitation and re-dissolution process.
- the crystal structure of the composite hydroxide can be controlled to a desired shape by adjusting the ammonium ion concentration of the aqueous ammonium ion supply solution.
- reaction conditions The conditions for the reaction step should be appropriately selected according to the size of the reaction vessel, the diameter and shape of the stirring blade, or the size and shape of the target particles, and cannot be uniquely determined.
- the particle size distribution of the resulting composite hydroxide may be widened depending on the reaction conditions. There is a possibility that the load of the separation process increases and the overall production efficiency deteriorates. Further, excessive repetition of the reaction process, separation process and reflux process may generate coarse particles, which may further widen the particle size distribution. For this reason, it is preferable to appropriately adjust the conditions in the reaction step from the viewpoint of controlling the particle size distribution of the resulting composite hydroxide within a predetermined range.
- reaction vessel with a volume of 34 L and a propeller blade having a diameter of 7 cm to 15 cm and 2 to 5 blades (inclination angle of 15 ° to 45 °)
- a substantially spherical composite hydroxide of about 10 ⁇ m to 30 ⁇ m
- the pH value of the reaction aqueous solution is preferably 11.8 or more, more preferably 12.0 or more, based on a liquid temperature of 25 ° C.
- the upper limit of the pH value is preferably about 13.0, more preferably about 12.8, based on a liquid temperature of 25 ° C.
- nucleation and particle growth tend to proceed simultaneously, and a composite hydroxide having an average particle size in the range of 10 to 30 ⁇ m and a sharp particle size distribution can be obtained. It becomes difficult.
- the liquid temperature of the reaction aqueous solution is preferably 35 ° C. or higher, more preferably 40 ° C. or higher. When the liquid temperature is less than 35 ° C., the tap density of the composite hydroxide is lowered, and similarly, the characteristics of the finally obtained battery may be deteriorated.
- the upper limit of the liquid temperature is preferably about 40 to 60 ° C., more preferably about 50 ° C. This is because when the liquid temperature exceeds 60 ° C., the volatilization amount of ammonia increases and the complex concentration of nickel, cobalt, and additive element M becomes unstable.
- the stirring speed of the reaction aqueous solution is preferably controlled in the range of 600 rpm to 1400 rpm, and more preferably in the range of 700 rpm to 1300 rpm.
- the stirring speed is less than 600 rpm, it is difficult to uniformly mix the raw material aqueous solution, the ammonium ion supply aqueous solution, and the caustic alkaline aqueous solution.
- it exceeds 1400 rpm the produced composite hydroxides may collide with each other and fine particles may be generated. For this reason, in any case, the particle size distribution of the obtained composite hydroxide tends to be widened.
- the raw material aqueous solution is not particularly limited, it is preferable to use an aqueous solution in which nitrates, sulfates or hydrochlorides of nickel and cobalt are dissolved. From the viewpoint of prevention of contamination by halogen and cost, these aqueous solutions of sulfuric acid It is more preferable to use
- the concentration of the raw material aqueous solution is preferably a total of nickel salt and cobalt salt, preferably 1.0 mol / L to 2.4 mol / L, more preferably 1.5 mol / L to 2.4 mol / L, still more preferably 2.0 mol. / L to 2.4 mol / L.
- concentration of the raw material aqueous solution is less than 1.0 mol / L, the amount of crystallized material per reaction tank is reduced, and productivity is lowered, which is not preferable.
- the salt concentration of the raw material aqueous solution exceeds 2.4 mol / L, the saturation solubility of the raw material aqueous solution is exceeded, and the metal salt is precipitated in the raw material aqueous solution. There is a risk that things will be generated.
- the nickel salt and cobalt salt do not necessarily have to be supplied to the reaction vessel as a raw material aqueous solution.
- the nickel salt or cobalt salt that reacts when mixed to produce compounds other than the desired composite hydroxide, prepare a nickel salt aqueous solution and a cobalt salt aqueous solution separately and include them in these aqueous solutions.
- the concentration of the nickel salt and cobalt salt to be adjusted may be adjusted so as to be in the above range in total, and simultaneously supplied to the reaction tank at a predetermined ratio.
- the composite hydroxide of the present invention contains an additive element M (M is at least one metal element selected from Al, Mg, Mn, Ti, Fe, Cu, Zn, and Ga). Can be made.
- M is at least one metal element selected from Al, Mg, Mn, Ti, Fe, Cu, Zn, and Ga.
- an aqueous solution in which the salt containing the additive element M is dissolved is added to or added to the aqueous solution containing the nickel salt and the cobalt salt.
- An aqueous solution in which a salt containing the element M is dissolved and an aqueous solution containing a nickel salt and a cobalt salt are simultaneously supplied to the reaction vessel, and the additive element M is co-precipitated while being uniformly dispersed inside the composite hydroxide. You can do it.
- the additive element M is not necessarily added in the reaction step, and the surface of the composite hydroxide obtained by the present invention may be coated with the additive element M.
- the large particle diameter part obtained by the separation step described later is mixed with an aqueous solution in which a salt containing the additive element M is dissolved or an alkoxide solution of the additive element M to make a slurry, and the slurry has a predetermined pH.
- the surface of the composite hydroxide can be uniformly coated with the additive element M by precipitating the additive element M on the surface of the composite hydroxide by a crystallization reaction while controlling to be a value.
- the surface of the composite hydroxide can be coated with the additive element M by spraying an aqueous solution or slurry containing the additive element M on the large particle diameter portion and drying it. Furthermore, the slurry in which the salt containing the large particle size portion and the additive element M is suspended is spray-dried, or the salt containing the composite hydroxide and the additive element M is mixed by the solid phase method. The surface of the hydroxide can also be coated with the additive element M.
- ammonium ion supply aqueous solution used in the present invention is not particularly limited, but aqueous ammonia or an aqueous solution containing ammonium sulfate or ammonium chloride is preferable, and from the viewpoint of preventing contamination by halogen, aqueous ammonia or ammonium sulfate is contained. An aqueous solution is more preferred.
- ammonia water when used as the ammonium ion supply aqueous solution, a general commercial product having an ammonium ion concentration of about 25% by mass to 30% by mass can be used as it is. If the ammonium ion concentration is too low as compared with the above range, a predetermined amount of ammonium ions is supplied, so a large amount of aqueous solution of ammonium ions must be supplied, and productivity is lowered. On the other hand, even if the ammonium ion concentration exceeds the above range, there is no particular problem as long as ammonium ions are supplied smoothly. However, when the ammonium ion concentration is higher than 30% by mass, Volatilization increases, making safe operation difficult.
- the aqueous caustic solution is used as a pH adjuster for the neutralization reaction.
- a caustic alkali aqueous solution a sodium hydroxide aqueous solution, a potassium hydroxide aqueous solution, a lithium hydroxide aqueous solution or the like can be used, but it is preferable to use a sodium hydroxide aqueous solution from the viewpoint of ease of handling and cost. .
- the concentration of the caustic aqueous solution is preferably 10% by mass to 30% by mass, more preferably 15% by mass to 25% by mass. If the amount is less than 10% by mass, the amount of the caustic aqueous solution necessary for pH adjustment is increased, and the productivity is lowered. On the other hand, when it exceeds 30% by mass, a caustic crystal is precipitated in the caustic aqueous solution or the viscosity of the caustic aqueous solution is increased, which causes a problem that a mechanical load is applied to the reaction apparatus. There is a fear.
- the supply of the caustic aqueous solution is appropriately adjusted according to the supply amounts of the raw material aqueous solution and the ammonium ion supply aqueous solution so that the pH value of the reaction aqueous solution can be controlled in the range of 10% by mass to 30% by mass. It is preferable.
- the large particle size portion produced and grown in the reaction vessel is selectively discharged out of the reaction vessel, and the small particle size portion repeats particle growth until reaching the target particle size. Therefore, the particle size of the finally obtained composite hydroxide becomes uniform, and the particle size distribution can be sharpened.
- a wet classification method for classification of the composite hydroxide.
- fine particles are generated by the collision of particles, so that the particle size distribution is likely to be widened, and the particle shape is deformed and the tap density may be reduced.
- the wet classification method is not particularly limited, but it is preferable to employ a method utilizing centrifugal force, specifically, a wet cyclone method.
- the classification point can be easily controlled by the shape and size of the cyclone portion and the introduction pressure of the treatment slurry.
- a substantially spherical composite hydroxide grown to an average particle size of 10 ⁇ m to 30 ⁇ m by the reaction step is (D50-D10) /D50 ⁇ 0.30 and (D90-D50) / D50 ⁇ 0.
- the shape of the cyclone portion is cylindrical and the introduction pressure of the treatment slurry is adjusted to be within a range of 0.3 MPa to 0.5 MPa.
- the slurry containing the small particle size portion discharged from the separation device in the separation step (hereinafter referred to as “small particle size portion slurry”) is returned (refluxed) into the reaction vessel. It is a process.
- the reflux method is not particularly limited, and known means can be used.
