Previews – Lithium-ion Battery Cathode Innovation & Patent Deep Dives

• Deep Dive – Recent Patents & Innovations in Ni-based Cathode Materials

  15 pages, addendum with patent summaries: 68 pages, version: 2024-12-26
• Introduction
  
  Recent innovations in nickel-based cathode materials for lithium-ion batteries reflect a product development community wrestling with multiple competing priorities: higher energy density, improved longevity, reduced raw material and process costs, and enhanced sustainability. This review analyzes patent filings and public disclosures from 2023 onwards to identify emerging patterns in how leading battery manufacturers, materials companies, and startups are addressing these challenges, in several cases in collaboration with academic research groups.
  
  The analysis reveals 14 key concepts shaping the evolution of cathode materials (Figure A-1).
  
  Figure A-1: technology decision tree – 14 commercially relevant concepts related to Ni-based active materials for positive Li-ion battery electrodes, identified in patent families published since 2023 (publication date of first patent family member, 2 additional earlier patent families and 2 commercialization efforts identified in public reports other than patents are included in Figures D-2 to D-15 that cover each of the 14 concepts)
  
  

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• Deep Dive – Recent Patents & Innovations in Lithium Manganese Iron Phosphate (LMFP) Cathode Materials

  Version: 2025-02-03
• Introduction
  
  LMFP (lithium manganese iron phosphate) has emerged as a promising cathode active material for lithium-ion batteries, combining advantages of both LFP (lithium iron phosphate, low raw material costs, favorable inherent safety profile) and manganese-rich chemistries (higher voltage than LFP, resulting in 15-20% higher energy density). This deep dive covers key LMFP-related product development decisions through an analysis of newly published patents (since 2023) and publicly disclosed information from key commercial players.
  
  LMFP product & process definition efforts involve the following aspects (Figure B-1):
  • Optimization of manganese / iron ratio to balance performance and stability (Figure B-2)
  • Various doping strategies using elements like titanium, niobium, and boron (Figure B-3)
  • Surface modifications (Figure B-4) and core-shell / gradient architectures (Figure B-5)
  • Particle size distribution and morphology control (Figure B-6)
  • Choice of manufacturing process steps (Figure B-7)
  • Positive electrodes based on active material blends (Figure B-8)
• The sections below are included in the full version.
• Perspectives for LMFP – Academic Viewpoint
  • LMP (Lithium Manganese Phosphate)
  • LMFP (Lithium Manganese Iron Phosphate)
  • Sustainability
• State of LMFP Commercialization
  • Table B-1: Summary of Key LMFP Commercialization Efforts (full version: 15 entries)
    
    
    

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• Preview – Deep Dive – Catholyte Options & Selection

  Version: 2024-06-17
• Introduction
  
  One of the main advantages of all-solid and semi-solid electrolyte cell designs is that a differentiation between the electrolytes that can migrate to the interface of the positive and the negative electrode is possible, allowing for the separate definition of anolytes (electrolytes in the vicinity of anode) and catholytes (electrolytes in the vicinity of cathode, Figure C-1).
  
  Figure C-1: cell in which liquid transfer from 'catholyte' to 'anolyte' regions is blocked or substantially slowed down by a solid or semi-solid electrolyte layer
  
  
  The most important implication of this differentiation between anolytes and catholytes is that no simultaneous stability at low potentials (0 V vs. Li⁺/Li) and high potentials (≥4 V vs. Li⁺/Li) is necessary for anolyte and catholyte components, as compared to fully liquid electrolytes that simultaneously have to be stable at the anode and the cathode, or form a stable SEI layer.
  
  Promising electrolyte components that thus far were not frequently used in commercial cells because of insufficient stability at the negative electrode therefore stand the chance of gaining prominence in future commercial catholytes.
  
  Prevention of parasitic shuttling (such as by leaked transition metal ions) between electrodes is a major advantage of all-solid and semi-solid cells that eliminates cell aging and failure mechanisms that have tended to slow down the move to higher energy / power and lower cost active materials in both electrodes.
  
  In case of semi-solid or partially porous solid electrolyte layers, the rate of migration of catholyte and anolyte components has to be checked and needs to be sufficiently mitigated as not to cause parasitic reactions that reduce longevity or safety.

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• About the Author

• Pirmin Ulmann obtained a diploma in chemistry from ETH Zurich (Switzerland) in 2004 and a PhD from Northwestern University (USA) in 2009. Thereafter, he was a JSPS Foreign Fellow in an ERATO academic-industrial project at the University of Tokyo (Japan). From 2010 to 2016, while working at a major battery materials manufacturer in Switzerland, he was a co-inventor of 7 patent families related to lithium-ion batteries. He was also in charge of a collaboration with the Paul Scherrer Institute, evaluated outside technologies for corporate strategy, and made customer visits to battery manufacturers in East Asia, North America & Europe. He holds the credential Stanford Certified Project Manager (SCPM) and has co-authored scientific articles with more than 2,000 citations.