- the small particle size portion slurry discharged from the separation device may be directly returned to the reaction vessel by a pump.
- concentration means and a dilution means when it is necessary to adjust the concentration of the small particle diameter portion slurry, it is necessary to separately provide a concentration means and a dilution means.
- the reflux rate that is, the rate at which the small particle size portion is returned to the reaction vessel may be appropriately adjusted according to the supply rate of the raw material aqueous solution or the aqueous solution containing the ammonium ion supplier.
- a composite hydroxide having a composition and particle size distribution suitable as a precursor of a positive electrode active material for a non-aqueous electrolyte secondary battery can be easily obtained.
- the composite hydroxide production device of the present invention while stirring the raw material aqueous solution, the ammonium ion supply aqueous solution, and the caustic aqueous solution.
- the reaction mixture is continuously supplied to the reaction tank and reacted to obtain the composite hydroxide, and the composite hydroxide is continuously extracted from the reaction tank (1) and classified to give the composite water.
- a separation device (7) for separating the oxide into a large particle size portion and a small particle size portion and a reflux device (9) for continuously refluxing the small particle size portion to the reaction vessel are provided.
- the reaction tank (1) used for the reaction step includes a stirring means (2), a raw material aqueous solution supply means (3), an ammonium ion supply aqueous solution supply means (4), and a caustic alkaline aqueous solution supply means (5), and is produced. If it is the thing of the overflow system which can discharge
- the slurry produced by the reaction step is introduced into the separation device (7) by the pump (6).
- the separation device (7) to be used is preferably a wet separation device, and more preferably a separation device using a wet cyclone method.
- the classification point can be easily controlled by the shape and size of the cyclone part and the pressure of the treatment slurry introduced.
- the reflux device (9) is not particularly limited, and a known device can be used.
- emitted from the separation apparatus should just return to a reaction tank directly with a pump.
- a diluting device or a dehydrating device for adjusting the slurry concentration of the small particle size slurry obtained in the separation step may be combined.
- the liquid component is usually distributed more to the small particle size portion side, so before returning the small particle size portion to the reaction vessel, It is necessary to perform dehydration.
- a coating apparatus means for precipitating the additive element M on the surface of the composite hydroxide, means for spraying and drying an aqueous solution or slurry containing the additive element M, or slurry in which a salt containing the additive element M is suspended It is preferable that the apparatus is provided with a means for spray drying.
- control means for controlling the reaction rate, classification rate or reflux rate in each step such as a computer control system.
- Cathode active material for non-aqueous electrolyte secondary battery and manufacturing method thereof (1) Cathode active material for non-aqueous electrolyte secondary battery
- the positive electrode active material for non-aqueous electrolyte secondary battery of the present invention is represented by the general formula: Li 1 + u Ni 1-xy Co x M y O 2 ( however, 0 ⁇ u ⁇ 0.30,0.05 ⁇ x ⁇ 0.50,0 ⁇ y ⁇ 0.10,0.05 ⁇ x + y ⁇ 0.50, M is And at least one metal element selected from Al, Mg, Mn, Ti, Fe, Cu, Zn, and Ga), and a hexagonal lithium composite oxide having a layered structure.
- the value of u indicating the excess amount of lithium is preferably 0 to 0.30, and more preferably 0 to 0.15. If the value of u is less than 0, the reaction resistance of the positive electrode in the nonaqueous electrolyte secondary battery using the obtained positive electrode active material increases, and the output of the battery decreases. On the other hand, if the value of u exceeds 0.30, not only the initial discharge capacity when the positive electrode active material is used for the positive electrode of the battery, but also the reaction resistance of the positive electrode is increased.
- the positive electrode active material of the present invention is characterized in that a relationship of (D50 ⁇ D10) /D50 ⁇ 0.30 and (D90 ⁇ D50) /D50 ⁇ 0.30 is established between D10, D50 and D90. To do.
- the capacity maintenance rate which is an index of the cycle characteristics of the nonaqueous electrolyte secondary battery, to 97.5% or more.
- the tap density of the positive electrode active material of the present invention is preferably 2.0 g / cm 3 or more, and more preferably 2.2 g / cm 3 or more. If the tap density of the positive electrode active material is within such a range, the battery characteristics of the non-aqueous electrolyte secondary battery used as the positive electrode active material can be further improved. On the other hand, when the tap density is less than 2.0 g / cm 3 , the packing density of the positive electrode active material is not sufficient, and the characteristics of the non-aqueous electrolyte secondary battery may not be sufficiently improved.
- the average particle diameter of the positive electrode active material of the present invention is preferably in the range of 10 ⁇ m to 30 ⁇ m, more preferably in the range of 13 ⁇ m to 26 ⁇ m, and still more preferably in the range of 15 ⁇ m to 25 ⁇ m. If the average particle diameter of the positive electrode active material is within such a range, the battery characteristics of the non-aqueous electrolyte secondary battery using this positive electrode active material can be further improved.
- the capacity retention rate is preferably 98.0% or more, more preferably 98.5% or more. be able to.
- the average particle size is less than 10 ⁇ m, the packing density of the positive electrode active material may not be sufficient, and the characteristics of the non-aqueous electrolyte secondary battery may not be sufficiently improved.
- the average particle size exceeds 30 ⁇ m, the specific surface area of the positive electrode active material becomes small, and similarly, the characteristics of the non-aqueous electrolyte secondary battery may not be sufficiently improved.
- the mixing step is a step of obtaining a lithium mixture by mixing the composite hydroxide and the lithium compound.
- the lithium compound used in this case is not particularly limited, and for example, lithium hydroxide, lithium nitrate, lithium carbonate, or a mixture thereof can be used.
- lithium hydroxide or lithium carbonate is preferably used in consideration of ease of handling and quality stability.
- the composite hydroxide and the lithium compound are the number of atoms of metals other than lithium in the lithium mixture, that is, the sum of the number of atoms of nickel, cobalt, and additive element M (Me) and the number of atoms of lithium (Li).
- Mixing is performed so that the ratio (Li / Me) is 1.00 to 1.30, preferably 1.00 to 1.15. That is, since Li / Me does not change before and after the firing step, Li / Me mixed in this mixing step becomes Li / Me in the positive electrode active material, so that Li / Me in the lithium mixture is to be obtained. To be the same as Li / Me.
- a general mixer for mixing the composite hydroxide and the lithium compound, a general mixer can be used, for example, a shaker mixer, a Roedige mixer, a Julia mixer, a V blender, or the like can be used. At this time, it is necessary to sufficiently mix the composite hydroxide so as not to be destroyed.
- the composite hydroxide Prior to the mixing step, it is preferable to further include a roasting step of roasting the composite hydroxide in advance in an oxidizing atmosphere at a temperature of 300 ° C. to 700 ° C.
- a roasting step of roasting the composite hydroxide in advance in an oxidizing atmosphere at a temperature of 300 ° C. to 700 ° C.
- the composite hydroxide can be made into a nickel cobalt composite oxide (hereinafter referred to as “composite oxide”).
- composite oxide When this composite oxide is mixed with a lithium compound, the lithium composite oxide The composition ratio of lithium and metal element in the lithium composite oxide can be stabilized while maintaining the filling property of the object.
- the roasting temperature is preferably 300 ° C to 700 ° C, more preferably 400 ° C to 600 ° C.
- the roasting temperature is less than 300 ° C., a part of the composite hydroxide may remain, and the composition of the obtained lithium composite oxide may not be stable.
- the temperature exceeds 700 ° C., sintering between particles occurs to generate coarse particles, which may deteriorate the particle size distribution.
- the firing step is a step of firing the lithium mixture obtained in the mixing step at 600 ° C. to 850 ° C. in an oxidizing atmosphere.
- the firing temperature in the firing step is 600 to 850 ° C., preferably 700 to 800 ° C.
- the diffusion reaction rate of lithium is not sufficient, surplus lithium remains, the crystal structure is not aligned, and sufficient characteristics cannot be obtained when used in a battery.
- the temperature exceeds 850 ° C. intense sintering occurs between the particles of the lithium composite oxide, and abnormal grain growth may occur. In this case, the particles after firing become coarse and cannot maintain a substantially spherical particle form. Since such a positive electrode active material has a reduced specific surface area, when used in a battery, the resistance of the positive electrode increases and the battery capacity decreases.
- the temperature is preferable to raise the temperature to the above temperature with a rate of temperature rise of 1 ° C./min to 2.5 ° C./min. . Furthermore, the reaction can be carried out more uniformly by maintaining the temperature around the melting point of the lithium compound for about 1 to 5 hours.
- the holding time at the firing temperature is preferably 5 hours or more, more preferably 5 to 10 hours.
- the holding time is less than 5 hours, the lithium composite oxide may not be sufficiently synthesized.
- the atmosphere during firing is preferably an oxidizing atmosphere.
- an atmosphere with an oxygen concentration of 18% by volume to 100% by volume is preferable, and an atmosphere with an oxygen concentration of 70% by volume to 100% by volume is more preferable. More preferably, a mixed atmosphere of gas is used. If the oxygen concentration is less than 18% by volume, the lithium composite oxide may not have sufficient crystallinity.
- the furnace used for firing is not particularly limited as long as it can heat the lithium mixture with an oxidizing atmosphere non-aqueous electrolyte. From the viewpoint of maintaining a uniform atmosphere in the furnace, gas generation is not caused. No electric furnace is preferred, and either a batch or continuous furnace can be used.
- Non-aqueous electrolyte secondary battery of the present invention includes the same components as a general non-aqueous electrolyte secondary battery, such as a positive electrode, a negative electrode, a separator, and a non-aqueous electrolyte solution.
- a general non-aqueous electrolyte secondary battery such as a positive electrode, a negative electrode, a separator, and a non-aqueous electrolyte solution.
- the embodiment described below is merely an example, and the nonaqueous electrolyte secondary battery of the present invention is applied to various modified and improved embodiments based on the embodiment described in the present specification. It is also possible to do.
- Positive electrode Using the positive electrode active material for a non-aqueous electrolyte secondary battery obtained by the present invention, for example, a positive electrode of a non-aqueous electrolyte secondary battery is produced as follows.
- a conductive material and a binder are mixed with the powdered positive electrode active material obtained according to the present invention, and activated carbon and a solvent such as viscosity adjustment are added as necessary, and these are kneaded and mixed.
- a material paste is prepared.
- the mixing ratio in the positive electrode mixture paste is also an important factor for determining the performance of the non-aqueous electrolyte secondary battery.
- the solid content of the positive electrode mixture excluding the solvent is 100 parts by mass
- the content of the positive electrode active material is 60 parts by mass to 95 parts by mass as in the case of the positive electrode of a general non-aqueous electrolyte secondary battery.
- the content of is preferably 1 to 20 parts by mass
- the content of the binder is preferably 1 to 20 parts by mass.
- the obtained positive electrode mixture paste is applied to the surface of a current collector made of aluminum foil, for example, and dried to disperse the solvent. If necessary, pressurization may be performed by a roll press or the like to increase the electrode density. In this way, a sheet-like positive electrode can be produced.
- the sheet-like positive electrode can be cut into an appropriate size according to the target battery and used for battery production.
- the method for manufacturing the positive electrode is not limited to such a method, and other methods may be used.
- the conductive material for example, graphite (natural graphite, artificial graphite, expanded graphite, etc.), and carbon black materials such as acetylene black and ketjen black can be used.
- the binder plays a role of anchoring the active material particles.
- PVDF polyvinylidene fluoride
- PTFE polytetrafluoroethylene
- fluorine rubber ethylene propylene diene rubber
- styrene butadiene styrene butadiene
- cellulosic resin and polyacrylic
- An acid can be used.
- a positive electrode active material, a conductive material and activated carbon can be dispersed and a solvent for dissolving the binder can be added to the positive electrode mixture.
- a solvent for dissolving the binder can be added to the positive electrode mixture.
- an organic solvent such as N-methyl-2-pyrrolidone can be used as the solvent.
- activated carbon can be added to the positive electrode mixture in order to increase the electric double layer capacity.
- Negative electrode The negative electrode composite material in which the negative electrode is made of metal lithium, lithium alloy, or the like, or a negative electrode active material capable of occluding and desorbing lithium ions, mixed with a binder, and added with an appropriate solvent to form a paste. Is applied to the surface of a metal foil current collector such as copper, dried, and compressed to increase the electrode density as necessary.
- the negative electrode active material for example, a fired organic compound such as natural graphite, artificial graphite and phenol resin, and a powdery substance of carbon material such as coke can be used.
- a fluorine-containing resin such as PVDF can be used as the negative electrode binder as in the positive electrode
- an organic material such as N-methyl-2-pyrrolidone can be used as a solvent for dispersing these active materials and the binder.
- a solvent can be used.
- Separator A separator is interposed between the positive electrode and the negative electrode.
- the separator separates the positive electrode and the negative electrode and retains an electrolyte, and a thin film such as polyethylene or polypropylene and a film having many minute holes can be used.
- Non-aqueous electrolyte is obtained by dissolving a lithium salt as a supporting salt in an organic solvent.
- organic solvent examples include cyclic carbonates such as ethylene carbonate, propylene carbonate, butylene carbonate and trifluoropropylene carbonate, chain carbonates such as diethyl carbonate, dimethyl carbonate, ethylmethyl carbonate and dipropyl carbonate, tetrahydrofuran, 2- Use one kind selected from ether compounds such as methyltetrahydrofuran and dimethoxyethane, sulfur compounds such as ethylmethylsulfone and butanesultone, phosphorus compounds such as triethyl phosphate and trioctyl phosphate, or a mixture of two or more. Can do.
- cyclic carbonates such as ethylene carbonate, propylene carbonate, butylene carbonate and trifluoropropylene carbonate
- chain carbonates such as diethyl carbonate, dimethyl carbonate, ethylmethyl carbonate and dipropyl carbonate, tetrahydrofuran, 2- Use one kind selected from ether compounds
- LiPF 6 LiBF 4 , LiClO 4 , LiAsF 6 , LiN (CF 3 SO 2 ) 2 , and complex salts thereof can be used.
- non-aqueous electrolyte solution may contain a radical scavenger, a surfactant, a flame retardant, and the like.
- the non-aqueous electrolyte secondary battery of the present invention composed of the positive electrode, negative electrode, separator and non-aqueous electrolyte described above has various shapes such as a cylindrical shape and a laminated shape. Can be.
- the positive electrode and the negative electrode are laminated via a separator to form an electrode body, and the obtained electrode body is impregnated with a non-aqueous electrolyte and communicated with the positive electrode current collector and the outside. Connect between the positive electrode terminal and between the negative electrode current collector and the negative electrode terminal leading to the outside using a current collecting lead, etc., and seal the battery case to complete the nonaqueous electrolyte secondary battery. .
- the coin-type battery (10) includes a case (11) and an electrode (12) accommodated in the case (11).
- the case (11) is composed of a positive electrode can (11a) that is hollow and open at one end, and a negative electrode can (11b) that is disposed in the opening of the positive electrode can (11a). If it arrange
- the electrode (12) includes a positive electrode (11a), a separator (12c), and a negative electrode (12b), which are stacked in this order, and the positive electrode (11a) is in contact with the inner surface of the positive electrode can (11a). (12b) is accommodated in the case (11) so as to contact the inner surface of the negative electrode can (11b).
- the case (11) is provided with a gasket (11c), and the gasket (11c) is arranged so that the positive electrode can (11a) and the negative electrode can (11b) are electrically insulated. 11) Arranged and fixed inside.
- the gasket (11c) has a function of sealing the gap between the positive electrode can (11a) and the negative electrode can (11b) so as to block the inside of the case (11) from the outside in an airtight and liquidtight manner. .
- a nonaqueous electrolyte secondary battery using the positive electrode active material of the present invention constitutes this nonaqueous electrolyte secondary battery, and after the open circuit voltage (OCV) is stabilized, the current density with respect to the positive electrode is 0.5 mA. capacity maintenance rate after 25 cycles of charge / discharge tests at 25 ° C. with a cut-off voltage of 4.3 V to 3.0 V / cm 2 , preferably 97.5% or more, more preferably 98.0% or more Is 98.5% or more.
- the nonaqueous electrolyte secondary battery of the present invention has very excellent cycle characteristics, it can be said that the nonaqueous electrolyte secondary battery is suitable as a power source for small portable electronic devices and electric vehicles.
- the present invention can be used not only as a power source for an electric vehicle driven purely by electric energy but also as a power source for a so-called hybrid vehicle used in combination with a combustion engine such as a gasoline engine or a diesel engine.
- each reagent grade sample manufactured by Wako Pure Chemical Industries, Ltd. was used for the production of the composite hydroxide, the positive electrode active material, and the production of the secondary battery.
- Example 1 Into an overflow crystallization reaction tank having a capacity of 34 L to which four baffle plates were attached, 32 L of industrial water and 1300 mL of 25% by mass ammonia water were added and heated to 50 ° C. in a thermostatic bath and a heating jacket. Thereafter, a 24% by mass aqueous caustic soda solution was added, and the pH value was controlled to 12.2 based on the liquid temperature of 25 ° C. Specifically, in order to accurately control the pH value, the reaction aqueous solution in the reaction vessel is collected, cooled to 25 ° C., and the pH value is measured. The pH value at 50 ° C. was controlled to be in the range of 12.3.
- the crystallization reaction was performed by stirring the inside of the reaction vessel maintained at 50 ° C., using a metering pump, and adjusting the Ni molar concentration to 1.69 mol / L and the Co molar concentration to 0.31 mol / L. While supplying an aqueous solution at 30 mL / min and supplying 25 mass% aqueous ammonia at 2.5 mL / min, a 24 mass% aqueous sodium hydroxide solution was intermittently added, and the pH value was 12.2 based on a liquid temperature of 25 ° C. The control was carried out so as to be maintained.
- the slurry generated in the reaction step is extracted by a metering pump through a extraction nozzle inserted into the reaction tank, and after adjusting the slurry concentration to 150 g / L, the slurry introduction pressure is 0.3 MPa to 0.5 MPa. After adjusting to the range, it was introduced into a wet cyclone separation apparatus (manufactured by Nippon Chemical Machinery Co., Ltd., Hydrocyclone NHC-10). In the wet cyclone separator used at this time, the shape of the cyclone portion was cylindrical, and the inner diameter of the cross section was 5 mm to 10 mm.
- this composite hydroxide was confirmed to be represented by the general formula: Ni 0.85 Co 0.15 (OH) 2 .
- the particle size distribution (D10, D50, D90) was measured using the laser diffraction scattering type particle diameter and particle size distribution meter (the Nikkiso Co., Ltd. make, Microtrac).
- the tap density was measured using a tap density measuring device (manufactured by Kuramochi Scientific Instruments Co., Ltd., shaking specific gravity measuring device KRS-409).
- the composite hydroxide is dispersed in an aqueous solution in which sodium hydroxide (NaOH) and sodium aluminate (NaAlO 2 ) are dissolved, and neutralized with an aqueous sulfuric acid solution (H 2 SO 4 ) while stirring.
- a slurry containing a composite hydroxide in which aluminum hydroxide was precipitated was obtained.
- the slurry was washed with water and filtered, then dried at about 100 ° C., and then heated to 700 ° C. and baked to synthesize a composite oxide coated with aluminum.
- this composite oxide was confirmed to be represented by the general formula: Ni 0.83 Co 0.13 Al 0.04 O 2 .
- lithium hydroxide (LiOH) as a lithium (Li) supply source is added to the obtained composite oxide, and the number of lithium atoms (Li) and the metal elements constituting the composite oxide (Ni, Co, Al) was mixed so that the ratio (Li / Me) to the sum of the number of atoms (Me) was 1.05 to prepare a lithium mixture. Thereafter, this lithium mixture is heated from room temperature to a temperature range of 700 ° C. to 800 ° C. in an oxidizing atmosphere, and is baked for about 7 hours in the temperature range to obtain a lithium composite oxide (positive electrode active material). It was.
- this positive electrode active material was confirmed to be represented by the general formula: Li 1.05 Ni 0.83 Co 0.13 Al 0.04 O 2 .
- the particle size distribution was measured using the laser diffraction scattering type particle diameter and the particle size distribution meter, and the tap density was measured using the tap density measuring apparatus, respectively.
- this positive electrode active material was analyzed by X-ray diffraction, it was confirmed that it had a hexagonal layered structure. In this analysis, it was confirmed that the lithium seat occupancy obtained from the X-ray diffraction chart using Rietveld analysis was 98.2% to 98.9%.
- a 2032 type coin battery (10) as shown in FIG. 4 was prepared and used as follows. First, 90% by mass of the obtained positive electrode active material powder was mixed with 5% by mass of acetylene black and 5% by mass of PVDF (polyvinylidene fluoride), and NMP (n-methylpyrrolidone) was added to make a paste. This paste was applied to an aluminum foil having a thickness of 20 ⁇ m so that the mass of the positive electrode active material after drying was 0.05 g / cm 2 , vacuum-dried at 120 ° C., and then on a 1 cm ⁇ disc. A positive electrode (12a) was punched out.
- PVDF polyvinylidene fluoride
- NMP n-methylpyrrolidone
- a coin battery (10) in a glow box in an argon (Ar) atmosphere with a dew point controlled to ⁇ 80 ° C. or lower. was made.
- lithium metal is used for the negative electrode (12b)
- a polyethylene porous film having a thickness of 25 ⁇ m is used for the separator (12c)
- ethylene carbonate using 1M lithium perchlorate (LiClO 4 ) as a supporting salt for the electrolyte An equivalent mixed solution of (EC) and diethyl carbonate (DEC) was used.
- the obtained coin battery (10) was allowed to stand for about 24 hours, and after the open circuit voltage (OCV) was stabilized, the current density with respect to the positive electrode was set to 0.5 mA / cm 2 and the cut-off voltage was 4.3 V to 3.0 V.
- a charge / discharge test was conducted at ° C. This charge / discharge was repeated, and the capacity retention rate after 25 cycles was measured.
- Example 2 A composite hydroxide was obtained in the same manner as in Example 1, except that the pH value of the aqueous reaction solution was maintained at 11.8 based on the liquid temperature of 25 ° C., and the stirring speed in the reaction step was 800 rpm. .
- the pH value is controlled by collecting the reaction aqueous solution in the reaction vessel, cooling to 25 ° C., and measuring the pH value so that the pH value at 25 falls within the range of 11.7 to 11.9.
- the pH value at 50 ° C. was controlled.
- the obtained composite hydroxide was appropriately solid-liquid separated, washed with water and dried to obtain a powdery composite hydroxide.
- this composite hydroxide was confirmed to be represented by the general formula: Ni 0.85 Co 0.15 (OH) 2 .
- the particle size distribution (D10, D50, D90) and the tap density were measured in the same manner as in Example 1. The results are shown in Table 1.
- a positive electrode active material was obtained in the same manner as in Example 1. As a result of ICP emission spectroscopic analysis, this positive electrode active material was confirmed to be represented by the general formula: Li 1.05 Ni 0.83 Co 0.13 Al 0.04 O 2 . Moreover, about this positive electrode active material, the particle size distribution was measured using the laser diffraction scattering type particle diameter and the particle size distribution meter, and the tap density was measured using the tap density measuring apparatus, respectively.
- Example 3 A composite hydroxide was obtained in the same manner as in Example 1 except that the pH value of the aqueous reaction solution was maintained at 12.0 based on the liquid temperature of 25 ° C. As a result of ICP emission spectroscopic analysis, this composite hydroxide was confirmed to be represented by the general formula: Ni 0.85 Co 0.15 (OH) 2 . For this composite hydroxide, the particle size distribution (D10, D50, D90) and the tap density were measured in the same manner as in Example 1. The results are shown in Table 1.
- a positive electrode active material was obtained in the same manner as in Example 1. As a result of ICP emission spectroscopic analysis, this positive electrode active material was confirmed to be represented by the general formula: Li 1.05 Ni 0.83 Co 0.13 Al 0.04 O 2 . Moreover, about this positive electrode active material, the particle size distribution was measured using the laser diffraction scattering type particle diameter and the particle size distribution meter, and the tap density was measured using the tap density measuring apparatus, respectively.
- Example 4 A composite hydroxide was obtained in the same manner as in Example 1 except that the temperature of the reaction aqueous solution was maintained at 35 ° C. As a result of ICP emission spectroscopic analysis, this composite hydroxide was confirmed to be represented by the general formula: Ni 0.85 Co 0.15 (OH) 2 . For this composite hydroxide, the particle size distribution (D10, D50, D90) and the tap density were measured in the same manner as in Example 1. The results are shown in Table 1.
- a positive electrode active material was obtained in the same manner as in Example 1. As a result of ICP emission spectroscopic analysis, this positive electrode active material was confirmed to be represented by the general formula: Li 1.05 Ni 0.83 Co 0.13 Al 0.04 O 2 . Moreover, about this positive electrode active material, the particle size distribution was measured using the laser diffraction scattering type particle diameter and the particle size distribution meter, and the tap density was measured using the tap density measuring apparatus, respectively.
- Example 5 The same procedure as in Example 1 was used except that the raw material aqueous solution adjusted so that the Ni molar concentration was 1.66 mol / L, the Co molar concentration was 0.26 mol / L, and the Al molar concentration was 0.08 mol / L.
- a composite hydroxide was obtained.
- this composite hydroxide was confirmed to be represented by the general formula: Ni 0.83 Co 0.13 Al 0.04 (OH) 2 .
- the particle size distribution (D10, D50, D90) and the tap density were measured in the same manner as in Example 1. The results are shown in Table 1.
- Lithium hydroxide was mixed with this composite hydroxide so that Li / Me was 1.05, and calcined under the same conditions as in Example 1 to obtain a positive electrode active material.
- this positive electrode active material was confirmed to be represented by the general formula: Li 1.05 Ni 0.83 Co 0.13 Al 0.04 O 2 .
- the particle size distribution was measured using the laser diffraction scattering type particle diameter and the particle size distribution meter, and the tap density was measured using the tap density measuring apparatus, respectively.
- Example 6 Except that the raw material aqueous solution adjusted so that the Ni molar concentration was 1.66 mol / L, the Co molar concentration was 0.26 mol / L, and the Mg molar concentration was 0.08 mol / L, was used in the same manner as in Example 5. A composite hydroxide was obtained. At this time, magnesium sulfate was used as a magnesium source. As a result of ICP emission spectroscopic analysis, this composite hydroxide was confirmed to be represented by the general formula: Ni 0.83 Co 0.13 Mg 0.04 (OH) 2 . For this composite hydroxide, the particle size distribution (D10, D50, D90) and the tap density were measured in the same manner as in Example 1. The results are shown in Table 1.
- Lithium hydroxide was mixed with this composite hydroxide so that Li / Me was 1.05, and calcined under the same conditions as in Example 1 to obtain a positive electrode active material.
- this positive electrode active material was confirmed to be represented by the general formula: Li 1.05 Ni 0.83 Co 0.13 Mg 0.04 O 2 .
- the particle size distribution was measured using the laser diffraction scattering type particle diameter and the particle size distribution meter, and the tap density was measured using the tap density measuring apparatus, respectively.
- Example 7 The composite hydroxide obtained in the same manner as in Example 1 was baked without coating to obtain a composite oxide. As a result of ICP emission spectroscopic analysis, this composite oxide was confirmed to be represented by the general formula: Ni 0.86 Co 0.14 O 2 .
- the particle size distribution (D10, D50, D90) and the tap density were measured in the same manner as in Example 1. The results are shown in Table 1.
- Lithium hydroxide was mixed with this composite hydroxide so that Li / Me was 1.05, and calcined under the same conditions as in Example 1 to obtain a positive electrode active material.
- this positive electrode active material was confirmed to be represented by the general formula: Li 1.05 Ni 0.86 Co 0.14 O 2 .
- the particle size distribution was measured using the laser diffraction scattering type particle diameter and the particle size distribution meter, and the tap density was measured using the tap density measuring apparatus, respectively.
- Example 8 A composite hydroxide was obtained in the same manner as in Example 1 except that the pH value of the aqueous reaction solution was maintained at 11.6 based on the liquid temperature of 25 ° C. As a result of ICP emission spectroscopic analysis, this composite hydroxide was confirmed to be represented by the general formula: Ni 0.85 Co 0.15 (OH) 2 . For this composite hydroxide, the particle size distribution (D10, D50, D90) and the tap density were measured in the same manner as in Example 1. The results are shown in Table 1.
- a positive electrode active material was obtained in the same manner as in Example 1. As a result of ICP emission spectroscopic analysis, this positive electrode active material was confirmed to be represented by the general formula: Li 1.05 Ni 0.83 Co 0.13 Al 0.04 O 2 . Moreover, about this positive electrode active material, the particle size distribution was measured using the laser diffraction scattering type particle diameter and the particle size distribution meter, and the tap density was measured using the tap density measuring apparatus, respectively.
- Example 9 A composite hydroxide was obtained in the same manner as in Example 1 except that the liquid temperature in the reaction vessel was maintained at 25 ° C. As a result of ICP emission spectroscopic analysis, this composite hydroxide was confirmed to be represented by the general formula: Ni 0.85 Co 0.15 (OH) 2 . For this composite hydroxide, the particle size distribution (D10, D50, D90) and the tap density were measured in the same manner as in Example 1. The results are shown in Table 1.
- a positive electrode active material was obtained in the same manner as in Example 1. As a result of ICP emission spectroscopic analysis, this positive electrode active material was confirmed to be represented by the general formula: Li 1.05 Ni 0.83 Co 0.13 Al 0.04 O 2 . Moreover, about this positive electrode active material, the particle size distribution was measured using the laser diffraction scattering type particle diameter and the particle size distribution meter, and the tap density was measured using the tap density measuring apparatus, respectively.
- Example 10 A composite hydroxide was obtained in the same manner as in Example 1 except that the slurry concentration in the small particle diameter portion slurry obtained in the separation step was not returned to the reaction vessel. As a result of ICP emission spectroscopic analysis, this composite hydroxide was confirmed to be represented by the general formula: Ni 0.85 Co 0.15 (OH) 2 . For this composite hydroxide, the particle size distribution (D10, D50, D90) and the tap density were measured in the same manner as in Example 1. The results are shown in Table 1.
- a positive electrode active material was obtained in the same manner as in Example 1. As a result of ICP emission spectroscopic analysis, this positive electrode active material was confirmed to be represented by the general formula: Li 1.05 Ni 0.83 Co 0.13 Al 0.04 O 2 . Moreover, about this positive electrode active material, the particle size distribution was measured using the laser diffraction scattering type particle diameter and the particle size distribution meter, and the tap density was measured using the tap density measuring apparatus, respectively.
- Example 11 A composite hydroxide was obtained in the same manner as in Example 1 except that the stirring speed was 600 rpm. As a result of ICP emission spectroscopic analysis, this composite hydroxide was confirmed to be represented by the general formula: Ni 0.85 Co 0.15 (OH) 2 . For this composite hydroxide, the particle size distribution (D10, D50, D90) and the tap density were measured in the same manner as in Example 1. The results are shown in Table 1.
- a positive electrode active material was obtained in the same manner as in Example 1. As a result of ICP emission spectroscopic analysis, this positive electrode active material was confirmed to be represented by the general formula: Li 1.05 Ni 0.83 Co 0.13 Al 0.04 O 2 . Moreover, about this positive electrode active material, the particle size distribution was measured using the laser diffraction scattering type particle diameter and the particle size distribution meter, and the tap density was measured using the tap density measuring apparatus, respectively.
- Example 12 A composite hydroxide was obtained in the same manner as in Example 1 except that the stirring speed was 1000 rpm. As a result of ICP emission spectroscopic analysis, this composite hydroxide was confirmed to be represented by the general formula: Ni 0.85 Co 0.15 (OH) 2 . For this composite hydroxide, the particle size distribution (D10, D50, D90) and the tap density were measured in the same manner as in Example 1. The results are shown in Table 1.
- a positive electrode active material was obtained in the same manner as in Example 1. As a result of ICP emission spectroscopic analysis, this positive electrode active material was confirmed to be represented by the general formula: Li 1.05 Ni 0.83 Co 0.13 Al 0.04 O 2 . Moreover, about this positive electrode active material, the particle size distribution was measured using the laser diffraction scattering type particle diameter and the particle size distribution meter, and the tap density was measured using the tap density measuring apparatus, respectively.
- Example 1 A crystallization reaction was performed in the same manner as in Example 1 except that the separation step was not performed. The supply amounts of the raw material aqueous solution, the ammonia water and the caustic soda aqueous solution were adjusted to be equal to the extracted slurry amount. After a lapse of 48 to 72 hours from the start of the reaction, the obtained composite hydroxide was appropriately solid-liquid separated, washed with water and dried to obtain a composite hydroxide. As a result of ICP emission spectroscopic analysis, this composite hydroxide was confirmed to be represented by the general formula: Ni 0.86 Co 0.14 (OH) 2 . For this composite hydroxide, the particle size distribution (D10, D50, D90) and the tap density were measured in the same manner as in Example 1. The results are shown in Table 1.
- a positive electrode active material was obtained in the same manner as in Example 1. As a result of ICP emission spectroscopic analysis, this positive electrode active material was confirmed to be represented by the general formula: Li 1.05 Ni 0.83 Co 0.13 Al 0.04 O 2 . Moreover, about this positive electrode active material, the particle size distribution was measured using the laser diffraction scattering type particle diameter and the particle size distribution meter, and the tap density was measured using the tap density measuring apparatus, respectively.
- Example 2 A crystallization reaction was performed in the same manner as in Example 2 except that the separation step was not performed. The supply amounts of the raw material aqueous solution, the ammonia water and the caustic soda aqueous solution were adjusted to be equal to the extracted slurry amount. After a lapse of 48 to 72 hours from the start of the reaction, the obtained composite hydroxide was appropriately solid-liquid separated, washed with water and dried to obtain a composite hydroxide. As a result of ICP emission spectroscopic analysis, this composite hydroxide was confirmed to be represented by the general formula: Ni 0.86 Co 0.14 (OH) 2 . For this composite hydroxide, the particle size distribution (D10, D50, D90) and the tap density were measured in the same manner as in Example 1. The results are shown in Table 1.
- a positive electrode active material was obtained in the same manner as in Example 1. As a result of ICP emission spectroscopic analysis, this positive electrode active material was confirmed to be represented by the general formula: Li 1.05 Ni 0.83 Co 0.13 Al 0.04 O 2 . Moreover, about this positive electrode active material, the particle size distribution was measured using the laser diffraction scattering type particle diameter and the particle size distribution meter, and the tap density was measured using the tap density measuring apparatus, respectively.
- the composite hydroxylation satisfying the relationship of (D50 ⁇ D10) /D50 ⁇ 0.30 and (D90 ⁇ D50) /D50 ⁇ 0.30 between D10, D50 and D90.
- the positive electrode active material obtained using the product as a precursor can have a capacity maintenance rate of 97.5% or more in a non-aqueous electrolyte secondary battery using the same.
- the capacity retention rate can be set to 98.0% or more, and the cycle characteristics can be significantly improved.
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Abstract
Description
前記ニッケルコバルト複合水酸化物のD10、D50およびD90の間に、(D50-D10)/D50≦0.30、かつ、(D90-D50)/D50≦0.30の関係が成り立つことを特徴とする。
(1)ニッケルコバルト複合水酸化物
本発明のニッケルコバルト複合水酸化物(以下、「複合水酸化物」という)は、一般式:Ni1-x-yCoxMy(OH)2(ただし、0.05≦x≦0.50、0≦y≦0.10、0.05≦x+y≦0.50、Mは、Al、Mg、Mn、Ti、Fe、Cu、Zn、Gaから選ばれる少なくとも1種の金属元素)で表される複合水酸化物であって、この複合水酸化物のD10、D50およびD90の間に、(D50-D10)/D50≦0.30、かつ、(D90-D50)/D50≦0.30の関係が成り立つことを特徴とする。すなわち、本発明の複合水酸化物は、きわめてシャープな粒度分布を有することを特徴とする。
上記一般式において、コバルト(Co)の添加量を示すxの値は0.05~0.50、好ましくは0.10~0.50、より好ましくは0.10~0.30とする。xの値が0.05未満では、Coの添加による効果を十分に得ることができない。一方、xの値が0.50を超えると、原料コストが増加してしまう。
本発明の複合水酸化物は、D10、D50およびD90の間に、(D50-D10)/D50≦0.30、かつ、(D90-D50)/D50≦0.30の関係が成り立つことを特徴とする。ここで、D10、D50、D90は、粒度分布の積算値がそれぞれ10%、50%および90%に相当する粒径を意味する。D10、D50、D90を求める方法は特に限定されないが、たとえば、レーザ回折散乱式粒度分析計で測定した体積積算値から求めることができる。
正極活物質の構造や大きさは、その前駆体である複合水酸化物の影響を受ける。このため、本発明の複合水酸化物は、充填性の指標となるタップ密度が2.0g/cm3以上であることが好ましく、2.2g/cm3以上であることがより好ましい。ここで、タップ密度とは、JIS Z-2504に基づき、容器に採取した試料粉末を、100回タッピングした後の密度を表し、振とう比重測定器を用いて測定することができる。
複合水酸化物の平均粒径は、10μm~30μmの範囲にあることが好ましく、13μm~26μmにあることがより好ましく、15μm~25μmの範囲にあることがさらに好ましい。なお、本発明における平均粒径は、粒度分布の積算値が50%に相当する粒径、すなわち、D50(メディアン径)を意味する。複合水酸化物の平均粒径がこのような範囲にあれば、この複合水酸化物を前駆体として得られるリチウム複合酸化物を正極活物質として用いた非水系電解質二次電池の電池特性を、より優れたものとすることができる。特に、タップ密度を上述の範囲に制御するとともに、平均粒径をこのような範囲に制御することで、容量維持率を、好ましくは98.0%以上、より好ましくは98.5%以上とすることができる。
本発明の複合水酸化物の製造方法は、図2に示すように、ニッケルおよびコバルトを含む水溶液と、アンモニウムイオン供給体を含む水溶液と、苛性アルカリ水溶液とを、撹拌しながら、それぞれ連続的に反応槽に供給して反応させることで、複合水酸化物を得る反応工程と、反応槽から複合水酸化物を含むスラリーを抜き出し、分級により大粒径部と小粒径部を分離する分離工程と、分離工程により得られた小粒径部を連続的に反応槽に還流する還流工程とを備えることを特徴とする。このような製造方法では、既存の反応工程とは別個に分離工程および還流工程を設けているので、反応工程で同時的に分級を行う方法と比べて、複合水酸化物の晶析条件などに対する制限が少なく、粒子成長に有利な条件のみを選択することができるため、工業規模での生産に有利といえる。また、未発達の粒子が混入する可能性もなく、回収される粒子をより均一なものとすることができる。以下、各工程について詳細に説明する。
反応工程は、ニッケルおよびコバルトを含む水溶液(以下、「原料水溶液」という)と、アンモニウムイオン供給体を含む水溶液(以下、「アンモニウムイオン供給水溶液」という)と、苛性アルカリ水溶液とを、撹拌しながら、それぞれ連続的に反応槽に供給することで、これらの混合水溶液からなる反応水溶液を形成し、晶析反応を起こさせることによって、上述した一般式により表される複合水酸化物を連続的に生成する工程である。ここで、苛性アルカリ水溶液は、反応水溶液のpH値が所定の範囲に維持されるように、その添加量を調整して供給される。
反応工程の条件は、反応槽の大きさ、撹拌翼の径および形状、あるいは、目的とする粒子の大きさや形状などに応じて適宜選択されるべきものであり、一義的に定めることはできない。特に、本発明では、同一の反応槽において核生成と粒子成長が同時に進行するため、反応条件によっては、得られる複合水酸化物の粒度分布が広くなってしまうことがあり、この場合、後述する分離工程の負荷が増大し、全体の生産効率が悪化する可能性がある。また、反応工程、分離工程および還流工程の過度の繰り返しにより粗大粒子が発生し、粒度分布がさらに広くなってしまう可能性もある。このため、得られる複合水酸化物の粒度分布を所定範囲に制御する観点から、反応工程における条件を適宜調整することが好ましい。
原料水溶液は、特に限定されるものではないが、ニッケルおよびコバルトの硝酸塩、硫酸塩または塩酸塩などを溶解した水溶液を用いることが好ましく、ハロゲンによる汚染の防止およびコストの観点から、これらの硫酸水溶液を用いることがより好ましい。
上述したように、本発明の複合水酸化物には、添加元素M(Mは、Al、Mg、Mn、Ti、Fe、Cu、Zn、Gaから選ばれる少なくとも1種以上の金属元素)を含有させることができる。
本発明で使用するアンモニウムイオン供給水溶液は、特に限定されるものではないが、アンモニア水、または、硫酸アンモニウムもしくは塩化アンモニウムを含む水溶液が好ましく、ハロゲンによる汚染を防止する観点から、アンモニア水または硫酸アンモニウムを含む水溶液がより好ましい。
本発明において、苛性アルカリ水溶液は中和反応のpH調整剤として用いられる。このような苛性アルカリ水溶液としては、水酸化ナトリウム水溶液、水酸化カリウム水溶液、水酸化リチウム水溶液などを用いることができるが、取扱いの容易性およびコストの観点から、水酸化ナトリウム水溶液を用いることが好ましい。
反応工程で生成し、成長した複合水酸化物を含むスラリーは、連続的に反応槽から抜き出され、分離装置により目的とする粒径に達した粒子(以下、「大粒径部」という)と、目的とする粒径に未達の粒子(以下、「小粒径部」という)に分級される。大粒径部は分離装置から反応槽外に排出され、小粒径部は還流装置により、反応槽内に戻される。反応槽内に戻された粒子は、再び反応槽内で成長した後、反応槽内から分離装置に導かれ、目的とする粒径に達していれば反応槽外に排出される。これを繰り返すことにより、反応槽内で生成し、成長した大粒径部を選択的に反応槽外に排出するとともに、小粒径部は、目的とする粒径に達するまで粒子成長を繰り返すことができるため、最終的に得られる複合水酸化物の粒径が均一になり、その粒度分布をシャープなものとすることができる。
還流工程は、分離工程において、分離装置から排出された小粒径部を含むスラリー(以下、「小粒径部スラリー」という)を反応槽内に戻す(還流する)工程である。還流方法は、特に限定されることなく公知の手段を用いることができる。たとえば、分級後の小粒径部をそのまま反応槽に戻す場合には、分離装置から排出された小粒径部スラリーをポンプにより直接反応槽へ戻せばよい。一方、小粒径部スラリーの濃度を調整することが必要な場合には、濃縮手段や希釈手段を別途設ける必要がある。
本発明の複合水酸化物の製造装置は、図3に示すように、原料水溶液と、アンモニウムイオン供給水溶液と、苛性アルカリ水溶液とを、撹拌しながら、それぞれ連続的に反応槽に供給して反応させることで、複合水酸化物を得る反応槽(1)と、反応槽(1)から連続的に複合水酸化物を抜き出し、分級により、複合水酸化物を大粒径部と小粒径部に分離する分離装置(7)と、小粒径部を連続的に反応槽に還流する還流装置(9)とを備える。
反応工程に使用する反応槽(1)は、撹拌手段(2)、原料水溶液供給手段(3)、アンモニウムイオン供給水溶液供給手段(4)、苛性アルカリ水溶液供給手段(5)を備え、かつ、生成された複合水酸化物を連続的に排出することができる、オーバーフロー方式のものであれば、特に限定されることはない。ただし、晶析条件を制御するため、温度制御手段、pH値制御手段などを備えることが好ましい。なお、撹拌手段(2)としては、公知のマグネチックスターラー、メカニカルスターラーなど工業規模の生産に適したものを適宜選択すればよい。また、温度制御手段、pH値制御手段、原料水溶液などの供給手段についても、適宜、公知のものを採用することができる。
反応工程により生成したスラリーはポンプ(6)により、分離装置(7)へ導入される。この際、使用する分離装置(7)としては湿式の分離装置であることが好ましく、湿式サイクロン法を利用した分離装置がより好ましい。湿式サイクロン法を利用した分離装置であれば、サイクロン部の形状、サイズおよび処理スラリーの導入圧力により、分級点を容易に制御することができる。
分離工程により分離された大粒径部は、反応槽外に排出される。一方、小粒径部は、還流装置(9)により反応槽に戻されることとなる。
各装置の間には、得られた複合水酸化物のスラリー濃度を調整するため、希釈装置あるいは脱水装置を備えることが好ましい。
(1)非水系電解質二次電池用正極活物質
本発明の非水系電解質二次電池用正極活物質は、一般式:Li1+uNi1-x-yCoxMyO2(ただし、0≦u≦0.30、0.05≦x≦0.50、0≦y≦0.10、0.05≦x+y≦0.50、Mは、Al、Mg、Mn、Ti、Fe、Cu、Zn、Gaから選ばれる少なくとも1種の金属元素)で表され、層状構造を有する六方晶系リチウム複合酸化物からなり、このリチウム複合酸化物のD10、D50およびD90の間に、(D50-D10)/D50≦0.30、かつ、(D90-D50)/D50≦0.30の関係が成り立つことを特徴とする。このような正極活物質は、後述するように、本発明の複合水酸化物を前駆体とすることで容易に得ることができる。
上記一般式において、リチウムの過剰量を示すuの値は、0~0.30とすることが好ましく、0~0.15とすることがより好ましい。uの値が0未満では、得られる正極活物質を用いた非水系電解質二次電池における正極の反応抵抗が大きくなるため、電池の出力が低くなってしまう。一方、uの値が0.30を超えると、正極活物質を電池の正極に用いた場合の初期放電容量が低下するばかりでなく、正極の反応抵抗も増加してしまう。
本発明の正極活物質は、D10、D50およびD90の間に、(D50-D10)/D50≦0.30、かつ、(D90-D50)/D50≦0.30の関係が成り立つことを特徴とする。
本発明の正極活物質のタップ密度は、2.0g/cm3以上であることが好ましく、2.2g/cm3以上であることがより好ましい。正極活物質のタップ密度がこのような範囲にあれば、この正極活物質として用いた非水系電解質二次電池の電池特性をより優れたものとすることができる。一方、タップ密度が2.0g/cm3未満では、正極活物質の充填密度が十分なものとならず、非水系電解質二次電池の特性を十分に向上させることができない場合がある。
本発明の正極活物質の平均粒径は、10μm~30μmの範囲にあることが好ましく、13μm~26μmの範囲にあることがより好ましく、15μm~25μmの範囲にあることがさらに好ましい。正極活物質の平均粒径がこのような範囲にあれば、この正極活物質を用いた非水系電解質二次電池の電池特性をより優れたものとすることができる。特に、タップ密度を上述の範囲に制御するとともに、平均粒径をこのような範囲に制御することで、容量維持率を、好ましくは98.0%以上、より好ましくは98.5%以上とすることができる。
以下、上述したニッケル複合水酸化物を前駆体として、非水系電解質電池用正極活物質を製造する方法について説明する。
混合工程は、複合水酸化物とリチウム化合物とを混合して、リチウム混合物を得る工程である。
前記混合工程の前に、予め、複合水酸化物を、酸化性雰囲気中で、300℃~700℃の温度で焙焼する焙焼工程を、さらに備えることが好ましい。このような焙焼工程により、複合水酸化物をニッケルコバルト複合酸化物(以下、「複合酸化物」という)にすることができ、この複合酸化物をリチウム化合物と混合した場合に、リチウム複合酸化物の充填性を保ったまま、リチウム複合酸化物中のリチウムと金属元素の組成比を安定させることができる。
焼成工程は、混合工程で得られたリチウム混合物を、酸化性雰囲気中、600℃~850℃で焼成する工程である。
本発明の非水系電解質二次電池は、正極、負極、セパレータ、非水系電解液などの、一般の非水系電解質二次電池と同様の構成要素を備える。なお、以下に説明する実施形態は例示にすぎず、本発明の非水系電解質二次電池は、本明細書に記載されている実施形態を基づいて、種々の変更、改良を施した形態に適用することも可能である。
本発明により得られた非水系電解質二次電池用正極活物質を用いて、たとえば、以下のようにして非水系電解質二次電池の正極を作製する。
負極には、金属リチウムやリチウム合金など、あるいは、リチウムイオンを吸蔵および脱離できる負極活物質に、結着剤を混合し、適当な溶剤を加えてペースト状にした負極合材を、銅などの金属箔集電体の表面に塗布し、乾燥し、必要に応じて電極密度を高めるべく圧縮して形成したものを使用する。
正極と負極との間には、セパレータを挟み込んで配置する。セパレータは、正極と負極とを分離し、電解質を保持するものであり、ポリエチレンやポリプロピレンなどの薄い膜で、微少な孔を多数有する膜を用いることができる。
非水系電解液は、支持塩としてのリチウム塩を有機溶媒に溶解したものである。
以上のように説明してきた正極、負極、セパレータおよび非水系電解液で構成される本発明の非水系電解質二次電池は、円筒形や積層形など、種々の形状にすることができる。
本発明の正極活物質を用いた非水系電解質二次電池は、この非水系電解質二次電池を構成し、開路電圧(OCV)が安定した後、正極に対する電流密度を0.5mA/cm2、カットオフ電圧4.3V~3.0Vとし、25℃での充放電試験を25サイクル行った後の容量維持率が97.5%以上、好ましくは98.0%以上、より好ましくは98.5%以上であることを特徴とする。このように本発明の非水系電解質二次電池は、非常に優れたサイクル特性を備えているため、小型携帯電子機器や電気自動車用の電源として好適であるといえる。なお、本発明は、純粋に電気エネルギで駆動する電気自動車用の電源のみならず、ガソリンエンジンやディーゼルエンジンなどの燃焼機関と併用するいわゆるハイブリッド車用の電源としても用いることが可能である。
邪魔板を4枚取り付けた容積34Lのオーバーフロー式晶析反応槽に、工業用水32L、25質量%アンモニア水を1300mL投入し、恒温槽および加温ジャケットにて50℃に加温した。その後、24質量%苛性ソーダ水溶液を投入して、液温25℃基準でpH値が12.2となるように制御した。具体的には、pH値の管理を正確に行うため、反応槽内の反応水溶液を採取し、25℃に冷却してpH値を測定することにより、25℃でのpH値が12.1~12.3の範囲となるように50℃でのpH値を制御した。
反応水溶液のpH値を、液温25℃基準で11.8に維持したこと、反応工程における撹拌速度を800rpmとして行ったこと以外は、実施例1と同様にして、複合水酸化物を得た。なお、pH値の管理は、反応槽内の反応水溶液を採取し、25℃に冷却してpH値を測定することにより、25でのpH値が11.7~11.9の範囲となるように50℃でのpH値を制御した。得られた複合水酸化物を適宜固液分離し、水洗および乾燥することにより、粉末状の複合水酸化物を得た。この複合水酸化物は、ICP発光分光分析の結果、一般式:Ni0.85Co0.15(OH)2により表されるものであることが確認された。また、この複合水酸化物について、実施例1と同様にして、粒度分布(D10、D50、D90)およびタップ密度を測定した。この結果を表1に示す。
反応水溶液のpH値を、液温25℃基準で12.0に維持したこと以外は、実施例1と同様にして、複合水酸化物を得た。この複合水酸化物は、ICP発光分光分析の結果、一般式:Ni0.85Co0.15(OH)2により表されるものであることが確認された。また、この複合水酸化物について、実施例1と同様にして、粒度分布(D10、D50、D90)およびタップ密度を測定した。この結果を表1に示す。
反応水溶液の温度を35℃に維持したこと以外は、実施例1と同様にして、複合水酸化物を得た。この複合水酸化物は、ICP発光分光分析の結果、一般式:Ni0.85Co0.15(OH)2により表されるものであることが確認された。また、この複合水酸化物について、実施例1と同様にして、粒度分布(D10、D50、D90)およびタップ密度を測定した。この結果を表1に示す。
Niモル濃度が1.66mol/L、Coモル濃度が0.26mol/L、Alモル濃度が0.08mol/Lとなるように調整した原料水溶液を使用したこと以外は実施例1と同様にして、複合水酸化物を得た。この複合水酸化物は、ICP発光分光分析の結果、一般式:Ni0.83Co0.13Al0.04(OH)2により表されるものであることが確認された。また、この複合水酸化物について、実施例1と同様にして、粒度分布(D10、D50、D90)およびタップ密度を測定した。この結果を表1に示す。
Niモル濃度が1.66mol/L、Coモル濃度が0.26mol/L、Mgモル濃度が0.08mol/Lとなるように調整した原料水溶液を使用したこと以外は実施例5と同様にして、複合水酸化物を得た。なお、この際、マグネシウム源として硫酸マグネシウムを使用した。この複合水酸化物は、ICP発光分光分析の結果、一般式:Ni0.83Co0.13Mg0.04(OH)2により表されるものであることが確認された。また、この複合水酸化物について、実施例1と同様にして、粒度分布(D10、D50、D90)およびタップ密度を測定した。この結果を表1に示す。
実施例1と同様にして得られた複合水酸化物を、被覆せずに焼成して、複合酸化物を得た。この複合酸化物は、ICP発光分光分析の結果、一般式:Ni0.86Co0.14O2により表されるものであることが確認された。また、この複合水酸化物について、実施例1と同様にして、粒度分布(D10、D50、D90)およびタップ密度を測定した。この結果を表1に示す。
反応水溶液のpH値を、液温25℃基準で11.6に維持したこと以外は、実施例1と同様にして、複合水酸化物を得た。この複合水酸化物は、ICP発光分光分析の結果、一般式:Ni0.85Co0.15(OH)2により表されるものであることが確認された。また、この複合水酸化物について、実施例1と同様にして、粒度分布(D10、D50、D90)およびタップ密度を測定した。この結果を表1に示す。
反応槽内の液温を25℃に維持したこと以外は、実施例1と同様にして、複合水酸化物を得た。この複合水酸化物は、ICP発光分光分析の結果、一般式:Ni0.85Co0.15(OH)2により表されるものであることが確認された。また、この複合水酸化物について、実施例1と同様にして、粒度分布(D10、D50、D90)およびタップ密度を測定した。この結果を表1に示す。
分離工程において得られた小粒径部スラリーのスラリー濃度を調整することなく、反応槽に還流したこと以外は、実施例1と同様にして、複合水酸化物を得た。この複合水酸化物は、ICP発光分光分析の結果、一般式:Ni0.85Co0.15(OH)2により表されるものであることが確認された。また、この複合水酸化物について、実施例1と同様にして、粒度分布(D10、D50、D90)およびタップ密度を測定した。この結果を表1に示す。
撹拌速度を600rpmとしたこと以外は、実施例1と同様にして、複合水酸化物を得た。この複合水酸化物は、ICP発光分光分析の結果、一般式:Ni0.85Co0.15(OH)2により表されるものであることが確認された。また、この複合水酸化物について、実施例1と同様にして、粒度分布(D10、D50、D90)およびタップ密度を測定した。この結果を表1に示す。
撹拌速度を1000rpmとしたこと以外は、実施例1と同様にして、複合水酸化物を得た。この複合水酸化物は、ICP発光分光分析の結果、一般式:Ni0.85Co0.15(OH)2により表されるものであることが確認された。また、この複合水酸化物について、実施例1と同様にして、粒度分布(D10、D50、D90)およびタップ密度を測定した。この結果を表1に示す。
分離工程を行わなかったこと以外は、実施例1と同様にして、晶析反応を行った。なお、原料水溶液、アンモニア水および苛性ソーダ水溶液の供給量は、抜き取ったスラリー量と同等になるように調整した。反応開始から48時間~72時間経過後、得られた複合水酸化物を適宜固液分離し、水洗および乾燥することにより、複合水酸化物を得た。この複合水酸化物は、ICP発光分光分析の結果、一般式:Ni0.86Co0.14(OH)2により表されるものであることが確認された。また、この複合水酸化物について、実施例1と同様にして、粒度分布(D10、D50、D90)およびタップ密度を測定した。この結果を表1に示す。
分離工程を行わなかったこと以外は、実施例2と同様にして、晶析反応を行った。なお、原料水溶液、アンモニア水および苛性ソーダ水溶液の供給量は、抜き取ったスラリー量と同等になるように調整した。反応開始から48時間~72時間経過後、得られた複合水酸化物を適宜固液分離し、水洗および乾燥することにより、複合水酸化物を得た。この複合水酸化物は、ICP発光分光分析の結果、一般式:Ni0.86Co0.14(OH)2により表されるものであることが確認された。また、この複合水酸化物について、実施例1と同様にして、粒度分布(D10、D50、D90)およびタップ密度を測定した。この結果を表1に示す。
2 撹拌手段
3 原料水溶液供給手段
4 アンモニウムイオン供給水溶液供給手段
5 苛性アルカリ水溶液供給手段
6 ポンプ
7 分離装置
8 受け槽
9 還流装置
10 2032型コイン電池
11 ケース
11a 正極缶
11b 負極缶
11c ガスケット
12 電極
12a 正極
12b 負極
12c セパレータ
Claims (12)
- 一般式:Ni1-x-yCoxMy(OH)2(ただし、0.05≦x≦0.50、0≦y≦0.10、0.05≦x+y≦0.50、Mは、Al、Mg、Mn、Ti、Fe、Cu、Zn、Gaから選ばれる少なくとも1種の金属元素)で表されるニッケルコバルト複合水酸化物であって、
前記ニッケルコバルト複合水酸化物のD10、D50およびD90の間に、(D50-D10)/D50≦0.30、かつ、(D90-D50)/D50≦0.30の関係が成り立つ、
ニッケルコバルト複合水酸化物。 - タップ密度が2.0g/cm3以上である、請求項1に記載のニッケルコバルト複合水酸化物。
- 平均粒径が10μm~30μmの範囲にある、請求項1に記載にニッケルコバルト複合水酸化物。
- ニッケルおよびコバルトを含む水溶液と、アンモニウムイオン供給体を含む水溶液と、苛性アルカリ水溶液とを、それぞれ連続的に反応槽に供給して反応させることでニッケルコバルト複合水酸化物を得る反応工程と、
前記反応槽から、前記ニッケルコバルト複合水酸化物を含むスラリーを連続的に抜き出し、分級により大粒径部と小粒径部に分離する分離工程と、
前記小粒径部を連続的に前記反応槽に還流する還流工程と
を備える、ニッケルコバルト複合水酸化物の製造方法。 - 前記分離工程において、遠心力を利用した湿式分離装置を使用する、請求項4に記載のニッケルコバルト複合水酸化物の製造方法。
- 前記分離された大粒径部の表面を、添加元素M(Mは、Al、Mg、Mn、Ti、Fe、Cu、Zn、Gaから選ばれる少なくとも1種の金属元素)で被覆する工程をさらに備える、請求項4または5に記載のニッケルコバルト複合水酸化物の製造方法。
- 反応槽と、
該反応槽に、ニッケルおよびコバルトを含む水溶液と、アンモニウムイオン供給体を含む水溶液と、苛性アルカリ水溶液とを、それぞれ連続的に供給する手段と、
前記反応槽内において反応により生成したニッケルコバルト複合水酸化物を該反応槽から連続的に抜き出す手段と、
該抜き出されたニッケルコバルト複合水酸化物を、分級により大粒径部と小粒径部に分離する分離装置と、
前記分離された小粒径部を連続的に前記反応槽に還流する還流装置と
を備える、請求項1に記載のニッケルコバルト複合水酸化物の製造装置。 - 一般式:Li1+uNi1-x-yCoxMyO2(ただし、0≦u≦0.30、0.05≦x≦0.50、0≦y≦0.10、0.05≦x+y≦0.50、Mは、Al、Mg、Mn、Ti、Fe、Cu、Zn、Gaから選ばれる少なくとも1種の金属元素)で表され、層状構造を有する六方晶系リチウムニッケルコバルト複合酸化物からなり、
前記リチウムニッケルコバルト複合酸化物のD10、D50およびD90の間に、(D50-D10)/D50≦0.30、かつ、(D90-D50)/D50≦0.30の関係が成り立つ、
非水系電解質二次電池用正極活物質。 - タップ密度が2.0g/cm3以上である、請求項8に記載の非水系電解質二次電池用正極活物質。
- 平均粒径が10μm~30μmの範囲にある、請求項8に記載に非水系電解質二次電池用正極活物質。
- 請求項1~3に記載のニッケルコバルト複合水酸化物、もしくは、該ニッケルコバルト複合水酸化物を酸化性雰囲気中、300℃~700℃の温度で焙焼することにより得られるニッケルコバルト複合酸化物を、リチウム化合物と混合してリチウム混合物を形成する混合工程と、このリチウム混合物を酸化性雰囲気中、600℃~850℃の温度で焼成する焼成工程とを備える、非水系電解質二次電池用正極活物質の製造方法。
- 正極と、負極と、セパレータと、非水系電解質とを備え、前記正極の正極材料として、請求項8~10のいずれかに記載の非水系電解質二次電池用正極活物質が用いられている、非水系電解質二次電池。
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US10236510B2 (en) | 2019-03-19 |
CN104661963B (zh) | 2017-07-04 |
CN104661963A (zh) | 2015-05-27 |
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US20180323431A1 (en) | 2018-11-08 |
US20150243984A1 (en) | 2015-08-27 |
US10141571B2 (en) | 2018-11-27 |
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CN107021528A (zh) | 2017-08-08 |
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